Troubleshooting
Why does my weld have excessive spatter?
Quick answer
Excessive spatter is caused by too high current for the wire, too long stick-out, or wrong polarity on gasless wire. The fix: drop the voltage a step, shorten stick-out, verify polarity on the wire packet.
Root causes
Too high current for the wire, too long stick-out, or wrong polarity on gasless wire.
The fix sequence
- drop the voltage a step, shorten stick-out, verify polarity on the wire packet
- Change one variable at a time and re-test on scrap
- Re-inspect the finished bead — chisel, brush, look
When to grind it out
Structural or pressure work with visible defects: grind back to sound metal and re-weld — never 'cap over' a defect and hope. For non-critical jobs, judge honestly: a cosmetic defect is a learning note; a fusion or crack defect is a redo.