Lawrence,
Your right, a good procedure should produce welds with little, if any spatter. And no, I didn't include the anti spatter in the PQR.
The audit was for a new customer. The customer makes parts for the Government. A TACOM representative witnessed the new customer's reps weld audit. The owner of my company told me to make them happy.
We've made parts for the government for 30 years. We have an in-house government Quality Assurance Representative. The TACOM rep and the new customer wouldn't recognize him. He was out ranked. Even though, both the new customer and the TACOM rep had extensive welding experience.
We were attempting to get four parts using three different codes approved with PQR's. The TACOM rep had issue with one of the PQR weld samples. He wanted another sample. I had metal ready and an open weld station, so we went into the shop. I wanted them to leave that day with success. We need the business.
I grabbed one of my best welders and we went to the station. The customer and the TACOM rep were actively engaged with the welder. They offered advice, pointers, and encouragement to the welder and myself. He was nervous. We welded three different sets of samples, one my way, one the welder's way, and one the TACOM reps way. It was a complete group effort.
I've always cut and etched my macro samples using a belt sander and muratic acid. I'd let them soak for about an hour. My new customer suggested 2% nitric acid. He claims the developing time is seconds. The TACOM rep was actually buffing the parts with a 90* air sander using Scotch Bright pads, I never new that. I think that my two visitors were having fun.
Near the end of the shop visit is where the TACOM rep spotted the anti spatter. He picked it up and said, "Never use this." He went on and on. He said it could cause porosity below the weld surface. And that's where the audit ended.
I also agree with anti spatter overuse. I did call the manufacture of the anti spatter about a year ago. I was trying to reduce spatter while welding a flange to 2" tube using my GMAW robot. The manufacture said the spatter was probably caused by improper torch angle. He actually talked me out of buying a 50-gallon drum of his product. I think it was Safety Kleen. I changed my torch angles to as close to 45*, and my travel angles to as close to 15* as possible (His suggestion). Amazing. No spatter.
It's my experience during an audit to give the auditor the low hanging fruit. I want them happy. I want to be as helpful as possible. I want the business!
Thanks for all your help,
Keith