Weld Defects

[Q2.2-1 6]
Classify the cracks occurring in the weld metal according to the place of occurrence, and show them by
schematic drawing.

[Q2.2-1 7]
Classify the cracking (cracks) occurring at welding according to the initiation temperature, and list up the
items generally considered as the causes.

[Q2.2-1 8]
Give at least two names of each of hot crack and cold crack respectively.

[Q2.2-1 9]
Give two welding defects which are influenced by hydrogen, and two main sources of supply of hydrogen in
welding.

[Q2 .2-20]
Give four conditions that cause reheat cracking (SR cracking) in low alloy steel weld.

[Q2.2-21]
Answer the following questions regarding to the weld cold cracking in high strength steels.
(1) Pick out three (3) major factors influencing on cold cracking.
(2) Pick out one (1) item influencing on the each major factor respectively.

[Q2 .2-22]
Pick out two (2) items which cause hot cracking in carbon steels.

[Q2 .2-23]
Choose the relevant one among words in each question and circle its alphabetical symbol.
(1) The risk of cold cracking can be reduced by use of welding consumables with less amount of:

(a) Nitrogen
(b) Hydrogen
(c) Nickel
(d) Oxygen.
(2) The risk of cold cracking increases with an increase of;
(a) welding heat input
(b) maximum hardness of weld heat affected zone
(c) ductility of base metal
(d) Sulfur content of base metal.
 (3) Preheating temperature which is necessary to prevent cold cracking should be higher with an increase
of;

(a) absorbed energy of base metal in Charpy impact test

(b) Aluminum content of base metal
(c) PCM of base metal
(d) Nitrogen content of weld metal
(4) Reheat cracking occurs during PWHT usually at the position of;
(a) scratch mark by grinding
(b) weld toe
(c) ripple of weld bead
(d) indentation of hammer peening
(5) Elements which enhance reheat crack susceptibility are;
(a) C, Si, Mn
(b) P, Sn, Sb
(c) Al, O, N
(d) Cr, Mo, V

[Q2 .2-24]
Preheating the base metal before arc welding the steel suppresses cold cracking. Describe two reasons.

[Q2 .2-25]
Simply describe the conditions in which the following welding flaw is liable to occur:
(1) Reheat cracking of Cr-Mo steel (SR cracking)
(2) Blowholes in the arc welded joint of an aluminum alloy
(3) Sensitization of an austenitic stainless steel
(4) Lamellar tearing of the weld of steel

[Q2 .2-26]
Describe the cause of blowholes in steel weld metal and the methods (countermeasures) to prevent the
formation of blowholes.

4.5 Prevention of weld defects

[Q4.5-1]
Out of the weld defects occurring in each side one pass submerged arc welding, name two most
significant internal defects, explaining the reasons for their being major defects.

[Q4.5-2]
Give five countermeasures for preventing blowholes.
[Q4.5-3]
Give four countermeasures against slag inclusion.
 [Q4.5-4]
Give four methods for preventing lack of fusion.

[Q4.5-5]
Give three preventive measures, in view of joint shape, against incomplete penetration.

[Q4.5-6]
Name five effective mean for preventing cold cracking in steel weld.

[Q4.5-7]
Below are the preventive measures against the solidification cracks of weld metal. Put F mark for
incorrect items, giving the reasons, and T mark for the correct ones in each parenthesis.
(1)Make proper selection of welding conditions so that the nugget shape of bead may not take the form of
a
pear. ( )
(2)Properly set the chemical composition of the material. ( )
(3)Use large heat input for welding. ( )
(4)Take care so as not to produce a large crater. ( )
(5)Properly set the shape and size of the welding groove. ( )

[Q4.5-8]
Supposing that a large amount of spatter appeared in shielded metal arc welding.
Give more than three possible causes.

[Q4.5-9]
Cracks appeared on a welded joint of high strength steel welded by shielded metal arc welding. Give
the procedures in sequence for repairing the defective part.

[Q4.5-10]
Choose the relevant one and circle its alphabet.
(1) In order to prevent lamellar tearing, the use of the steel which contains smaller amount of;
(a) S
(b) Si
(c) Mn
(d) Ti is effective.
(2) In order to prevent re-heat cracking, it is effective;
(a) to perform PWHT
(b) to remove the weld reinforcement and finish by a grinder
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(c) to weld with higher heat input
(d) to use the steel containing higher Cr
(3) In order to prevent cold cracking, it is the best way to apply;
 (a) MAG welding with solid wire
(b) SMAW with lime-titania type electrode
(c) MAG welding process with flux core wire
(d) SMAW with high cellulose type electrode
(4) In order to prevent pear shape cracking, it is effective;
(a) to adopt a narrower welding groove
(b) to adopt higher welding current
(b) to make penetration depth smaller than bead width
(d) to make penetration depth larger than bead width

(5) In order to prevent toe crack, it is effective;

(a) to adopt smaller heat input
(b) to adopt smaller fillet weld
(c) to adopt pre-heating
(d) to adopt SMAW with ilmenite type electrode

[Q4.5-11]
Choose the relevant one and circle its alphabet.
(1) Welding defect in which inorganic substances are remained between weld metal and base metal or
within weld metal. In order to prevent this, it is necessary to keep proper electrode aiming position
and angle. Furthermore, it is necessary not to make sharp valley on inter layers. If sharp valley is
formed interlayer, it should removed by grinding before subsequent welding starts.
(a)incomplete penetration
(b)Slag inclusion
(c)Pitting
(d)Overlap
(2) Welding defect in which fusion is not sufficient between weld and base metal or between passes. In
order to prevent this, the same countermeasure to (1) above are effective.
(a)incomplete penetration
(b)Lack of fusion
(c)Blowholes
(d)Overlap
(3) Welding defect in which a narrow trench made by arc force is not filled with weld metal and
remained like sharp groove along weld toe. In order to prevent this, it is effective to reduce welding
current and to keep proper electrode angle and aiming position.
(a)Overlap
(b)Lack of fusion
(c)pitting
(d)Undercut
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(4) Spherical cavity or hollow in the weld metal. In order to prevent this it is necessary to
make perfect shielding and clean up welding groove.
(a)hot cracking,
(b)cold cracking
(c)Blowholes
(d)Fisher eye
(5) Crack which is produced in welded joint after cooled down below 300 C and strongly influenced by
hydrogen.
(a)Hot crack
(b)Cold crack
(c)Re-heat crack
(d)Hydrogen attack