SPATTER ANALYSIS AND

REDUCTION

Project by : Vipin Kumar Chaurasia

Summer Trainee MSIL, WS 2-3

Unrestricted
 Introduction of Plant
• Weld shop 2-3 department is the second weld shop of Maruti Suzuki
India Limited (MSIL) in Gurugram Plant. Weld shop 2-3 has 100%
automation. Weld shop 2-3 is in between the Press Shop and the
Paint Shop.
• The model which is manufactured over here are Alto 800 (YE3/YE3
MC 19), Vitara Brezza (YBA), Ignis (YJC) , S-cross (YAD). An updated
model Alto (YE3 MC19) has been started its production from 18th
march, 2019. A lot of automations were carried out to improve the
capacity.
 Sequence of
Manufacturing
Of
Weld Shop 2-3
 Division of Weld Shop 2-3
• Under Body: Here different underbody
panels are welded together. These
comprises of rear underbody, central
underbody, front engine room panel.
These underbody panels are prepared on
sub line starting from singular
components. The sub lines have specific
jigs for each. There are chain hosts for
transferring the jobs from one jig to
another on sub lines. Finally, these
underbodies are put on the conveyor and
welded together to give the underbody.
The chassis no. is punched on the cowl top
and it is welded to the front engine room
panel.
 Division of Weld Shop 2-3
• Main Body: As the body moves
on the conveyor, roof and side
body panels are welded to it to
give the main body. The side body
panels are prepared on the sub
lines. Each side body consists of
an inner side body and an outer
side body. All the spots are
welded onto the inner side body
which is welded onto the outer
side body.
 Division of Weld Shop 2-3
• White Body: The White
Body line is common for
both line-2 and line-3. The
doors, hood and back
door are attached onto
the main body with the
help of bolts and screws
to make it a “White Body”.
The body is checked for
dents, burr and spatter
and these defects are
repaired. After inspection
and repairs the body is
called WBOK. It is sent to
the paint shop thereafter.
 Welding Techniques used in Weld Shop 2-3:

For welding purpose, the following welding techniques are used in the
Weld shop:

• Resistance welding
• MIG welding
• Gas welding
• Precision welding
 Resistance Welding:
Resistance welding basically consists of spot welding. In this process, an electric current
flow through a resistive circuit to generate enough heat between two pieces of sheet
metal so that the metal reaches molten stage. The resistance to the flow of current is
provided by the work piece. The maximum heat is generated at the point of maximum
resistance.
• Weld current
• Weld time
• Pressure
• Electrode press
Heat generated is given by, H = 𝑰𝟐 𝒙𝑹𝒙𝑻
Where, H = Heat.
𝐼 2 = Current in amperes.
R = Resistance of the work in ohms.
T = Time the current flow in cycles.
Equipment used for Spot Welding:
 MIG Welding:

This is a modern Arc welding technique which uses an inert gas atmosphere
in place of flux and has auto feeding. This technique is used specially, for
welding of thin sheets. In sheet metal work, this technique is extensively
used. Inert gases like Argon are mainly used. C𝑂2 gas is relatively cheap to
Argon and has similar inert property. So, in mass production, where finishing
quality is not much required, C𝑂2 gas is used in place of Argon. That’s why,
the MIG welding which uses C𝑂2 gas for inert atmosphere is called C𝑂2
Welding.
Parameters of C𝑶𝟐 welding:
• Voltage : 16-24 V
• Current : 60-100 A
• C𝑂2 Flow Rate : 16-20 Lt/min
 Gas Welding:
BRAZING:
• Brazing is defined as a joining where in coalescence is produce by heating to a suitable
temperature and by using a filler metal having a melting point above 427°C and below
the melting point of base metal.
• This is a non- fusion process in which a dissimilar filler material fills the gap between
close fitted surfaces of joining parts through capillary rise.

SOLDERING:
• It’s also a joining process similar to Brazing, but with a difference in temperature.
Soldering is done below the 427°C.
• This joining process is suitable for low application of heat.
• Example – Body outer skin is very sensitive to heat. So, any repairs like dent etc. are
repaired by soldering.
 Precision Welding:

The stud welding is being done in Weld Shop, through precision

welding. The welding instrument consists of controller, feeder, cable,
feed pipe, gun, etc.
 Project Contents

• What is Spatter?
• Types of spatter
• Need and scope of Spatter Reduction
• Effects of Spatter
• Reasons of Spatter
• Spatter reduction flow chart
• Activities done for Spatter Reduction
• Results achieved after Spatter Reduction
• Learning
 Spatter
• Weld spatter consists of droplets of
molten metal or non-metallic material
that are scattered or splashed during the
welding process. These small bits of hot
material may fly and fall on the
workbench or on the floor, while others
may stick to the base material or any
surrounding metallic material.
• Spatter is nothing but solidified particles
of the molten metal which fly or come out
of the molten pool act as a burr during
spot welding because of heat generated
and continuous electrode force during
spot welding.