Mig welding Anti Spatter Treatment enabled real time
Protecting the Shielding Nozzle is a technique that comes in all shapes and sizes from the various manufacturers. Spray on ceramic, ceramic nozzles, chrome coated nozzles, no touch reaming systems, magnetic spatter removal and of course the most common and popular method, anti spatter spray on the Torch Service Center. All these systems have there merits and of course preferred users.
Simplistic systems are quite often overlooked or receive bad publicity because they do not appear complicated enough.
The MASter system is a simple system that can be applied to both manual and robotic mig welding applications. The operation is quite simple in that the co-developed anti spatter material is delivered in real time along with the shielding gas.
The delivery method already exists therefore no additional power supply or monitoring is required. The anti spatter liquid is converted to a fine mist or fog caused by the pressure and agitation of the liquid as the shielding gas passes through the liquid and is drawn into the delivery pipes by the venturi system on the MASter unit. The shielding gas flow is split with a controlled volume passing through the liquid and the remaining passing through the venturi.
The gas reunifies after the venturi with the liquid carried along as a mist to the delivery point exiting the torch through the diffuser and as a result the nozzle and the weld area receives protection in real time from the spatter that occurs during the welding process.
Full instructions and video can be found at the manufacturers website here and at the exclusive marketing agent Ian Hamilton Engineering here.
Case study: TS Tech, Swindon, Wiltshire - Car Seat manufacturer for Honda UK Ltd use the MASter in Mig Weld process and a visible difference in spatter protection is noted between conventional anti spatter system delivery on the torch service center in comparison with the MASter in use with a torch reaming station.
The product is compatible with all of the welding gases: Carbon Dioxide , Argon, Argon Based Mixtures, Helium, Hydrogen, etc
-Applicable in the welding of: Carbon Steel, Galvanized Steel, Stainless Steel, Bronze, Hard Facing,etc
-The System may be tuned according to the various requirements of levels of diffusion hydrogen.
-It is easily mounted on any existing manual, automatic or robotic MIG/MAG welding system.
When MIG/MAG welding process is used, welding spatters are common problem. When welding is being carried out, the spatters stick permanently to every adjacent to the welding zone, surface also the gas nozzle, the contact tip, the gas distributor, the nozzle holder and welding details. The spatters collect on the gas nozzle and contact tip and hinder the free exit of the welding wire and laminar stream of the welding gas. These spatters also stick permanently to the welding details and lead to expenditures for their cleaning.
The presented product uses a Method in which the welding gas, which is a natural component of the MIG/MAG welding process, is used for generating and transiting an anti-spatter mist into the welding zone, where an effective anti-spatter shield of the welding hand piece and welding details is carried out.
The Method is carried out via device (MASter Sprayer) ,created with the goal of generating a precisely adjusted quantity (level) of shielding anti-spatter mist, which is transmitted by the welding gas into the arc burning zone, where the shielding mist eliminates or reduces the effect of adherence of welding spatters.
The anti-spatter-fluid-containing device is a tightly sealed chamber placed between the source of the welding gas and the welding hand piece, in which the welding gas passed through a special nozzle, submerged in an anti-spatter liquid, comes out in the form of a jet stream with a specific form and generates a specific amount of fine mist, comprised of separate molecules or groups of molecules of the special anti-spatter fluid. The welding gas is collected in the space above the surface of the liquid, along with the generated anti-spatter mist. From there the welding gas transits the shielding mist through the whole welding gun into the arc burning zone.
The device is fed with a working fluid (MASter fluid). The fluid represents a mixture in specific limits of hydrocarbons /natural or petrol distillates/, mineral oils / natural or petrol distillates/ and corrosion inhibitors. The working fluid in the device is dispersed in the welding gas in the form of a shielding anti-spatter mist, via the passing of the welding gas through it.
The Anti-Spatter liquid (fluid) is designed to be able to form a mist with the necessary shielding properties,which have to be transited from the welding gas to the outlet of the welding hand piece, in a stable condition. It is accepted that, during the welding process, the anti-spatter mist creates a slight condensation on all contacting surfaces in the arc burning area. This condensation is evaporated by the heat of the welding arc and by the impacts of hot welding spatters, but a new condensation is simultaneously formed from the constantly incoming shielding anti-spatter mist. It is considered that the above written, including the fact that the welding spatters contact with the shielding mist during their flight, does not allow them to stick to these surfaces. The process is continuously resumed.