Weld Discontinuities and defects

Causes & Remedies

Definition
Influence
Types
Causes
Remedies
 Discontinuity & Defect

Discontinuity refers to any interruption or

in-homogeneity in the material that is
otherwise homogenous

Defect refers to an interruption having

dimensions/features beyond acceptable
limits.
Defects are otherwise called as Flaw or
Imperfections that are to be repaired so that
the material is made more homogeneous as
assumed in the design
 Weld joint is itself is a Discontinuity
HAZ

WM
PM

The Microstructure is different in the different

regions of weld zones of weld joint.
So the mechanical properties also vary from
zone to zone causing heterogeneity
Weld Discontinuities and defects
Causes & Remedies
 Discontinuity & Strength

Strength of the weld joint is influenced by

Filler metal strength
The extent of penetration
Presence of discontinuities in the weld
Presence of stresses in the weld joint

t t
Weld Strength
Lack of penetration

Presence of Fusion related discontinuities

Weld Strength

100% Joint Efficiency is obtained when

The weld is carried out on both sides
Back gouging is done after welding the first side
LPI or MPT is carried out after Back gouging
100% RT / UT is carried out after second side
welding
Weld Strength
The Electrode or the filler wire should be selected
such that it
Matches with the strength of the base material
Has fairly low carbon & controlled impurities to
avoid cracking
Moisture level is controlled and is of low H2 type
Is usable in all positions
 Influence of discontinuities
They act as stress raisers
They reduce the cross sectional
area and thereby increase the stress
concentration around them
They provide a leak path
They are potential sites of crack
initiation
They act as potential sites of corrosion
and erosion
 Types of discontinuities
Metallurgical discontinuity
Fusion type discontinuity
Geometrical discontinuity

Surface discontinuity
Internal discontinuity

Voluminar discontinuity
Planar discontinuity
 Common surface Discontinuities

Un-equal weld size

Under sized weld
Weld offset ( from seam)
Non-uniform weld size
(along the length)
Oversized weld
Excess Penetration
Weld crater
 Common surface Discontinuities

Improper Weld bead Profile

Coarse weld Ripples
Excess Convexity
Root concavity
Excess Reinforcement
Overlap
Undercut
Misalignment
Lack of Penetration
 Common Surface Discontinuities

Surface Porosity
Spatter
Wire sticking
Crater pin hole
Crater crack
Surface cracks
 Common Internal Discontinuities
Porosity
Blow Holes / Aligned / distributed /
Cluster / worm hole Porosities
Lack of fusion/ Lack of Penetration
Lack of side wall fusion / Inter run
fusion / lack of fusion at root
Cracking
Under-bead cracking / delayed
cracking / Delayed cracking
/Hydrogen induced cracking
Hot cracking, shrinkage cracks,
Fatigue cracking
Gouges & defects on Gas cut surfaces
Arc strikes & Spatter
Excess Penetration

P
Excess Penetration

Proper Penetration
Excess Penetration
Root Concavity
Weld Size & Reinforcement

R = max 3 mm
Weld Size & Reinforcement
Shallow Obtuse
angle > 100

Obtuse angle > 90

High level of SC
Acute angle > 90
Weld Size & Reinforcement

L T Throat Size
T R
T L Leg size
R- Reinforcement

L L
Weld bead Profile

Fillet Weld with

straight bead

Fillet Weld with

Convex bead

Fillet Weld with

Concave bead
 Weld Bead Profile

Straight bead without Convex bead with re-

re-enforcement enforcement

L2

L1
Concave bead with Convex bead with un-
under sized weld equal sized weld
Undercut & Bead Off-set