Radiograph Interpretation - Welds

Radiograph Interpretation - Welds
WELDING DEFECT
Any irregularity (discontinuity or flaw) in the weld metal, which exceeds the applicable
code limit, is termed as a WELD DEFECT (or Welding Defect). Please note that a
discontinuity can be termed as a defect only when, if it exceeds the specified code
limit, hence we can say that every defect present in a weld metal is a discontinuity
but every discontinuity present in the weld metal may not necessarily be a defect.
Defects may occur due to the following reasons
1. Incorrect welding parameters
2. Inappropriate welding procedures
3. Poor process condition
4. Inappropriate selection of filler metal and parent metal
5. Unskilled welder or welding operator
6. Incorrect job preparation
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Ravi Shankar Pandey Gireesh Azhakappath
GENERAL WELDING DISCONTINUITIES
1. COLD LAP
2. POROSITY
3. CLUSTERE POROSITY
4. SLAG INCLUSION
5. INCOMPLETE PENETRATION (IP) OR LACK OF PENETRATION (LOP)
6. INCOMPLETE FUSION
7. INTERNAL CONCAVITY OR SUCK BACK
8. INTERNAL OR ROOT UNDERCUT
9. EXTERNAL OR CROWN UNDERCUT
10. OFFSET OR MISMATCH
11. INADEQUATE WELD REINFORCEMENT
12. EXCESS WELD REINFORCEMENT
13. CRACKS
14. TUNGSTEN INCLUSIONS (in TIG Welding only)
15. OXIDE INCLUSIONS (in TIG /GMAW Welding )
16. BURN-THROUGH

COLD LAP
Cold lap is a condition where the weld filler metal does not properly fuse with the base metal or the
previous weld pass material (Interpass cold lap). The arc does not melt the base metal sufficiently and
causes the slightly molten puddle to flow into the base material without bonding.

POROSITY
Porosity is the result of gas entrapment in the solidifying metal. Porosity can take many shapes on a radiograph
but often appears as dark round or irregular spots or specks appearing singularly, in clusters, or in rows.
Sometimes, porosity is elongated and may appear to have a tail. This is the result of gas attempting to escape
while the metal is still in a liquid state and is called wormhole porosity. All porosity is a void in the material and it
will have a higher radiographic density than the surrounding area.

CLUSTER POROSITY
Cluster porosity is caused when flux coated electrodes are contaminated with moisture. The moisture turns
into a gas when heated and becomes trapped in the weld during the welding process. Cluster porosity
appear just like regular porosity in the radiograph but the indications will be grouped close together.

SLAG INCLUSIONS
Slag inclusions are non-metallic solid material entrapped in weld metal or between weld and base metal. In a
radiograph, dark, jagged asymmetrical shapes within the weld or along the weld joint areas are indicative of
slag inclusions.

INCOMPLETE PENETRATION (IP) OR LACK OF PENETRATION (LOP)
Incomplete penetration (IP) or lack of penetration (LOP) occurs when the weld metal fails to penetrate the joint. It
is one of the most objectionable weld discontinuities. Lack of penetration allows a natural stress riser from which
a crack may propagate. The appearance on a radiograph is a dark area with well-defined, straight edges that
follows the land or root face down the centre of the weldment.

INCOMPLETE FUSION
Incomplete fusion is a condition where the weld filler metal does not properly fuse with the
base metal. Appearance on radiograph: usually appears as a dark line or lines oriented in the
direction of the weld seam along the weld preparation or joining area.

INTERNAL CONCAVITY OR SUCK BACK
Internal concavity or suck back is a condition where the weld metal has contracted as it cools and has
been drawn up into the root of the weld. On a radiograph it looks similar to a lack of penetration but the
line has irregular edges and it is often quite wide in the centre of the weld image.

Radiograph Interpretation
INTERNAL OR ROOT UNDERCUT
- Welds
Internal or root undercut is an erosion of the base metal next to the root of the weld. In
the radiographic image it appears as a dark irregular line offset from the centerline of the
weldment. Undercutting is not as straight edged as LOP because it does not follow a ground
edge.

EXTERNAL OR CROWN UNDERCUT
External or crown undercut is an erosion of the base metal next to the crown of the weld. In the
radiograph, it appears as a dark irregular line along the outside edge of the weld area.

Radiograph
OFFSET OR MISMATCH
Interpretation - Welds
Offset or mismatch are terms associated with a condition where two pieces being welded
together are not properly aligned. The radiographic image shows a noticeable difference in
density between the two pieces. The difference in density is caused by the difference in
material thickness. The dark, straight line is caused by the failure of the weld metal to fuse
with the land area.

INADEQUATE WELD REINFORCEMENT
- Welds
Inadequate weld reinforcement is an area of a weld where the thickness of weld metal
deposited is less than the thickness of the base material. It is very easy to determine by
radiograph if the weld has inadequate reinforcement, because the image density in the area
of suspected inadequacy will be higher (darker) than the image density of the surrounding
base material.

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EXCESS WELD REINFORCEMENT
- Welds
Excess weld reinforcement is an area of a weld that has weld metal added in excess of
that specified by engineering drawings and codes. The appearance on a radiograph is a
localized, lighter area in the weld. A visual inspection will easily determine if the weld
reinforcement is in excess of that specified by the engineering requirements.

CRACKS
Cracks can be detected in a radiograph only when they are propagating in a direction that
produces a change in thickness that is parallel to the x-ray beam. Cracks will appear as
jagged and often very faint irregular lines. Cracks can sometimes appear as "tails" on
inclusions or porosity.

Radiograph
TUNGSTEN INCLUSIONS
Interpretation - Welds
Tungsten is a brittle and inherently dense material used in the electrode in tungsten inert gas
welding. If improper welding procedures are used, tungsten may be entrapped in the weld.
Radiographically, tungsten is more dense than aluminum or steel, therefore it shows up as a
lighter area with a distinct outline on the radiograph.

OXIDE INCLUSIONS
Oxide inclusions are usually visible on the surface of material being welded (especially
aluminum). Oxide inclusions are less dense than the surrounding material and, therefore,
appear as dark irregularly shaped discontinuities in the radiograph.

BURN-THROUGH
Burn-Through results when too much heat causes excessive weld metal to penetrate the
weld zone. Often lumps of metal sag through the weld, creating a thick globular condition on
the back of the weld. These globs of metal are referred to as icicles. On a radiograph, burn-
through appears as dark spots, which are often surrounded by light globular areas (icicles).


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Radiograph Interpretation - Welds

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

Prepared By CR Asia – Your Reliable Partner Approved By

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