Which factor can lead to higher spatter in GMAW?

Unstable arc conditions are a significant factor that can lead to higher spatter in Gas Metal Arc Welding (GMAW). When the arc is unstable, it tends to produce inconsistent energy delivery and can make it difficult for the molten metal to flow smoothly. This instability can lead to erratic transfer of the filler material from the welding electrode to the weld pool, resulting in excessive spatter.

In an unstable arc, the metal transfer might occur unevenly, causing some droplets to detach from the electrode prematurely or with inadequate force, which allows them to be flung away from the weld pool instead of being absorbed into it. Consistent and controlled arc characteristics are essential for minimizing spatter, as they promote a stable molten pool and efficient transfer of molten material.

Stability can be influenced by factors such as welding speed, voltage, and the geometry of the workpieces. Therefore, ensuring stable arc conditions is crucial for producing clean, high-quality welds with minimal spatter.