Spatter

Spatter particles are ejected from the arc and, upon cooling, bond to the adjacent base metal with significant mechanical strength; removing spatter requires grinding, picking, or chemical methods that add post-weld labor cost. Reduced spatter improves aesthetics and reduces finishing costs, particularly on decorative or high-visibility equipment like NEMA control enclosures or architectural structural members.

FCAW and TIG processes typically produce less spatter than MIG welding at equivalent travel speeds, making them preferred for applications where appearance is critical or where spatter cleanup labor is prohibitively expensive. Modern power supplies with pulsed transfer modes and specialized contact tips significantly reduce spatter generation in GMAW, often matching FCAW cleanliness while maintaining the higher deposition rates of MIG processes.