Which metal transfer type produces the most spatter?

Globular transfer is known for producing the most spatter in welding processes. This happens because, during globular transfer, molten metal droplets are larger and have a more irregular size distribution compared to other transfer modes. These larger droplets can easily break away from the electrode and are typically propelled out of the welding arc, leading to increased spatter.

In contrast, short circuiting transfer contains smaller droplets that contact the workpiece, reducing the likelihood of spatter. Spray transfer, while it creates a more focused weld pool with less spatter, involves smaller droplets that are ejected in a more controlled manner. Pulsed spray further minimizes spatter by controlling the molten metal transfer in a pulsed manner, allowing for precision and reduced splatter compared to globular transfer. Thus, globular transfer is characterized by excessive spatter due to the nature of the droplet formation and detachment from the welding arc.