FIVE ESSENTIAL

VARIABLES OF WELDING
• CURRENT SETTING
• LENGTH OF ARC
• ANGLE OF ELECTRODE
• SPEED OF TRAVEL
• SELECTION OF ELECTRODE
Current setting
The welding current or amperage is essential to producing welds with good appearance and required strength characteristics.

Length of Arc
When electricity is made to jump across a gap it is said to arc across the gap.

Angle of Electrode
In the shielded metal arc welding process there two electrode angles that the welder must control.

Speed of Travel
The rate of travel across the joint is controlled by the welder during welding and greatly affects the appearance and strength
characteristics of the weld.
• Selection of Electrode
• There are variety of electrodes available for welding a wide range of
metal.
WELDING DEFFECTS, CAUSES
AND REMEDIES

What are welding defects?

Welding defects are excessive
conditions, outside the acceptance
limits, which risk to compromise the
stability or the functionality of the
welded structure.
Types of Welding Defects
• Welding defects are divided into two categories: exterior and interior defects.

Exterior Welding Defects

• Porosity
• Weld Crack
• Spatter
• Undercut
• Crater
• Overlap
• Interior Welding Defects
• Incomplete penetration
• Slag Inclusion
• Incomplete Fusion
• Necklace cracking
Exterior Welding Defects
The following are the diverse types of external defects, along with their causes and
remedies:
Porosity
Porosity is a cluster of little bubbles, whereas blowholes are comparatively large
concealed holes or pores. They are caused mainly by trapped gases. Porosity is caused
by weld metal deposition.
Causes of Porosity
• When the electrode isn’t genuinely
effective, this occurs.
• Using a longer arc may help you to
improve.
• The amount of current used in welding
has grown.
• The rusty or oily welding surface.
Remedies for porosity
• Picking the appropriate electrode.
• Reduce the welding current
• Slowing the operation and using a minor
arc to allow the gases to pass.
• Use a suitable procedure to remove rust
or grease from the surface.
 Weld Crack
• These are the most
hazardous types of welding
defects. It is prohibited in
operation by mostly all
standards. It can appear on
the surface, in the weld
metal, or a place with a lot of
heat.
1. Hot Cracks
Hot cracks can arise during the welding process or the crystallization phase of the weld
zone. At this time, temperatures can approach 10,000 degrees Celsius.

2. Cold Cracks
These cracks form after the weld is completed and the metal temperature has cooled.
They can even be made after the steel has been welded, hours or days later. This is most
typical when a steel frame develops cracks.

3. Crater Cracks
Such cracks emerge toward the end of the welding operation even before operators
accomplish the weld joint. They’re constantly made near the final step.
The weld volume must be large enough to compensate for metal shrinkage when the weld
pool cooled down and froze. A crater crack will form eventually.
Causes of Weld Crack
• The flexibility of the supplied base metal is low.
• A crack might form if there is residual stress on the weld metal.
• The stiffness of the joint, which prevents the metals from expanding or contracting.
• Cracks may emerge if there is a lot of sulfur and carbon in the mixing.
• Using hydrogen as a shielding gas while welding stainless steels

Remedies for Weld crack

• Using the correct technique might help reduce the possibility of a crack.
• Cracks can be reduced by preheating the weld and slowing down the cooling speed of the joint.
• Use good weld joints to reduce the distance between the weld joints.
• While welding, the clamping force is gradually released, increasing the fill-to-capacity of the
welding material.
3. Spatter
• Spatters are thin metal
particles that gather on the
base metal along the length
of the weld bead due to the
arc during welding. In gas
metal arc welding, this is a
common phenomenon.
Causes of Spatter • Remedies for Spatter
A high welding current can Shortening the welding arc and lowering the
produce this defect. welding current
The more prolonged the arc, Welding with proper polarity and in compliance
the more likely this defect will with welding conditions.
appear. Increasing the panel angle and using appropriate
The polarity is inaccurate. gas shielding.
A lack of enough gas shielding
could be the source of this
problem.
Causes of Undercut
When the angle is incorrect, more
heat is provided to the free edges.
Welding speed was extremely fast.
Welding procedures that aren’t up to
standard.
Gas shielding and filler material were
used incorrectly.
The weld current is very high.
Larger-diameter electrodes are used.
5. Crater
When the crater isn’t filled
before the arc splits, the
outside edges of the
crater cool faster than the
crater itself. This causes a
crack to form as a result of
the stress.
Causes of the crater
The torch is held at the wrong angle.
Making use of a large electrode.
Welding technique that isn’t satisfactory.

Remedies for crater

• Using a suitable torch angle can help to reduce metal stress.
• Using a tiny electrode may help to reduce crater size.
• Make sure you’re using good technique.
7. Overlap
• When the weld face reaches
beyond the weld toe, this
defect occurs. In this case,
the weld metal rolls and
forms an angle less than 90
degrees.
Causes of Overlap
Welding method that isn’t good enough
anymore.
If larger electrodes are applied, this problem
may develop.
Welding current is high.

Remedies for Overlap

• Welding with a suitable method.
• Make use of a bit of electrode. 3.
Welding current is reduced.
 Interior Welding Defects
The following are the diverse types of internal defects, along with their causes and remedies.
1. Incomplete Penetration
• In these types of welding defects, the
distance between the highest surface
of the base plate and the maximum
extent of the weld nugget is referred
to as penetration.
• The weld metal does not entirely
extend over the joint thickness when
the metal gap is not filled, resulting in
incomplete penetration.
Causes of Incomplete Penetration

• Metal deposition in the weld is decreased.

• Using an incorrectly sized electrode.

• Welding technique that is not really up to standard.

• The electrode is placed incorrectly.

Remedies for Incomplete Penetration
• Increased metal deposition at the weld.
• Double-check that the electrode is the proper length.
• Using the proper welding methods.
• Ensure the electrode is in the correct location.
2. Slag Inclusion
• Slag inclusion is a type of weld defect.
Slag is produced by stick welding, flux-
core arc welding, and submerged arc
welding, and it is a toxic product
Causes Of Slag Inclusion
• Slag arises when the welding current is insufficient to provide the intensity – to melt the
metal surface.
• Slag can develop when the welding speed is too high.
• Slag can form if the weld surface’s edge is not properly cleaned.
• Incorrect welding rod travel rate and angle.

Remedies for Slag Inclusion

• Increase the current density.
• Slow down the welding operation to avoid combining the slag and the weld pool.
• Clean the weld surfaces and remove slags from earlier weld layers.
• Double-check the electrode angle and travel rate.
3. Incomplete Fusion
• Many types of welding defects arise when
there is an insufficient fusion between the
metal and the weld. As a result, there is a
gap inside the joint that is not filled with
molten material. It’s also possible that it will
appear between adjacent weld beads.
Causes of Incomplete fusion
• It occurs due to a lack of heat input.
• When there is a big weld pool that goes beyond the arc.
• When the angle of a joint is too small.
• Incorrect electrode and torch angles might potentially result in incomplete fusion.
• Incorrect bead placement.
Remedies for Incomplete Fusion
• Incomplete fusion is reduced by increasing the welding current while lowering the travel
speed.
• Slow down the deposition process.
• Increasing the joint’s angle.
• Align the electrode and torch angle in such a way that the plate’s borders melt away.
• Placing the bead correctly to avoid sharp edges from neighboring beads.
4. Necklace Cracking
• When electron beam welding is applied and the weld does not enter
correctly, this occurs. As a result, the molten metal fails to pour into
the hollow, resulting in “Necklace Cracking.”
Causes of Necklace Cracking
• A welding method that can’t keep up with the demands.
• It can be located in various materials, including nickel-base alloys,
aluminum, carbon steels, and tin alloys.
• Using high-speed electron beam welding.
Remedies for Necklace Cracking
• You can reduce the chances of your necklace cracking if you utilize the
proper welding procedure.
• Using the proper materials during welding.
• Maintain a constant speed throughout the welding process.
• A suitable welding technique.