Common Weld Discontinuities

Visual Inspection

Porosity

Causes of Porosity

Insufficient interpass cleaning Unsteady travel speed Welding weave too wide Allowing slag to run ahead of the arc Using too large and electrode

Slag Inclusions

Causes of Slag Inclusions

Base Metal contaminated Wet, unclean electrodes Insufficient or damp shielding gas Excessive arc length Welding current too high Weld speed too fast

Incomplete Penetration

Causes of Incomplete Penetration

Too small a root opening Too large a root face Excessive high low Travel speed too fast Welding current too low Electrode diameter too large Excessive arc length

Excess Penetration

Causes of Excessive Penetration

Too large a root opening Too small a root face Welding current too high Travel speed too low Arc length too short

Incomplete Fusion

Causes of Incomplete Fusion

Improper electrode angle Travel speed too fast Welding current too low Faulty joint preparation Electrode diameter too large

Cracks

Causes of Cracks

Base metal contaminated Excessive joint restraint Incorrect pre-heat Incorrect filler metal Too fast a cooling rate

Undercut

Causes of Undercut

Incorrect electrode manipulation Welding current too high Excessive arc length Travel speed too fast

Tungsten Inclusions

Causes of Tungsten Inclusions

Contact with electrode tip with weld pool Contact of filler metal with tip of electrode Contamination of electrode Exceeding current limit for the electrode Splits or cracks in electrode