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KTA-TATOR, INC.
Corporate Headquarters
115 Technology Drive
Pittsburgh, PA 15275
Phone: 412.788.1300
Fax: 412.788.1306
E-mail: info@kta.com

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1-800-KTA-GAGE
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KTA Challenge #6
Answer - Weld Spatter


Photograph 1 - Challenge microphotograph at 100x	Photograph 2 - Weld surrounded by weld spatter

Challenge 6 (Photograph 1) is a microphotograph of weld spatter (100x digital photograph taken in the KTA laboratory). Photograph 2 confirms that Challenge 6 is weld spatter. While the spatter shown in the microphotograph is very uniform in shape and appears to be tightly bonded to the steel, this is not always the case. Weld spatter can be irregular and exhibit poor adhesion to the surface. If poorly adherent weld spatter is painted, it can become dislodged in service, exposing pinpoints of bare steel. Coatings can also draw thin on weld spatter, or provide incomplete coverage of the surface, allowing corrosion to form.

When the service environment involves immersion or highly corrosive conditions, the weld spatter is typically removed prior to blast cleaning and painting. Note however, that there is a frequent misconception in the blast cleaning specifications regarding the treatment of weld spatter. None of the specifications, including SSPC-SP5, White Metal, require that the spatter be removed. The blast cleaning specifications simply indicate the point in the cleaning process that the spatter should be removed if removal is required by the project specification. Accordingly, the removal of weld spatter, or the grinding of sharp edges, need to be specifically addressed in the project specification.

Welds should be cleaned by grinding, needle de-scaling or other appropriate means to ensure the proper weld profile and surface conditions are met. This will aid in the inspection of the weld and assure proper paint coverage. After cleaning, the welds can be evaluated using a number of non-destructive testing techniques including visual testing (VT), magnetic particle testing (MT), dye-penetrant testing (PT), ultrasonic testing (UT) and radiographic testing (RT). Weld spatter must be completely removed in areas subject to UT and RT.

The KTA Steel Group can answer any of your questions regarding non-destructive testing, and can conduct the necessary shop or field evaluations to verify specification compliance.

While nearly 30% of those responding correctly guessed weld spatter, 45% of the responses indicated it was a rivet. The remaining guesses included rusted bolts, studs, backside of steel where a stud had been welded, reverse impact used in laboratory testing, crevice corrosion, blisters, embedded steel shot, and flash rusting that forms after water jetting.
The winner, selected by random drawing of all who guessed it was weld spatter, is Juan Martinez of Industrial Specialists L.L.C..