What occurs as a result of spatter in the GMAW process?

Spatter is a common phenomenon in the Gas Metal Arc Welding (GMAW) process, and its primary consequence is the formation of unwanted metal dots on the surface of the material being welded. This occurs when molten metal droplets are expelled from the welding arc due to various factors such as parameters set on the welding machine, the type of filler material used, or the conditions in which welding takes place.

When spatter forms, it can result in a rough weld surface that may require additional clean-up and can affect the aesthetic appearance of the finished product. It also has the potential to inhibit the proper fusion of the welded materials, which can lead to defects if not properly addressed. Since spatter is generally seen as an undesirable outcome, it contrasts sharply with improving factors such as electrical efficiency or weld bead appearance, making the formation of unwanted metal dots the most relevant result of spatter in the GMAW process.