Weld splatter is the iconic layman's view of the car production process. Althogh photogenic, it represents the worst practice in resistance spot welding. Energy, destinded for the weld is rerouted to weld splatter that is thrown around on the job. The result is:

1. Health and safety issues
2. Health issues with welded beryllium waste
3. Additional post processing
4. Poor weld quality
5. Poor repeatability

** Most production weld guns use AC supplies. In order to reduce weld splatter with this type of supply, it is essential that the squeeze current phasing is set correctly. The Diverse Squeeze Analyser will do this.

There are techniques to reduce weld splatter, particularly those that control the welding waveform and or monitor the weld current.

The best solution is to use the Diverse Squeeze Analyser. It allows resistance spot weld guns to be set with precisely the correct phasing between the squeeze and weld current times. With this done, all the weld energy is in the weld, the variability weld to weld is reduced, there is less rework and the tear test results are better.

Health and safety

Welded parts with poor weld splatter can be such that they are unable to meet stringent release requirements for beryllium surface contamination. This can be significant at the low levels such as required for beryllium release. Using the squeeze Analyser to reduce splatter enhanses Worker protection.