The best way to remove spatter

Is gas nozzle overheating a problem?

Spatter becomes sticky when gas nozzle temperatures are too high. If that happens, the nozzle and contact tip cannot do their job effectively – if they are covered in spatter, gas shielding quality deteriorates and the chances of weak welds due to porosity increase. To prevent this, the nozzle has to be replaced more often.

We know that high nozzle temperatures reduce productivity, but it is also important to remember that this can negatively affect the contact tip. Even if the tip has effective cooling, an overheated nozzle creates a powerful furnace effect on the tip that shortens its life while increasing consumable use.

How do you measure gas nozzle temperature?

In the past it was difficult to compare gas nozzle temperatures effectively, because welding applications and working methods can vary considerably. However, by creating a simulated welding arc with a fixed arc distance, we were able to achieve a continuous welding simulation that allowed us to compare gas nozzle temperatures accurately.

_{In this test, the gas nozzle temperature of the Kemppi Flexlite GX was significantly lower.}

What is the ideal gas nozzle temperature?

The best way to remove spatter is to prevent it from sticking. But when gas nozzle temperatures start rising toward 200°, spatter becomes increasingly sticky and harder to remove. This matters because too much spatter inside the gas nozzle directly causes a lack of gas shield. So is there a temperature at which spatter does not stick? And can a gas nozzle maintain that temperature?

During our temperature test (see the chart above), the Kemppi Flexlite GX nozzle stayed at approximately 150° for a 6-minute period of use.

This is important because spatter is significantly less likely to stick at lower temperatures. Also, when the nozzle temperature stays lower, consumables are used at a lower rate and contact tip performance remains optimized for smooth wire feeding.

Can a gas nozzle save you money?

Yes! Eliminating spatter and preventing contact tip overheating have direct financial benefits. When a gas nozzle functions properly, fewer nozzle changes are needed and less time is lost to maintenance interruptions. And in the long run, fewer gas nozzle changes means less money spent on buying new nozzles.

Excessive consumable use from a scored and overheated tip also costs you money. But when the contact tip stays cool, consumables are used at a steady rate.

Flexlite GX reduces overall costs and improves productivity by:

Extending the life of your gas nozzle and contact tip.

Reducing consumable use.

Minimizing unnecessary maintenance interruptions.

_Source:

_{https://weldingvalue.com/2023/02/best-way-to-eliminate-spatters/#794ba45e}