Copper. It can be applied as a plated coating but if you need more durability it can be used as a sleeve as well. See the nozzle on your wire feed gun for an example.

I need wear resistance for the pins though. I have steel car parts being set on the pins and templates, so the repeatability is a paramount factor to consider. Secondly, I was reading that I'd need something with higher melting temperature than that of spatters. Copper doesn't seem to have higher melting temperature than steel. Why do you think it is a good metal for this application?

I only have experience and can't explain why. Welders and welding masks often use copper for parts in the spatter zone.

Also, welding benches are often cast iron as it also resists build up of spatter. https://www.thefabricator.com/thefabricator/articl...

Perhaps a grade of cast iron will give you the wear resistance you need?

Copper's high thermal conductivity will tend to freeze spatter quickly before it can melt the copper and fuse to it. However, I do not think this would be a good solution for your problem.

I would suggest spatter shields located close to the point of welding. Are you not concerned with spatter onto your parts?. These can be sheet metal or fabric made from carbon, silica, or aramid (A.K.A., welding blankets).

Copper (and cast iron) only benefit if there is a large mass behind, to quickly disperse the heat. Copper plating or copper pins probably won't help much, if anything.

Have you tried anti spatter spray? Need to be re-applied regularly, but it is a possibility.
The better sprays are ceramic based anti spat sprays. I've coated several C-clamps, the mass clamp, and other welding related thing in the spatter zone with this ceramic coating from 3M, and it certainly helps (but don't expect miracles).

Imposter666

what welding process is being used that is causing splatter issues, and how big and complex is this welding assembly?
using mig , tig or stick?

Have you looked into ceramics?

The OP mentions automotive manufacturing, so I think the welder here is probably a robot.
Close process control and consequent issues like spatter as consumables degrade during continuous operation are going concerns that the robotic welding community is well familiar with. Physical barriers and sprays might not be very feasible in a robotic cell environment. I also know that welding gas mixtures are very finely tuned; is yours optimized?
Have you reached out to your consumables supplier or robot maker for tech support?

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

I agree that in first place, the cause should be adressed. But in reality, welding spatter free on thin plates is quite the challenge. Has everything been done to minimize spatter? What are the consumables, gas shielding, base materials (+ coating!), joint geometry, welding positions and parameters, ...

Assuming wire feed welding, consider switching to a pulsed MIG as it can completely eliminate spatter.

https://blog.perfectwelding.fronius.com/en/mig-mag...

Quote (TugboatEng)

Assuming wire feed welding, consider switching to a pulsed MIG as it can completely eliminate spatter.

I like pulsing too, but you can never can completely eliminate spatter, at least not after the first 5 minutes. Robots run 24/7.

(And don't get me started with Fronius and their Cold Metal Transfer, the biggest act of hype in the welding world since T.I.M.E. gas. Not that it's so terrible, but they take a fundamentally wrong approach to intelligent short-arc. Lincoln and Miller do it better.)

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."