How can I reduce spatter in yasakawa spot welding ?

The purpose of spatter reduction is to enhance safety in subsequent operations, improve the quality of spot strength, appearance, and body accuracy, prolong the equipment life, and ultimately reduce the overall cost of the vehicle.

Reason of Spatters occurrence:- Spatters occur due to variation in resistance during spot welding , Resistance varies due to many reason , detail below and how to control is also explained below

In spot welding heat is generated with the principle of Joules law H= I2 R t.

I is current and t is Weld time, R is the resistance that is maintained to ideal condition in spot welding due to electrode force .

Spatter is nothing but solidified particles of the molten metal which fly or come out of the molten pool act as a burr during spot welding because of heat generated and continuous electrode force during spot welding

Procedure and steps for Spatter reduction

There are 5 steps to control the spatters

1, Recording of data of spot schedule , parameters , panel quality and action- Each spot must have individual schedule or set of parameters

2, Tip dressing check & correct

3, Electrode alignment check & correct

4. Zero touch-up - During spot teaching or manual welding, fixed side electrode first touch the work piece & than moveable electrode to generate electrode force.

5, Change of worn out tip to new

Correction can be done by comparing the template resistance graph with actual graph and control it by adjusting parameters

Step 1

1) Note down the Schedule, in which robot maximum spatter occurring. ( all spot should have individual parameter schedule )

2) Spatter data should be noted only after dressing and within 5 cycles after dressing

3) Record the spot which is giving Spatter ( Record minimum 5 reading ) Note the schedule , choose and modify weld spot

4) Spot status check with 3G (on site check) Check the panel matching (gap) status and correct

5) Check the panel quality for wrinkles, dust, rust, damage etc. take action to correct

Step 2

Tip dressing check , Reteach & correct

1) During dressing fixed tip should be touch

2) Dresser pressure should be between 150 kgf to 170 kgf

3) Dressed tip dia. Should be 6-7 mm.

Step 3

Gun alignment & Matching check , if NG →correct

1) In Straight shank always take fixed tip as reference point.

2) In one Bend Shape shank always take Straight shank as reference point.

3) In Both Bend Shape shank take Scale as reference by placing scale in vertically.

We can also observe the graphic trend of resistance variation during spot welding in case of adoptive system used of different makers ie Denyo - Nadex , Obara etc and we can control the spatter after studying it

Each steps have detail, For detail of each may contact