According to the different causes of splash under different droplet transition forms, different causes of splash reduction should be used, and different methods should be used to reduce splash:

1. In the free transition of droplets, reasonable welding current and welding voltage parameters should be selected to avoid the use of large drop exclusion transition form; At the same time, high-quality welding materials should be selected, such as the selection of welding wire H08Mn2SiA with low C content and deoxidation elements Mn and Si, etc., to avoid sputtering caused by gas precipitation or expansion due to metallurgical reaction of welding materials.

2. In the short circuit transition, can use (Ar+CO2) mixed gas instead of CO2 to reduce splashing. For example, add φ(Ar)=20% ~ 30% Ar. This is because the arc shape and droplet transition characteristics change with the increase of argon content. The arc root of the arc expands and the droplet's axiality is enhanced. This aspect makes it easy for the droplet to meet the molten pool, and the short circuit bridge appears between the welding wire and the molten pool. On the other hand, under the action of axial force, a more uniform short-circuit transition process is obtained, and the peak short-circuit current is not too high, which is conducive to reducing the spatter rate.

In the pure CO2 atmosphere, the welding current waveform control method is usually used to reduce the initial short-circuit current and the current of the short-circuit bridge breaking moment, reduce the electric explosion energy of the bridge, and achieve the purpose of reducing splash.

3. The minimum splash when the welding torch is vertical, the maximum tilt Angle, the more splash. Tilt the torch forward or backward preferably not more than 20 degrees.

4. The use of low splash rate welding wire. ① Solid core welding wire. On the premise of ensuring mechanical properties, the carbon content should be reduced as much as possible, and an appropriate amount of titanium, aluminum and other alloying elements should be added. Both particle over-welding and short-circuit over-welding can significantly reduce the splash caused by gases such as CO. ② Using Cs2CO3, K2CO3 and other substances to activate the treated welding wire, positive polarity welding. ③ Use flux-cored welding wire. The metal spatter rate of the flux-cored wire is 1/3 of that of the solid wire.

5 The general current is less than 150A or greater than 300A splash rate is small, between the two splash rate is larger. When selecting the welding current, the current area with high splash rate should be avoided as much as possible. The current is determined after matching the appropriate voltage to ensure the minimum splash rate. Extension length of welding wire. Under the condition of ensuring normal welding, the extension length of the welding wire should be shortened as far as possible.

By improving the wire feeding system and using pulse wire feeding instead of conventional constant speed wire feeding, the melt drop is short-circuited with the melt pool under the condition of pulsating feed, so that the short-circuit transition frequency is basically consistent with the frequency of pulsating wire feeding, the electrical parameters of each short circuit cycle are good, the peak current of short circuit is uniform, and its value is not high, so as to reduce the splash.

If the pulsating wire feed is based on the current waveform control, the effect is better. The relationship between welding spatter rate and welding current when different control methods are used.