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Defects in Weldments (WT)

The document discusses welding defects, categorizing them into external and internal types, and outlines their causes and prevention methods. It highlights specific defects such as cracks, porosity, undercut, and lack of penetration, detailing their implications on weld integrity. Understanding these defects is crucial for ensuring safety and quality in welding practices.

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5 views11 pages

Defects in Weldments (WT)

The document discusses welding defects, categorizing them into external and internal types, and outlines their causes and prevention methods. It highlights specific defects such as cracks, porosity, undercut, and lack of penetration, detailing their implications on weld integrity. Understanding these defects is crucial for ensuring safety and quality in welding practices.

Uploaded by

sivasankart859
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Understanding Welding

Defects: Types, Causes, and


Prevention
Any discontinuity in weld metal exceeding code limits is termed a weld
defect. While every defect is a discontinuity, not all discontinuities are
defects. Defects can be macroscopic or microscopic and are also called
"reflectors" in some codes.

Defects arise from incorrect welding parameters, poor procedures,


unskilled operators, and improper material selection. They are
classified as external (surface) or internal (subsurface) defects,
affecting weld integrity and safety.
Classification of Welding
Defects
Welding defects are categorized as external (visible on the surface) or
internal (hidden beneath the surface). External defects can be
detected visually, while internal defects require specialized inspection.

Common causes include improper welding parameters, poor joint


preparation, and contamination. Understanding these classifications
helps in selecting appropriate inspection and repair methods.

External Defects Surface cracks, porosity,


undercut

Internal Defects Lack of fusion, slag inclusion,


incomplete penetration
Cracks: The Most Dangerous Welding Defect
Cracks can be microscopic or macroscopic and occur anywhere in the weld or heat-affected zone (HAZ). They form when localized
stress exceeds the material's ultimate tensile strength and can propagate, compromising structural integrity.

There are two main types: hot cracks, which occur during or immediately after welding, and cold cracks, which develop after
solidification, sometimes days later.

1. Hot Cracks
2. Cold Cracks
Hot and Cold Cracks: Causes and Prevention
Hot Cracks Cold Cracks
Occur during solidification of the molten weld pool, mostly in Develop after welding, often in HAZ, linked to hydrogen
weld metal or HAZ. Causes include high residual stress, rapid diffusion and microstructural changes like martensite
cooling, thick base material, and high welding current. formation.
Prevention involves preheating/post-heating and using the Prevented by preheating, post-weld heating, and using low
right filler metal. hydrogen electrodes.
Porosity and Blow Holes in Welds
Porosity is caused by gas entrapment in the molten weld pool, forming small pores or larger blowholes. It can appear on the
surface or inside the weld metal, often in clusters.
Gases like hydrogen, carbon monoxide, and oxygen cause porosity, originating from flux, moisture, oil, or insufficient shielding
gas flow in processes like TIG and MIG welding.

• Scattered Porosity
• Cluster Porosity
• Piping Porosity
• Linear Porosity
• Elongated Porosity
Common Surface Defects: Undercut, Underfill, and
Overlap

Undercut Underfill Overlap


A narrow groove along the weld Occurs when weld metal Molten metal overflows base
edge acting as a stress raiser, surface is below adjacent base metal surface without fusion,
caused by high current, large metal, indicating undersized caused by low current, slow
electrode diameter, or incorrect welds. travel speed, or long arc length.
angle.
Internal Defects: Lack of Penetration and Lack of Fusion

Lack of Penetration Lack of Fusion


Weld metal fails to fully penetrate the joint, creating stress Improper melting between weld layers or base metal,
raisers. Causes include small root gap, fast travel speed, often due to low current or incorrect travel speed. It can
and low heat input. be internal or surface-level (sidewall fusion).
Prevention involves proper joint prep, correct heat input, Prevented by adjusting welding current, travel speed, and
and suitable electrode size. heat input.
Spatters, Excessive Penetration
Spatters Excessive Penetration
Small metal droplets splashed onto base metal during Weld metal penetrates too deeply, causing stress
welding, removable by brushing. Caused by excessive concentration and material waste. Caused by wide
arc current or improper shielding gases. root gap, high current, or slow travel speed.
Wagon Tracks, Arc Strikes, and Shrinkage Cavities
Wagon Tracks Arc Strike Shrinkage Cavity

Linear slag inclusions along weld axis Unintentional arc caused by Cavity formed due to metal
caused by wrong welding techniques electrode contact with workpiece, shrinkage during solidification of the
during root pass, trapping slag in leading to potential failure and weld pool, affecting weld integrity.
grooves. aesthetic issues.
Preventing Internal Welding Defects: Slag Inclusion,
Incomplete Fusion, and Penetration
Slag Inclusion Incomplete Fusion Incomplete Penetration

Caused by incorrect welding angle, Results from low heat input, wrong Occurs when weld metal doesn’t fill
poor cleaning, or low current density. joint or torch angle, and large weld joint thickness fully. Prevented by
Prevented by proper welding angle, pool. Prevention includes higher correct technique, electrode size, and
cleaning, and adequate current. current, slower travel, and better higher deposition rate.
welding positions.
ThankYou

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