Weld defects

Sr No Clasification of defects Types of defects

1 Cracks Transverse cracks

Longitudinal cracks

Toe cracks/Underbead Cracks

Crater Cracks

Hot Cracks
Cold Cracks(Hydrogen Induced Cracking(HIC))

2 Cavities Blowholes
Porosity
Shrinkage
3 Solid Inclusions Slag Inclusion
Flux Inclusion
Metal Oxides Inclusion
Tungsten Inclusion
4 Incomplete Fusion or Penetration Lack of Fusion
Lack of Penetration
suck Back
5 Imperfect shape or Unaccecptable contour Dimensional Deviation
Undercut

Underfill
Overlap
Excessive Reinforcement
Excessive Penetration
Bead Shape
6 Miscellaneous Defects Arc Strike
Excessive Spatter
Rough Surface
Uneven Ripples
Pock Marks
Lami
 categories Causes
Visual/Surface Defects Hidden/Sub-Surface Defect
√ 1.High contraction stresses.
2.Poor fit-up and incorrect
welding procedure
3.Poor edge quality

1.Relatively High carbon or alloy

content steel that allows to cool
rapidly from welding
temperature.
2.Hydrogen pick up during
welding.

Interrupted welding cause crater

cracks
√ Improper selection of process
√ 1.Hydrogen in the weld metal
2.High Stresses
3.Suscreptible Microstructure e.g.
Martensite
4.Relatively Low Temperature
between 200 & -100⁰C
5.High welding speed.
6.Low current density.
7.Weld of insufficient cross-
sectional area

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Permitted Maximum Repair Allowance

Not Permitted

Slightly intermittent undercut is

permitted provided the depth does
not exceed 0.4 mm.

Not Permitted