Welding anti-spatter

Protective against welding sparks.

During welding operations, problems may arise due to the production of incandescent sparks of molten alloy. This causes obvious fouling on the adjacent surfaces and on the welding tools themselves, metallization, encrustations that are difficult to remove, micro cracks and defects that can lead to corrosion over time. These inconveniences would create considerable inefficiencies in production and considerable costs due to rework, scrap and waste of resources.

These defects can be prevented or minimized by using suitable release agents which, forming an inert coating with sparks, act as a barrier between the molten metal and the item. The application is easy and it can be carried out with a brush or spray, covering nozzles and areas that are not involved in welding. At the end of the operation it will be sufficient to clean up in order to continue with further processing.

On the market there are different types of release agents for welding, which can be used both industrially and for domestic or semi-professional works. Products based on dichloromethane and toxic solvents in which paraffins or oily components are dissolved are still widespread; other products are totally hydrocarbon based, oily, aqueous or in emulsion. Some versions contain talc and zinc stearate dissolved in solvents such as methyl ethyl ketone. There are also ceramic release agents in acetone solution or similar, specific for protecting the welding torch even after many working hours, thanks to the resistance to extreme temperatures.

Below you can find the tested formulation and the production process of an anti-spatter in aqueous emulsion, based on ecological and non-toxic raw materials, easily washable and ideal for applications in close contact with the operator and.

The production is developed in three phases:

1) Mixing of ester and hydrogenated oil

• Hydrogenated and ethoxylated (castor) oil OE40: 3-5%
• Soybean or rapeseed methyl ester: 7-9%

2) First addition of water

• Demineralized water: 4-6%

3) Second addition of water and additives, creation of the emulsion

• Demineralized water: 70-80%
• Ethoxylated alcohol: 3-5%
• Triethanolamine 85%: 1-3%

The first phase presents difficulties because a very dense paste will form which, until it is uniform, cannot be diluted (otherwise the emulsion will not be stable). After proceeding with the first addition of water, mix properly for at least half an hour. Now it is possible to make subsequent additions and mix until a milky emulsion without lumps is created, paying attention that the initial dense part could stick on the walls or shaft of the mixer.