Welding Inspection: Defects/Repairs Course Reference WIS 5

Welding Inspection
Defects/Repairs
Course Reference WIS 5
ET
Copyright © 2003 TWI Ltd Faisal Yusof

Definition
A perfect butt weld joint, when subjected to an external
force, provide a distribution of stress throughout its
volume which is not significantly greater than parent
metal.
ET

Definition
This is achieved as long as the following features

apply :-
• Welds should consists of solid metal throughout a cross

section at least equal to that of parent metal.
• All parts of a weld should be fully fused to the parent
metal.
•Welds should have smoothly blended surfaces.
ET

Weld Defects
Defects which may be detected by visual inspection can
be grouped under five headings
 Cracks
 Lack of solid metals
 Lack of fusion
 Lack of smoothly
blended surfaces
 Miscellaneous
ET

Cracks
ET

Cracks
Cracks that may occur in welded materials are caused
generally by by many factors and may be classified by
shape and position, cracks are classed as planar.
Classified by Shape Classified by Position

 Longitudinal  HAZ
 Transverse  Centreline
 Branched  Crater
 Fusion zone
 Chevron
 Parent metal
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Process Cracks
HAZ hydrogen cracking
 Weld metal hydrogen cracking
Solidification cracking (Hot Tearing)
Lamellar tearing
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Cracks
Weld metal hydrogen cracking

HAZ hydrogen cracking
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Solidification cracking Lamellar Tearing

ET
Transverse crack Longitudinal crack

LACK OF SOLID METALS
ET

POROSITY
Description : Gas pores trapped within the weld metal
Causes : Preventation :
• Damp fluxes/ corroded electrode • Use dry electrodes in good
•Grease/hydrocarbon/water condition
contamination of prepared surface •Optimise gas flow
•Air entrapment in gas shield •Use electrode with sufficient
•Too high arc voltage/arc length deoxidation activity
•Reduce arc voltage or arc length
•Incorrect/insufficient deoxidant
ET
in electrode, filler or parent metal

Gas Cavities
Porosity
Root piping
ET

ET
Cluster porosity Herring bone porosity

Crater Pipe
A shrinkage cavity at the end of a weld run where the arc is
terminated
•Lack of welder skill due to using • Retrain welder
processes with too high current.
•Use correct crater filling
•Inoperative crater filler ( GTAW ) technique
ET

Crater Pipe/Cracks
Crater Cracks
Crater pipe
ET

Root concavity
A shallow groove, which may occur in the root of a butt weld
•Insufficient arc power to produce • Raise arc energy
positive bead
•Reduce gas pressure
•Excessive backing pressure ( GTAW )
•Retraint welder
•Lack of welder skill
ET
•Tilt work to prevent slag

•Slag flooding in backing bar groove flooding
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root concavity
Underfill
A weld with thickness less than that of the parent metal
•Insufficient weld metal • Increase number of weld run
•Irregular weld bead surface •Retrain welder
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ET
Incomplete filled groove

Slag Inclusions
Slag or other matters trapped during welding. The imperfection is of
an irregular shape and thus differs in appearance from a gas pore
•Heavy millscale/rust on work surface • Grind surface prior welding
•Incomplete slag removal from •Improve interun slag removal
underlying surface of multipass weld
•Position work to gain control of
•Slag flooding ahead of the arc slag
•Entrapment of slag in work surface •Dress work surface smooth
ET
•Unfused flux due to damage coating •Use electrode in good condition

ET
Interpass slag inclusions Elongated slag lines

Inter- run Imperfections
Irregular along the fusion line between weld beads
•Low arc current resulting in low • Increase current
fludity of weld pool
•Reduce travel speed
•Too high travel speed
•Retrain welder
•Inaccurate bead replacement
ET

Lack of Fusion
ET

Incomplete root penetration
Failure of the weld metal to extend into root of a joint
•Excessively thick root face, insufficient root gap • Improved back gouging and edge
or failure to cut back sound metal in a ‘back preparation
gouging’ operation
•Increase arc power or decrease travel
•Low heat input speed
•Excessive inductance in GMAW dip transfer •Improve electrical settings and possibly
•SMAW electrode too large( low current density ) switch to spray transfer
•Reduce electrode size
ET
•Use of vertical down welding

•Switch to vertical up procedure
Root Defects
Lack of root fusion Lack of root Penetration

ET

ET
Lack of root penetration Lack of root fusion

Lack of sidewall fusion
Lack of fusion between weld metal and parent metal at one side of weld
•Low heat input to weld •Increase arc energy or increase travel
•Molten metal flowing ahead of arc speed
•Oxide or scale on weld preparation •Improve electrode angle and work

position
•Excessive inductance in GMAW dip transfer
welding •Improve edge preparation procedure
ET
•Reduce inductance, even if this increase

spatter
Lack of Smoothly
Blended Surfaces
ET

Surface porosity
Gas pores which break the surface of the weld
•Damp or contaminated surface of electrode •Clean surface and dry electrodes
•Low fluxing activity •Use a high activity flux
•Excess sulphur ( particularly free – cutting steels) •Use high manganese to produce MnS,
producing sulphur oxide note free cutting should not normally be
•Loss of gas shield gas due to long arc or high welded
ET
breezes ( GMAW ) •Reduce arc length

Excess Weld Metal ( Reinforcement )
Reinforcement is the extra metal which produces convexity in fillet
welds and a welds thickness than the parent metal plate in butt welds.
Causes : Preventation
•Excess arc energy ( GMAW,SAW ) •Reduction of energy input
•Shallow edge preparation •Deepen edge preparation
•Faulty electrode manipulation •Improve welder skill
•Incorrect electrode size •Reduce electrode size
ET

ET
Excess cap reinforcement

Excessive Penetration
Projection of the root penetration bead beyond a specified limit
•Weld input energy too high •Reduce arc power/increase weld speed
•Improve work piece preparation
•Incorrect weld preparation i.e excessive
root gap, thin edge preparation, lack of •Use correct electrode position
backing •Retrain welder
•Use electrode unsuited to welding position
ET
•Lack of welder skill

ET
Excessive root penetration

Undercut
An irregular groove at the toe of a run in the parent metal or in
previously deposited welding, cause by welding
Causes :
•Melting of top edge due to too high welding Preventation
current ( especially at free edge) or high •Reduce power input,especially
travel speed approaching a free edge where overheating
can occur
•Attempting an HV fillet weld leg length
•Weld in a flat position or use multirun
>9.0 MM technique
• Excessive/Incorrect weaving
ET
•Direct arc towards thicker member

•Incorrect electrode angle
Cap Undercut
Measured in both Length & Depth

ET

ET
Root undercut Cap undercut

Overlap
An Imperfection at the toe of a weld caused by metal flowing on to the
surface of the parent metal without fusing to it
• Poor electrode manipulation •Retrain welder
• High energy input/low travel speed •Reduce the heat input or limit size of
causing surface flow of fillet weld fillet weld to 9.0 mm leg by using multi
run weld
• Incorrect positioning of weld •Change the flat position
ET
• Electrode having too high a fluidity •Change to less fluid weld metal

Profile Defects
Poor stop/starts
ET

Miscellaneous
ET

Misalignment
The non – alignment of two abutting edges in a butt joint
• Inaccuracies in assembly procedures or •Adequate checking of alignment prior to
distortion from other welds welding coupled with the use of clamps
and wedges
• Excessive ‘out of flatness' in hot rolled
•Check accuracy of rolled section prior to
plate or sections
welding
ET

Arc strikes
Random areas of fused metal where the electrode, the holder, or
current return clamp accidentally touched the work and produced a
short duration arc
• Poor Access to work •Improve access ( modify assembly
sequence )
• Missing insulation on electrode holder
•Institute a regular inspection scheme for
or torch
electrode holders and torches
• Failure to provide an insulated resting •Provide an insulated resting place
place for the electrode holder or torch
•Regularly maintain current return clamp
ET
when not in use

• Loose current return clamp
Spatter
Small droplets of electrode material can be projected clear of the weld
and may fused to the parent metal
Causes: Preventation :
• High arc power •Reduce arc power
• •Reduce arc length or swith to AC power

Magnetic arc blow
•Modify electrical settings ( but be careful
• Incorrect setting for GMAW process
ET
to maintain full fusion

• Damp electrodes •Use dry electrodes
Burn Through
A localized collapse of the weld pool due to excessive
penetration resulting in a hole in the root run
 High Amps/volts
 Small Root face
 Large Root Gap
 Slow Travel Speed

Burn through
ET

Root Defects
Burn
Through
ET
Copyright © 2003 TWI Ltd

Burn through Faisal Yusof
Root Coking/Oxidized Root
 Loss or insufficient back

purging gas
 Most commonly occurs

when welding stainless
steels
 Purging gases include

argon, helium and
occasionally nitrogen
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Mechanical Damage
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Mechanical Damage
Mechanical damage can be defined as any surface material
damage cause during the manufacturing process.
This can included damage caused by:
 Grinding
 Hammering
 Chiselling
 Chipping
 Breaking off welded attachments (torn surfaces)
 Using needle guns to compress weld capping runs

ET

Parent Material Defects
A welding inspector should also inspect the parent
material for any visible defects
Mechanical damage Lap
Lamination
Segregation line
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ET Plate Lamination

Any
Any Questions?
Questions?
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Questions
QU 1. Give two main causes for the occurrence of a burn through
QU 2. Give two main causes for the occurrence of excessive root

penetration on a single-V butt weld
QU 3. Give five defects, which may occur when welding carbon

steel using the MMA welding process with the current setting
to low
QU 4. Give three possible causes for the occurrence of lack of

side wall fusion
QU 5. Sketch the following defects

a. Lack of root wall fusion b. Lack of root penetration
c. Incomplete filled groove d. Concave root
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Weld Repairs
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Welding Repairs
In the event of repair

 Authorization for repair
 Removal and preparation for repair
 Testing of repair - visual and NDT

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Weld Repairs
 A weld repair may be used to improve weld profiles or
extensive metal removal
 Repairs to fabrication defects are generally easier than
repairs to service failures because the repair procedure may
be followed
 The main problem with repairing a weld is the maintenance
of mechanical properties
 During the inspection of the removed area prior to welding
the inspector must ensure that the defects have been totally
removed and the original joint profile has been maintained
as close as possible
ET

Weld Repairs
The specification or procedure will govern how the defective
areas are to be removed. The method of removal may be
 Grinding
 Chipping
 Machining
 Filing
 Oxy-Gas gouging
 Arc air gouging
ET
Arc air gouging


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Welding Inspection

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

This is achieved as long as the following features

• Welds should consists of solid metal throughout a cross

Copyright © 2003 TWI Ltd Faisal Yusof

 Lack of solid metals

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Classified by Shape Classified by Position

Copyright © 2003 TWI Ltd Faisal Yusof

HAZ hydrogen cracking

 Weld metal hydrogen cracking

Solidification cracking (Hot Tearing)

Copyright © 2003 TWI Ltd Faisal Yusof

Weld metal hydrogen cracking

Solidification cracking Lamellar Tearing

Transverse crack Longitudinal crack

Copyright © 2003 TWI Ltd Faisal Yusof

in electrode, filler or parent metal

Copyright © 2003 TWI Ltd Faisal Yusof

Cluster porosity Herring bone porosity

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

•Tilt work to prevent slag

Copyright © 2003 TWI Ltd Faisal Yusof

Incomplete filled groove

•Unfused flux due to damage coating •Use electrode in good condition

Interpass slag inclusions Elongated slag lines

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

•Use of vertical down welding

Lack of root fusion Lack of root Penetration

Copyright © 2003 TWI Ltd Faisal Yusof

Lack of root penetration Lack of root fusion

•Oxide or scale on weld preparation •Improve electrode angle and work

•Reduce inductance, even if this increase

Copyright © 2003 TWI Ltd Faisal Yusof

breezes ( GMAW ) •Reduce arc length

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Excess cap reinforcement

•Lack of welder skill

Excessive root penetration

•Direct arc towards thicker member

Measured in both Length & Depth

Copyright © 2003 TWI Ltd Faisal Yusof

Root undercut Cap undercut

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd Faisal Yusof

when not in use

• •Reduce arc length or swith to AC power

to maintain full fusion

 Small Root face

 Large Root Gap

 Slow Travel Speed

Copyright © 2003 TWI Ltd Faisal Yusof

Copyright © 2003 TWI Ltd

 Loss or insufficient back

 Most commonly occurs

 Purging gases include