Welding Spatter Protection

Whether it is in manufacturing processes or in engineering: when pressure and heat result in small particles being emitted from welded surfaces, sparks are created. These can often be prevented by adapting the current or creating a protective atmosphere. These spatters are particularly troublesome when they adhere to the component. To avoid later problems in downstream processes such as insufficient coating and subsequent corrosion, the welding spatters are often removed manually. In these cases, high-quality coating solutions also offer a reliable solution.

DELTA-HEAT^®: Optimal Welding Spatter Protection

To avoid quality problems and costly reworking, the application of a special coating such as DELTA-HEAT^® is advisable. This prevents the welding spatters from adhering to the substrate, thus ensuring a homogeneous surface. In the further process the DELTA-HEAT^® can be painted over. The removal of the applied layer for later coating processes can also be achieved without problem using a high-pressure cleaner and standard solvents, lyes or acids – for example acetone, 5% sodium hydroxide solution or 5% hydrochloric acid.

In comparison: in the tested welding forms MIG welding (left) and arc welding (right) the upper section of the welded sheets were left untreated (golden) and the lower section (silver) coated with DELTA-HEAT^®. The plates on the right were also cleaned.

DELTA-HEAT^® not only significantly reduces the spattered surface, it also reduces the scaling at the edge of the welding seam.

In comparison: The scaling at the edge of the welding seam with DELTA-HEAT^® (left) and without coating (right).

Avoid Damage from Excessive Heat

Whether it is exhaust and exhaust train components, brake components, heat shield or in the engine area: all cars contain parts that need to be protected against corrosion that are also exposed to high temperatures at the same time. Typically coated as bulk products, these components represent a particular challenge for corrosion protection coating, as key elements of the coating can lose their ability to function under the influence of heat, or no longer work reliably. Special coating solutions are therefore required here.

DELTA-HEAT^®300: Heat and Corrosion Protection Combined

Although standard zinc flake systems or galvanic systems offer superb cathodic corrosion protection, they are not suitable for applications where they are subjected to very high temperatures. However, if a zinc flake base coat is used – the DELTA-PROTEKT^® KL 120 is particularly well-suited – with DELTA-HEAT^® 300 as topcoat, very good cathodic corrosion protection is achieved at temperatures of up to 1112 °F (600 °C). In addition, this high-performance system also satisfies further requirements typical of OEMs – for example good adhesiveness, coatability, chemical resistance and mechanical resistance with subsequent corrosion exposure.

This sheet was tempered at 932 °F (500 °C) for 30 minutes, subjected to stone impact (DIN EN ISO 20567) and exposed to 720 hours of salt spray testing (DIN EN ISO 9227). Outcome: no red rust can be seen. The extremely resistant combination of DELTA-PROTEKT^® KL 120 zinc flake base coat and DELTA-HEAT^® 300 has already been included in MAN specification 183-3 for the B7 surface form.

Discover More Special Solutions

Prevent Material Loss Due to Scale

If raw materials, components or semi-finished products are exposed to great heat during their processing, uncontrolled scaling occurs. If this is not removed, it can have a negative influence on subsequent work processes. In the worst case scaling results in material loss or wastage, for example where deep scaling holes render rollers unusable.

Avoid Greases Deposits on Components

Production processes with steel are often greasy and oily. Oils temporarily protect against corrosion, as well as being used as grease or lubricating oils. However, they need to be removed again in downstream processes – for example for effective corrosion protection coating – to ensure that coatings can adhere to the metallic substrate.

Ideal Protection of Thread-Rolling Screws Against Corrosion: With Solutions from DÖRKEN

Thread-forming screws express themselves through a characteristic property: during assembly, they automatically generate their matching nut thread by forming the material in the mating component. They therefore offer significant advantages: Direct bolting eliminates the process steps of drilling, threading and chip removal, which saves both time and costs. At the same time, the material consolidation in the thread ensures higher load capacity. Thread forming screws are thus a very economical solution for building structures and are therefore the preferred choice

Avoid Damage Caused by Sparks

DELTA-HEAT®: Optimal Welding Spatter Protection