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Welding Defects

The document outlines various types of welding defects, their causes, prevention methods, and repair techniques. It also discusses weldability, inspection and testing methods including visual inspection, nondestructive evaluation, and destructive testing. Key defects mentioned include slag inclusion, undercut, porosity, incomplete fusion, and others, along with their respective characteristics and solutions.

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snehal patil
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11 views22 pages

Welding Defects

The document outlines various types of welding defects, their causes, prevention methods, and repair techniques. It also discusses weldability, inspection and testing methods including visual inspection, nondestructive evaluation, and destructive testing. Key defects mentioned include slag inclusion, undercut, porosity, incomplete fusion, and others, along with their respective characteristics and solutions.

Uploaded by

snehal patil
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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WELDING DEFECTS

M
SIVAKUMAR
Types of defects
➢
Slag Inclusion
➢
Undercut
➢
Porosity
➢
Incomplete fusion
➢
Overlap
➢
Underfill
➢
Spatter
➢
Excessive Convexity
➢
Incomplete Penetration
➢
Excessive Penetration
Slag Inclusion
Slag is the waste material created and bits of this solid material can
become incorporated into weld. Bits of flux and rust can be counted
as slag.
Cause:- Low amperage, improper techniques, slow travel rate

Prevention:- Increase amperage, increase travel rate

Repair:- Remove by grinding or other mechanical process


UNDERCUT
Undercutting is an extremely common welding defect. It happens when
your base metal is burned away at one of the toes of a weld. portion of
base metal melted away
Cause:- High amperage, wrong electrode angle, long arc length,
electrode is too large for the base metal

Prevention:- clean metal before welding

Repair:- Weld with smaller electrode, sometimes must be low hydrogen


with preheat.
POROSITY
In this defect, air bubbles or gases are present in the weld zone
Cause:- inclusion of atmospheric gases, sulfur in weld metal, or surface
contaminants
Prevention:- slower speed to allow gases time to escape
INCOMPLETE FUSION
A weld bead in which fusion has not occurred throughout entire cross
section of joint
Cause:- Low amperage, fast travel speed, short arc gap, lack of preheat,
electrode too small, unclean base metal
Prevention:- Eliminate the potential causes

Repair:- Remove & reweld, being careful to completely remove the


defective area.
Cracks
It is a discontinuity in the metal that significantly reduces strength
Cause:- low ductility of weld, solidification shrinkage

Prevention:-
When finishing move back the electrode to fill up the crack, Increase
crater fill time by power source.
OVERLAP
Weld metal spills beyond joint onto part surface but no fusion occurs
Cause:- Improper welding technique, steep electrode angle, fast travel
speed

Prevention:- Overlap is a contour problem. Proper welding technique


will prevent this problem
UNDERFILL
Depression in weld below adjacent base metal surface
Cause:- Improper welding techniques

Prevention:- Apply proper welding techniques for the weld type &
position. Use stripper beads before the cover pass.

Repair:- Simply weld to fill. May require preparation by grinding.


SPATTER
Small particles of metal that attach themselves to the surface of the
material
Cause:- High arc power, Damp electrodes

Prevention:- Reduce arc power, reduce arc length, use dry electrodes

Repair:- Remove by mechanical process


INCOMPLETE PENETRATION
Incomplete penetration happens when your filler metal and base metal
aren’t joined properly, and the result is a gap or a crack of some sort.

Cause:- Low amperage, low preheat, tight root opening, fast travel speed,
short arc length

Prevention:- Correct the contributing factors.

Repair:- Back gauge and back weld


EXCESSIVE PENETRATION
EXCESSIVE CONVEXITY
Cause:- Amperage & travel speed

Prevention:- Observe proper parameters & techniques

Repair:- Must blend smoothly into the base metal


EXCESSIVE CONCAVITY
Cause:- Amperage & travel speed

Prevention:- Observe proper parameters & techniques

Repair:- Must blend smoothly into the base metal


Arc blow
Arc deflection as a result of magnetic effects into the opposite direction of
the earth lead clamp.
Arc deflection as a result of magnetic effects in the direction of heavy part of
work piece especially at corner and edges.

Remedies:
Use AC electrode where possible.
Try welding away from earth clamp connection. Try splitting the earth clamp
and correct to both side of the joint.
Fusion Weld Zone
Weldability
•
Capacity of a metal or combination of metals to be welded into a
suitable structure, and for the resulting weld joint(s) to possess
the required metallurgical properties to perform satisfactorily in
intended service
•
Good weldability characterized by:
• Absence of weld defects
• Strength, ductility, and toughness in welded joint
Inspection and Testing Methods
•
Visual inspection
•
Nondestructive evaluation
•
Destructive testing
Visual Inspection
•
Most widely used welding inspection method
•
Human inspector visually examines for:
• Cracks, cavities, incomplete fusion, and other
surface defects
•
Limitations:
•
Only surface defects are detectable
• Welding inspector must also decide if additional
tests are warranted
Nondestructive Evaluation (NDE) Tests

•
Ultrasonic testing - high frequency sound waves through
specimen to detect cracks and inclusions
•
Radiographic testing - x-rays or gamma radiation provide
photograph of internal flaws
•
Dye-penetrant and fluorescent-penetrant - to detect small
tests cracks and cavities at part surface
•
Magnetic particle testing – iron filings sprinkled on surface reveal
subsurface defects by distorting magnetic field in part
Destructive Testing
Tests in which weld is destroyed either during testing or to prepare
test specimen
•
Mechanical tests - purpose is similar to conventional testing
methods such as tensile tests, shear tests, etc
•
Metallurgical tests - preparation of metallurgical specimens (e.g.,
photomicrographs) of weldment to examine metallic structure,
defects, extent and condition of heat affected zone, and similar
phenomena
Mechanical Tests in Welding
•
(a) Tension-shear test, (b) fillet break test, (c) tension-shear
of spot weld, and (d) peel test for spot weld

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