Defects analysis and corrections

Defects encountered
Radiography examination provided two major defects Co2 welding LOF TIG welding Porosity. Macrostructure examination of co2 welding produced slag inclusions

Porosity
Reasons Humidity present on the filler wire Contaminated shielding gas(leaks,humidity diffusion) Localized cooling Voltage (high) Prevention Welding above the dew point. Remove leaks and replace old hoses. Preheating of the base plate

Optimize the parameters

Torch angle (small)

LOF(lack of fusion)
Not easy to detect. Improper cohesion between the weld and parent metal Due to improper preheating, fast weld speeds, incorrect edge preparations etc.

Types of LOF

Side wall fusion

Inter-run fusion

Rectification
Joint preparation Dont keep the joint narrow. Welding parameters Current and weld speed Welder techniques Angle, weaving with dwell at side wall

Slag inclusions
These are basically present due to improper cleaning of the weld surfaces resulting in entrapment.