Visual Inspection of Welds

Butt Weld Size

a) excess weld metal height

b) root penetration

c) weld width

d) root bead width

Fillet welds (size)

Consider:

a) z minimum (and maximum) leg

length size

b) a minimum design
throat thickness

Shape (Butt Welds)

Consider:
Ideally, (a) is the most desirable
but very often it may be difficult
to achieve. Because of this, one
should assess the excess weld
height in conjunction with the
weld profile and perhaps the
toe blending.

Shape (Fillet Welds)

Consider:

In normal practice, (a) is the most

desirable but, again, in many instances
it is difficult to achieve. Acceptance
levels, therefore, allow tolerances on
weld shape.

Toe Blend (Butt Welds)

For butt welds,
consider:

In normal practice, (a) is the

most desirable but, again, in
many instances it is difficult to
achieve. Acceptance levels,
therefore, allow tolerances on
weld shape.
Depending on the service
conditions of the product, the
toe blend may be of greater
importance than the size and
shape of the weld. A poor toe
blend may reduce service life by
a considerable margin if the
product is under a cyclic load.

Toe Blend (Fillet Welds)

For fillet welds,
consider:

In normal practice, (a) is the

most desirable but, again, in
many instances it is difficult
to achieve. Acceptance levels,
therefore, allow tolerances on
weld shape.

Root Defects

Incomplete root penetration

Failure of weld metal to extend into the root of a

Lack of root fusion

Lack of union at the root of a joint
Excess penetration bead
Excess weld metal protruding through the
root of a fusion weld made from one side
only

Root Defects
Root concavity
(suck-back; underwashing - non-standard
terms)
A shallow groove which may occur in the root
of a butt weld, but full fusion is evident

Shrinkage groove
A shallow groove caused by contraction in the
metal along each side of a penetration bead o
along the weld centreline
Burnthrough
(melt through)
A localised collapse of the molten pool
due to excessive penetration, resulting in
a hole in the weld run

Contour Defects

Incompletely filled groove

A continuous or intermittent
channel in the surface of a
weld, running along its length,
due to insufficient weld metal.
The channel may be along the
centre or along one or both
edges of the weld

Bulbous Contour

Bulbous contour
A non-standard term used to
describe poor appearance

Unequal Legs

Unequal legs
(non standard term)
Variation of leg length on a fillet weld
Note: Unequal leg lengths may be
specified as part of the design - in
which case they are not imperfections

Undercut

Undercut
An irregular groove at a toe of a run
in the parent metal or in previously
deposited weld metal
The inspector must determine if the
undercut is continuous or
intermittent, or sharp or smooth

Overlap

Overlap
An imperfection at the toe or root of a
weld caused by metal flowing on to
the surface of the parent metal
without fusing to it

Gas Pore

Gas pore
A cavity, generally under
1.5mm in diameter,
formed by trapped gas
during the solidification of
molten metal
Porosity
A group of gas pores

Crater Pipe

Crater pipe
A depression due to shrinkage at the end
of a run where the source of heat was
removed. Crater pipes may also lead to
micro-cracking

Surface Cracks
Crack
A linear discontinuity produced by fracture
Cracks may be ...
a) ... longitudinal, in the weld metal, i.e. centreline

b) ... longitudinal, in the parent metal or heat affected

c) ... transverse

d) Crater crack
(star cracking)

Arc Strike

Stray flash/arc burn/arc strike

(stray arcing)
1. The damage on the parent material
resulting from the accidental striking
of an arc away from the weld
2. The accidental striking of an arc
away from the weld
Note that the same term is used for
both the action and the result

Weld Width
Weld width and consistency of weld
width

For butt welds and fillet

welds, consider: