Dis

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inu
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co

Slag

ty

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a
C

edy
m
Re

Insufficient cleaning
Insufficient Electrode Coating / Flux Composition
Expired Electrode / Coating
Moisture in electrode
Insufficient Arc Length
Insufficient manipulation of electrode
Insufficient elctrorde composition
Contaminations in base metal
excessive hydrogen contents in electrode

Cleaning should be done properly

Electrode used should be of proper coating of flux

Undercut

Excessive welding current or voltage

Slow welding speed

Use correct welding current

Follow WPS for welding

LOP
Lack Of penetration

Insufficient heat input

Improper control of welding arc
Improper Joint configuration / preparation

Only qualified welder operate welding equipment

Properly prepare joint or bevels

LOF
Lack Of Fusion

Insufficient heat input

Wrong welding technique

Use correct welding current

clean the area to be welded properly prior to welding

Under Fill

Inexperience welder

Only qualified welder should perform operation

Use proper welding technique

Improper control of welding process

Improper ceaning
Tightly adhering oxide on the surface may also interfare fusion

Use proper welding technique

clean the area to be welded properly prior to welding

Porosity

(depression on weld face)

Over Lap
(Extension of weld
over the weld toe
or weld root)

Heat electrodes prior to welding

maintain same arc length throughout the weld

clean the area to be welded properly prior to welding
use elecrodes of hydrogen contents
Flux composition must be appropriate

mechanical notch formed

Crater
depressed are at the
end of the weld

Inexperience welder

Only qualified welder should perform operation

Crack

c
Dis

Spatter
(metalparticles expelled
during Welding)
Arc Strikes
change in surface
profile

inu
ont

i ty

s
Cau

edy
m
e
R

es

Insufficient heating and cooling

hydrogen embrittlement
Notches or edges in welded area
Insufficient heat input
*Spatters are not considered as discontinuity unless their
presence may cause interruption in NDT operations

Low hydrogen eectrode should be used

Electrode used should be of proper coating of flux
Use correct welding current

Under Fill
(Capping / reinfocement is not more than or eqaul to the base meat thickness)
Sufficient Capping( Not more the 1.5 mm upto 6mm)

Lack Of Penetration
Sufficient Penetration ( Not more the 1.5 mm upto 6 mm)

Lack Of Fusion

Lack Of Fusion

Sufficient Fusion

Over Lap

No Over Lap