WELDING IMPERFECTIONS
3.1
WELD IMPERFECTION
3.2
WELD DISCONTINUITY
3.3
DEFECT
An unacceptable imperfection
3.4
PLANER DEFECTS
Planer defects are two dimensional defects e. g. Cracks, Lack of Penetration, Lack of Side Wall
Fusion etc.
3.5
VOLUMETRIC DEFECTS
Volumetric (Non-Planer) defects are three dimensional e.g. Porosity / Pores, Slag etc.
3.6
3.7
Cracks
Cavities
Solid Inclusions
Lack of Fusion and Penetration
Imperfect Shape and Dimension
Miscellaneous Imperfections
CRACKS
An imperfection produced by a local rupture in the solid state, which may arise from the effect of
cooling stresses.
3.7.1
TYPES OF CRACKS
1)
2)
3)
4)
5)
3.7.2
Longitudinal Cracks
Transverse cracks
Radiating Cracks
Crater Cracks
Branching Cracks
LOCATION OF CRACKS
Page 1 of 10
Section 3
Welding Imperfections
3.7.4
Remedies
Preheat
Relieve residual stresses mechanically
Minimize shrinkage using backstep or block welding sequence
Excessive Dilution
Defective Electrodes
Poor fit-up
Angular distortion
Crater Cracking
Hydrogen in welding
atmosphere
Hot cracking
Low ductility
Use preheat
Anneal base metal
High hardenability
Preheat
Increase heat input
Heat treat without cooling to room temperature
Page 2 of 10
Section 3
Welding Imperfections
3.8
CAVITIES
1)
2)
3.8.1
Gas Cavities
Shrinkage cavities
GAS CAVITIES
3.8.1.1
GAS PORE
A gas cavity essentially of spherical shape trapped within the weld metal. Gas cavity can be present in
various forms:
1)
Isolated Porosity
2)
Clustered (Localized) Porosity
3)
Linear Porosity
4)
Elongated Porosity
5)
Surface Pore
3.8.1.1.1
Causes
Remedies
3.8.1.2
WORM HOLE (PIPING)
Elongated or tubular cavities formed by entrapped gas during solidification of weld metal
Causes
Remedies
Page 3 of 10
Section 3
Welding Imperfections
3.8.1.3
SURFACE POROSITY
A gas pore that breaks the surface of the weld
Causes
Remedies
Excess sulphur
3.8.1.4
CRATER PIPE
A shrinkage cavity at the end of a weld run
Causes
Remedies
Retrain welder
Current high
Reduce current
Page 4 of 10
Section 3
Welding Imperfections
3.9
SOLID INCLUSIONS
3.9.1
SLAG INCLUSIONS
Causes
Remedies
3.9.2
FLUX INCLUSIONS
Causes
Remedies
3.9.3
OXIDE INCLUSIONS
Causes
Remedies
3.9.4
TUNGSTEN INCLUSIONS
Causes
Remedies
Page 5 of 10
Section 3
Welding Imperfections
3.10
LACK OF FUSION
Lack of union between the weld metal and the parent metal or between the successive layers of weld
metal.
1)
Lack of side wall fusion
2)
Lack of inter-run fusion
3)
Lack of root fusion
3.10.1
Lack of union between the weld and parent metal at one or both sides of the weld
Causes
Remedies
Reduce inductance
3.10.2
A lack of union along the fusion line, between the weld beads
Causes
Remedies
Increase current
Retrain welder
3.10.3
Lack of fusion between the weld and parent metal at the root of a weld
Causes
Remedies
Incorrect angle
Retrain welder
Page 6 of 10
Section 3
Welding Imperfections
3.11
3.11.1
LACK OF PENETRATION
1)
Incomplete penetration
2)
INCOMPLETE PENETRATION
Causes
Remedies
3.11.2
Causes
Remedies
Incorrect angle
Retrain welder
3.12
UNDERCUT
An irregular groove at the toe of a run in the parent metal or in a previously deposited weld metal due
to welding. It is characterised by its depth, length and sharpness
1)
Continuous undercut
2)
Intermittent Undercut
3)
Inter run undercut
Causes
High welding current
High travel speed
Excessive / incorrect weaving
Incorrect electrode angle
Incorrect shielding gas selection (MAG)
Page 7 of 10
Remedies
Reduce welding current
Reduce travel speed
Reduce weaving width or switch to multirun
Direct arc towards thicker member
Ensure correct gas mixture for material type and
thickness
Section 3
Welding Imperfections
3.13
Excess weld metal is the extra metal that produces excessive convexity in fillet welds and a weld
thickness greater than the parent metal plate in butt welds
Causes
Remedies
3.14
EXCESS PENETRATION
Projection of the root bead penetration beyond a specified limit. Excess penetration can be local or
continuous
Causes
Remedies
Retrain welder
3.15
OVERLAP
Imperfection caused by metal flowing on to the surface of the parent metal without fusing at the toe of
weld
Causes
Remedies
Retrain welder
3.16
LINEAR MISALIGNMENT
Misalignment between members of a weld joint such that their surface planes are parallel but they
are not in the required same plane
Causes
Remedies
Page 8 of 10
Section 3
Welding Imperfections
3.17
ANGULAR MISALIGNMENT
Misalignment between two welded pieces such that their surface planes are not parallel or at the
intended angle
Causes
Remedies
3.18
A continuous or intermittent channel in the surface of a weld metal due to insufficient deposition of
weld filler metal
Causes
Remedies
Retrain welder
3.19
IRREGULAR WIDTH
Causes
Remedies
Switch from DC to AC
Arc length shall be as short as possible
Retrain welder
3.20
ROOT CONCAVITY
A shallow groove that occurs due to shrinkage at the root of a butt weld
Causes
Remedies
Retrain welder
3.21
BURN THROUGH
Causes
Insufficient travel speed
Excessive welding current
Lack of welder skill
Excessive grinding of root face
Excessive root gap
Page 9 of 10
Remedies
Increase the travel speed
Reduce welding current
Retrain welder
Retrain welder
Ensure correct fit up
Section 3
Welding Imperfections
3.22
Local damage to the surface of the parent metal adjacent to the weld, resulting from arcing or striking
the arc outside the weld groove.
Causes
Remedies
3.23
Improve access
Regularly inspect electrode holders and torches
Maintain current return clamps regularly
Provide an insulated resting place
Retrain welder
SPATTER
Globules of weld metal or filler metal expelled during welding and adhering to the surface of parent
metal or solidified weld metal
Causes
Remedies
Page 10 of 10
Section 3
Welding Imperfections