Defects and Discontinuities

Tim Turner Elizabethtown Technical College

Defect
A flaw or flaws that by nature or accumulated effect render a part or product unable to meet minimum applicable acceptance standards or specifications. The term designates rejectability.

Discontinuity
An interruption of the typical structure of a material, such as a lac of homogeneity in its mechanical, metallurgical, or physical characteristics. A discontinuity is not necessarily a defect.

!eld "oint Discontinuities

Misalignment #hi$lo% Undercut Underfill Concavity or Convexity Excessive reinforcement Improper reinforcement Overlap Burn-through Incomplete or Insufficient Penetration Incomplete Fusion urface irregularity
& '(erlap

Inclusions
& )lag & !agontrac s & Tungsten

Base Metal #iscontinuities

& *amellar tearing & *aminations and Delaminations & *aps and )eams

patter !rc Craters Crac"s

& & & & & & & *ongitudinal Trans(erse Crater Throat Toe +oot ,nderbead and -eat$affected zone & -ot & Cold or delayed

Porosity
& & & & ,niformly )cattered Cluster *inear .iping

!rc tri"es

$eat-affected %one microstructure alteration Base Plate laminations i%e or dimensions

Misalignment #hi$lo%
#efinition& Amount a joint is out of alignment at the root Cause& Carelessness. Also due to joining different thic nesses #transition thic ness% Prevention& !or manship. Transition angles not to e/ceed 0.1 to 2. 'epair& 3rinding. Careful on surface finish and direction of grind mar s. 4nside of .ipe 5Tube difficult.

Undercut
#efinition& A groo(e cut at the toe of the weld and left unfilled. Cause& -igh amperage, electrode angle, long arc length, rust Prevention& )et machine on scrap metal. Clean metal before welding. 'epair& !eld with smaller electrode, sometimes must be low hydrogen with preheat. )ometimes must gouge first.

,ndercut
#cont......%

,ndercut typically has an allowable limit. Different codes and standards (ary greatly in the allowable amount. .late $ the lesser of 25607 or 18 #typ.%

4nsufficient 9ill
Definition: The weld surface is below the adjacent surfaces of the base metal Cause: 4mproper welding techni;ues .re(ention: Apply proper welding techni;ues for the weld type and position. ,se stripper beads before the co(er pass. +epair: )imply weld to fill. <ay re;uire preparation by grinding.

4nsufficient 9ill on the +oot )ide

#suc bac %
Definition: The weld surface is below the adjacent surfaces of the base metal at the weld root. Cause: Typically improper joint preparation or e/cessi(e weld pool heat. .re(ention: Correct cause. #see ne/t slide% +epair: =ac weld to fill. <ay re;uireremo(al of weld section by grinding for access to the joint root.

Cause for 4nsufficient 9ill at the +oot

)ome li;uids, li e water or molten steel, try to co(er as much surface area of whate(er they are in contact with as possible. !elding a root pass too wide can also cause the bead to sag #o(erhead position%.

+emo(ing a root pass by grinding

2. +ecreate the groo(e geometry as closely as possible. 0. ,se a saw or die grinder and 252> $ 25?7 cut off wheel to recreate root opening. +emember repairs are sometimes re;uired to be made with a smaller electrode. 6. 'pen the groo(e angle. =e careful to lea(e the proper root face dimension. @. 9eather the start and stop to blend smoothly into and out of the e/isting weld.

E/cessi(e Conca(ity or Con(e/ity

#efinition& Conca(ity or con(e/ity of a fillet weld which e/ceeds the specified allowable limits Cause& Amperage and tra(el speed Prevention& 'bser(e proper parameters and techni;ues. 'epair& 3rind off or weld on. <ust blend smoothly into the base metal.

Concavity

Convexity

The amount of a groo(e weld which e/tends beyond the surface of the plate

+einforcement

E/cessi(e 4nsufficient 4mproper contour

9ace +einforcement

+oot +einforcement

E/cessi(e +einforcement
Definition: )pecifically defined by the standard. Typically, +einforcement should be flush to 252>7#pipe% or flush to 25?7 #plate or structural shapes%. Cause: Tra(el speed too slow, amperage too low .re(ention: )et amperage and tra(el speed on scrap plate. +epair: +emo(e e/cessi(e reinforcement and feather the weld toes to a smooth transition to the base plate.

4nsufficient +einforcement
Definition: )pecifically defined by the standard. Typically, ,nderfill may be up to 18 of metal thic ness not to e/ceed 25607 as long as the thic ness is made up in the opposite reinforcement. Aot applied to fillet welds. Cause: 'n root reinforcement $ Too little filler metal will cause thinning of the filler metal. 4n '- position, too hot or too wide will cause drooping of the open root puddle. .re(ention: ,se proper welding techni;ue. ,se bac ing or consumable inserts. ,se bac weld or bac ing. +epair: .ossibly simply increase the face reinforcement. 4f bac welding is not possible, must remo(e and reweld.

4mproper !eld Contour

Definition: !hen the weld e/hibits less than a 261B 261B transition angle at the weld toe. Cause: .oor welding techni;ue .re(ention: ,se proper techni;ues. A wea(e or whip motion can often eliminate the problem. +epair: The weld face must be feathered into the base plate.

'(erlap
Definition: !hen the face of the weld e/tends beyond the toe of the weld Cause: 4mproper welding techni;ue. Typically, electrode angles and tra(el speed. .re(ention: '(erlap is a contour problem. .roper welding techni;ue will pre(ent this problem. +epair: '(erlap must be remo(ed to blend smoothly into the base metal. =e careful of deep grind mar s that run trans(erse to the load. Also be careful of fusion discontinuities hidden by grinding. ,se ADT to be sure.

Overlap
'(erlap is measured with a s;uare edge such as a >7 rule. Ao amount of o(erlap is typically allowed.

=urn$through #non$standard%
Definition: !hen an undesirable open hole has been completely melted through the base metal. The hole may or may not be left open. Cause: E/cessi(e heat input. .re(ention: +educe heat input by increasing tra(el speed, use of a heat sin , or by reducing welding parameters. +epair: !ill be defined by standards. 9illing may suffice. 'therwise, remo(al and rewelding may be re;uired. )ome standards may re;uire special filler metal and5or .!-T.

4ncomplete or 4nsufficient .enetration

Definition: !hen the weld metal does not e/tend to the re;uired depth into the joint root Cause: *ow amperage, low preheat, tight root opening, fast tra(el speed, short arc length. .re(ention: Correct the contributing factor#s%. +epair: =ac gouge and bac weld or remo(e and reweld.

4ncomplete 9usion
Definition: !here weld metal does not form a cohesi(e bond with the base metal. Cause: *ow amperage, steep electrode angles, fast tra(el speed, short arc gap, lac of preheat, electrode too small, unclean base metal, arc off seam. .re(ention: Eliminate the potential causes. +epair: remo(e and reweld, being careful to completely remo(e the defecti(e area. This is sometimes e/tremely difficult to find.

Arc )tri e
Definition: A localized coalescence outside the weld zone. Cause: Carelessness .re(ention: 4n difficult areas, adjacent areas can be protected using fire blan ets. +epair: !here applicable, arc stri es must be sanded smooth and tested for crac s. 4f found, they must be remo(e and repaired using a ;ualified repair procedure and inspected as any other weld.

4nclusions
)lag !agontrac s Tungsten

)lag 4nclusion
Definition: )lag entrapped within the weld Cause: *ow amperage, improper techni;ue, Trying to weld in an area that is too tight. )low tra(el in Certical Down .re(ention: 4ncrease amperage or preheat, grind out tight areas to gain access to bottom of joint. +epair: +emo(e by grinding. +eweld.

!agon Trac s #non$standard%

Definition: )lang term for a groo(e left at the toe of a root pass which becomes filled with slag and is trapped in the weld. Cause: The contour of the root pass is too high, or the weld toe is not bonded to the base metal .re(ention: ,se proper techni;ue to deposit the weld root. +epair: =est repaired before applying the hot pass. Carefully grind the root pass face flat. be careful not to gouge other areas on the weldment.

Tungsten 4nclusion
Definition: A tungsten particle embedded in a weld. #Typically 3TA! only% Cause: Tungsten electrode too small, amperage too high, AC balance on D, ,pslope too high, electrode tip not snipped, electrode dipped into the weld pool or touched with the fill rod, electrode split. .re(ention: Eliminate the cause +epair: 3rind out and reweld

4nclusions
fi/ when you see it. otherwise grind out E fi/

!his ers
,nsightly 4nhibits material flow in piping Are inclusions Can brea off in pipes and damage e;uipment downline

)patter
Definition: )mall particles of weld metal e/pelled from the welding operation which adhere to the base metal surface. Cause: *ong arc length, se(ere electrode angles, high amperages. .re(ention: Correct the cause. =ase metal can be protected with co(erings or hi$temp paints.

+epair: +emo(e by grinding or sanding. )ometimes must be tested as if it were a weld.

Arc Craters
Definition: A depression left at the termination of the weld where the weld pool is left unfilled. Cause: 4mproper weld termination techni;ues .re(ention:

+epair: 4f no crac s e/ist, simply fill in the crater. 3enerally welding from beyond the crater bac into the crater.

Crac s
*ongitudinal Trans(erse Crater Throat Toe +oot ,nderbead and -eat$affected zone -ot Cold or delayed

*ongitudinal Crac
Definition: A crac running in the direction of the weld a/is. <ay be found in the weld or base metal. Cause: .reheat or fast cooling problem. Also caused by shrin age stresses in high constraint areas. .re(ention: !eld toward areas of less constraint. Also preheat to e(en out the cooling rates. +epair: +emo(e and reweld

Trans(erse Crac

Definition: A crac running into or inside a weld, trans(erse to the weld a/is direction. Cause: !eld metal hardness problem .re(ention: +epair:

Crater Crac
Definition: A crac , generally in the shape of an FG7 which is found in a crater. Crater crac s are hot crac s.

Cause: The center of the weld pool becomes solid before the outside of the weld pool, pulling the center apart during cooling .re(ention: ,se crater fill, fill the crater at weld termination and5or preheat to e(en out the cooling of the puddle +epair:

Throat Crac
Definition: A longitudinal crac located in the weld throat area. Cause: Trans(erse )tresses, probably from shrin age. 4ndicates inade;uate filler metal selection or welding procedure. <ay be due to crater crac propagation. .re(ention: Correct initial cause. 4ncreasing preheat may pre(ent it. be sure not to lea(e a crater. ,se a more ductile filler material. +epair: +emo(e and reweld using appropriate procedure. =e sure to correct initial problem first.

Toe Crac
Definition: A crac in the base metal beginning at the toe of the weld Cause: Trans(erse shrin age stresses. 4ndicates a -AH brittleness problem. .re(ention: 4ncrease preheat if possible, or use a more ductile filler material. +epair:

+oot Crac
Definition: A crac in the weld at the weld root. Cause: Trans(erse shrin age stresses. )ame as a throat crac . .re(ention: )ame as a throat crac +epair:

,nderbead Crac
Definition: A crac in the unmelted parent metal of the -AH. Cause: -ydrogen embrittlement .re(ention: ,se *o5-i electrodes and5or preheat +epair: #only found using ADT%. +emo(e and reweld.

-ot Crac
Definition: A crac in the weld that occurs during solidification. Cause: <icro stresses from weld metal shrin age pulling apart weld metal as it cools from li;uid to solid temp. .re(ention: .reheat or use a low tensil filler material. +epair:

Cold Crac
Definition: A crac that occurs after the metal has completely solidified Cause: )hrin age, -ighly restrained welds, Discontinuities .re(ention: .reheat, weld toward areas of less constraint, use a more ductile weld metal +epair: +emo(e and reweld, correct problem first, preheat may be necessary.

+epairs to Crac s
Determine the cause Correct the problem Ta e precautions to pre(ent reoccurrence 3enerally re;uired to repair using a smaller electrode

Base Metal #iscontinuities

*amellar tearing *aminations and Delaminations *aps and )eams

*aminations
=ase <etal Discontinuity <ay re;uire repair prior to welding 9ormed during the milling process

*amination effects can be reduced by joint design:

Delaminations

*aps and )eams

A mill$induced discontinuity in which results from a lump of metal being s;ueezed o(er into the surface of the material. 4f beyond acceptable limits, must be remo(ed and repaired or discarded.

.orosity
)ingle .ore ,niformly )cattered Cluster *inear .iping

)ingle .ore
)eparated by at least their own diameter along the a/is of the weld

,niformly )cattered .orosity

Typically judged by diameter and pro/imity to a start or stop often caused by low amperage or short arc gap or an unshielded weld start

Cluster .orosity
Typically (iewed as a single large discontinuity

*inear .orosity
being linear greatly affects the se(erity of this discontinuity

.iping .orosity
3enerally has special allowable limits

.orosity
preheat will help eliminate may need an electrode with more deo/idizers ,se run$on5run$off taps restart on top of pre(ious weld and grind off lump

-eat$affected zone microstructure alteration

add drawing of -AH of groo(e weld with leaders to:
& & & & & grain refinement grain growth hardened areas softened areas precipitate suseptable areas.

)ize or dimension
4f it renders the part unusable, it is a defect. 4f it is outside the allowable limit, it renders the part unusable. Things donIt ha(e to be perfect, just within the acceptable tolerance. !or ing to perfection is too time consuming and costly

-ammer mar s
)tress risers ,nsightly ,nnecessary

+E.A4+ TEC-A4J,E)
<ay in(ol(e:
& & & & & different process different procedure different preheat5.!-T different electrode smaller electrode

Only repair defects( #iscontinuities are) *y definition) accepta*le( 'epair is therefore unnecessary and not cost effective(

4nspection Tools

<easuring !eld )izes

Fillet +eld i%e $ 9or e;ual leg fillet welds, the leg lengths of the largest isosceles right triangle that can be inscribed within the fillet weld cross section. 9or une;ual leg fillet welds, the leg lengths of the largest right triangle that can be inscribed within the fillet weld cross section

9ibre <etal 9illet 3age

9ibre <etal 9illet 3age

9ibre <etal 9illet 3age

9ibre <etal 9illet 3age

9ibre <etal 9illet 3age

9ibre <etal 9illet 3age

9ibre <etal 9illet 3age

9ibre <etal 9illet 3age

,ndercut 3uage

3al 3age Co.

.almgrin 3uage

<agnifying 3lass

,sed to read small scales

9lashlight
,sed to cast shadows to find porosity, undercut and o(erlap.