Spatter Remover 511 is an innovative product in welding process technology that will improve the quality of weld metal.

Features of Spatter Remover 511 :

  » Incombustible, non-toxic and safe to use
  » Non-pollutant thus environment friendly
  » Silicone free
  » Emulsion form – use special spray bottle or apply with brush
  » Easy to apply on required area, no wastage
  » Easily removed from metal surface after welding for further painting
  » Tremendously reduces noise and air pollution in the workshop meeting the WHO guidelines for the industry
  » Enhances depth of penetration as the heat loss from top of the weld metal is held by the film, conserving around 5-10 percent of energy
  » Acts as a temporary rust preventive for about 10 days (helpful in avoiding V-groove flash rusting and hence abandons re-grinding of V-groove     prior to welding)

Suitability of Spatter Remover 511 :

Spatter Remover 511 can be applied to any kind of weld metal including arc, manual, CO2, argon, MIG, etc. for any kind of ferrous materials such as CS, SS, MS and all alloy steels. Spatter Remover 511 is ideal for fabrication of industrial equipments, tanks, boilers, vessels, pipelines, fabricated pinions and gears etc.

How to apply Spatter Remover 511 :

  » Stir the container well before using
  » The application surface must be free from grease and oil etc.
  » Apply a thin and uniform film of Spatter Remover 511 on any metal surface with any brush; or use a special spray bottle/system on both sides     of welding surface – prior to welding. (Around 3–4 inches where spatters are likely)
  » Start welding on the metal surface to be welded only after Spatter Remover 511 has dried completely
  » Remove Spatter Remover 511 film along with welding spatter particles using a separate fresh cloth or a dry brush, any time after welding

Metallurgical Aspects of Spatter Remover 511 Welding Anti Spatter and Flux

 »  The steel and weld metal contains 0.01% - 0.02% and 0.02% - 0.03% oxygen content respectively. Excess oxygen can have adverse consequences      on the mechanical properties of the weld metal (especially impact strength) apart from formation of additional Ferrous Oxide.

 »  Oxygen content in weld metal varies depending upon the welding current, arc length, and the sort of shielding employed. The coating of the      electrode upholds a shield of slag that is not sufficient (even with standard quality of electrode) to have lower level of oxygen in the weld metal.

 »  The contact of air with the weld pool may also boost the nitrogen content in the weld metal which is harmful. In open arc welding, weld metal      contains 0.12% - 0.18% nitrogen, while the parent metal contains merely 0.001% - 0.008% nitrogen. The gaseous inclusions lower the impact      strength of the weld metal which in turn leads to weld failure.

 »  The coating of Spatter Remover 511 aids to eliminate this problem in the weld pool. This coating acts as a flux when the arc is formed by      formulating a film over the weld metal. This film protects this weld pool from the surrounding air, which is mostly very active, thus minimizing      the reaction of oxygen and nitrogen with the surrounding area. This activity gives a clean and dense weld with enhanced mechanical and      metallurgical properties.

Refinement of Metal:

Apart from protecting the weld pool from the atmosphere, the coating that acts as a flux also partially removes oxygen from the molten metal by the process of de-oxidation. The oxides being lighter than metal formed by the process of de-oxidation of the weld pool floats up, and are removed along with the molten slag. Spatter Remover 511 helps to refine the weld metal thus improves the mechanical properties. As slags do not stick to the surface, it is easily removed. Deep penetration of the weld metal is yet another achievement.

Noise / Air pollution control comparison with Spatter Remover 511

 »  It provides dense and clean weld metal.
 »  It helps to eliminate the chipping and grinding process to remove spatters required for clean surface.

The second feature of this compound has become more pronounced as it has direct impact to maintain the clean environment needed at the work place in any industry. This has been noticed by a number of senior executives from various industries especially the ISO-14000 organizations. It is crucial for them to maintain their work place clean for which they need to compromise on a various process/products, which are not environment friendly.

In such circumstances, the use of Spatter Remover 511 helps to avoid a precarious situation because of its anti-spatter compound properties. It is advantageous since the absence of chipping and grinding process improves the environment of the working place thereby reducing the noise and dust pollution as shown under

Categories	Noise Pollution	Air pollution (Concentration of SPM*)
Without coating	150db (A) leq (8h) and above	More than 1200 mg/m3
With coating of Spatter Remover 511	50db (A) leq (8h) and below	Up to 150 mg/m3
Permissible limit of WHO for industries	Up to 75db (A) leq (8h)	Up to 200 mg/m3

As is evident, it reduces the SPM (Solid Particulate Matter) concentration in the working place from as high as 1200 mg/m3 to below 150 mg/m3; though the recommended level is 250 mg/m3. To maintain the healthy working standard in a workshop and to improve the environment at the working place, WHO has specified a minimum level of noise and air pollution (refer table), beyond which it creates health hazards. The manual of ISO-14000 too supports this aspect.