Weld and Base Metal Discontinuities

Module 9 - 1
Module 9
Weld and Base Metal

Discontinuities
Am e r i c a n We l d i n g So c i e t y
Module 9 - 2
Discontinuity
“Any interruption in the uniform nature of an

item”
Module 9 - 3
Discontinuities
 Seams and laps
 Laminations
 Weld undercut
 Weld cracks
 Weld porosity
 Many others
Module 9 - 4
Defect
“A non-conforming discontinuity”
All discontinuities are not defects.

All defects are discontinuities.
Module 9 - 5
Discontinuity Criticality
 Linear - non-linear
 End condition - sharpness
 Surface - sub-surface
 Loading - uniform, non-uniform
– Fatigue
– Impact
Module 9 - 6
Crack
“A fracture type discontinuity characterized

by a sharp tip and high ratio of length and
width (depth) to opening displacement”
Module 9 - 7
Crack Types
 Hot / cold
 Delayed / underbead
 Longitudinal
 Transverse
 Throat /toe / root
 HAZ / base metal
 and many more
Module 9 - 8
Longitudinal Crack
Module 9 - 9
Transverse Crack
Module 9 - 10
Throat Crack
Module 9 - 11
Toe Crack
Module 9 - 12
Crater Cracks in Aluminum Weld
Module 9 - 13
Propagation of Crater Crack in

Aluminum Weld
Module 9 - 14
Underbead
Cracks
Module 9 - 15
Underbead Cracking
 Often delayed cracking
 Caused by hydrogen
 Difficult to detect
 Avoid with low H2 process
Module 9 - 16
Incomplete Fusion
“ A weld discontinuity in which fusion did

not occur between weld metal and fusion
faces or adjoining weld beads”
Module 9 - 17
Locations of Incomplete Fusion
Module 9 - 18
Incomplete Fusion at Weld Face
Module 9 - 19
Incomplete Fusion Between

Weld Metal and Base Metal
Module 9 - 20
Radiograph of Side-Wall
Incomplete Fusion
Module 9 - 21
Incomplete Joint Penetration
“Weld metal does not extend entirely through

the joint thickness. The term is used only for
groove welds.”
Module 9 - 22
Examples of Incomplete Joint

Penetration
Module 9 - 23
Incomplete Joint Penetration
Module 9 - 24
Radiograph of Penetration Faults

at Bead Starts and Stops
Module 9 - 25
Partial Joint Penetration
“Penetration not required to be complete by

designer”
Module 9 - 26
Inclusions
“Entrapped foreign solid material such as

slag, flux, tungsten or oxide”
Module 9 - 27
Surface Slag Inclusion
Module 9 - 28
Radiograph of Elongated Slag

Inclusions
Module 9 - 29
Radiograph of Tungsten
Inclusions
Module 9 - 30
Porosity
“Cavity type discontinuities formed by gas

entrapped during weld metal solidification”
Module 9 - 31
Scattered Surface Porosity
Module 9 - 32
Linear Surface Porosity with

Connecting Crack
Module 9 - 33
Isolated Surface Porosity
Module 9 - 34
Elongated Surface Porosity
Module 9 - 35
Radiograph of Scattered Porosity
Module 9 - 36
Radiograph of Cluster Porosity
Module 9 - 37
Radiograph of Linear Porosity
Module 9 - 38
Undercut
“A groove melted into the base metal adjacent

to the weld toe or weld root and left unfilled
by weld metal”
Module 9 - 39
Typical Appearance of Undercut
Module 9 - 40
Undercut Adjacent to Fillet Weld
Module 9 - 41
Radiograph of Surface Undercut
Surface undercut should be found with

VT, NOT RT !
Module 9 - 42
Underfill
“A condition in which the weld face or the

root surface is below the adjacent surface of
the base metal”
Module 9 - 43
Underfill in
Groove Welds
Module 9 - 44
Overlap
“The protrusion of weld metal beyond the

weld toe or weld root”
Module 9 - 45
Overlap in
Fillet and
Groove Welds
Module 9 - 46
Overlap Examples
Overlap
Overlap
Module 9 - 47
Undercut & Overlap in Fillet Weld
Undercut
Overlap
Module 9 - 48
Fillet Weld Convexity
“The maximum distance from the face of a

convex fillet weld perpendicular to a line
joining the weld toes”
Module 9 - 49
Fillet Weld Convexity
Module 9 - 50
Weld Reinforcement
“Weld metal in excess of the quantity

required to fill a joint”
Module 9 - 51
Face and Root Reinforcement
Module 9 - 52
Face Reinforcement on both sides

when welded from both sides
Module 9 - 53
Effect of Weld
Reinforcement
angle on Fatigue
Strength
Module 9 - 54
Improper and Acceptable

Treatment of Weld Reinforcement
Module 9 - 55
Arc Strike
“A discontinuity resulting from an arc,

consisting of any localized remelted metal,
heat-affected metal, or change in the surface
profile of any metal object”
Photomicrograph of Martensitic
Module 9 - 56
Structure Produced by an Arc Strike
Module 9 - 57
Spatter
“Metal particles expelled during fusion

welding that do not form part of the weld”
Module 9 - 58
Crack Formed at Weld Spatter
Module 9 - 59
Lamination
“A discontinuity with separation or weakness

generally aligned parallel to the worked
surface of a metal”
Module 9 - 60
Cracking and
Delamination
Due to
Lamination
Module 9 - 61
Delamination
“Separation of a lamination under stress”
Module 9 - 62
Lamellar Tear
“A subsurface terrace - and step-like

separation in the base metal, parallel to the
surface, caused by tensile stresses in the
through-thickness direction.
Module 9 - 63
Lamellar Tearing
Module 9 - 64
Seams and Laps
“Longitudinal base metal surface

discontinuities found in wrought products”
Module 9 - 65
Deep Seam on Surface of Semi-

Finished Rolled Product
Module 9 - 66
Cluster Seams on Surface of

Semi-Finished Rolled Product
Module 9 - 67
Lap on Surface of Rolled Steel Billet
Module 9 - 68
Dimensional
 Size irregularities
 Shape imperfections
 Distortion
Discontinuities in EBW and Module 9 - 69
LBW
“Unique to the special attributes of the high-
energy beams and narrow weld width”
 Beam deflection (missed joint)

 Root Porosity
 Shrinkage voids
 Hot cracks
 Lack of fusion (spiking)

Weld and Base Metal Discontinuities

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Module 9 - 1

Weld and Base Metal

“Any interruption in the uniform nature of an

All discontinuities are not defects.

“A fracture type discontinuity characterized

Crater Cracks in Aluminum Weld

Propagation of Crater Crack in

“ A weld discontinuity in which fusion did

Locations of Incomplete Fusion

Incomplete Fusion at Weld Face

Incomplete Fusion Between

Incomplete Joint Penetration

“Weld metal does not extend entirely through

Examples of Incomplete Joint

Incomplete Joint Penetration

Radiograph of Penetration Faults

Partial Joint Penetration

“Penetration not required to be complete by

“Entrapped foreign solid material such as

Surface Slag Inclusion

Radiograph of Elongated Slag

“Cavity type discontinuities formed by gas

Scattered Surface Porosity

Linear Surface Porosity with

Isolated Surface Porosity

Elongated Surface Porosity

Radiograph of Scattered Porosity

Radiograph of Cluster Porosity

Radiograph of Linear Porosity

“A groove melted into the base metal adjacent

Typical Appearance of Undercut

Undercut Adjacent to Fillet Weld

Surface undercut should be found with

“A condition in which the weld face or the

“The protrusion of weld metal beyond the

Fillet Weld Convexity

“The maximum distance from the face of a

Fillet Weld Convexity

“Weld metal in excess of the quantity

Face and Root Reinforcement

Face Reinforcement on both sides

Improper and Acceptable

“A discontinuity resulting from an arc,

Structure Produced by an Arc Strike

“Metal particles expelled during fusion

Crack Formed at Weld Spatter

“A discontinuity with separation or weakness

“Separation of a lamination under stress”

“A subsurface terrace - and step-like

Seams and Laps

“Longitudinal base metal surface

Deep Seam on Surface of Semi-

Cluster Seams on Surface of

Lap on Surface of Rolled Steel Billet

 Beam deflection (missed joint)

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