8/13/13 Handbook - Weld Defects

Variations-
Metal
Transfer

Equipment
LONGITUDINAL CRACKING

Longitudinal or centerline cracking, of the weld bead is not often encountered in mig welding. However, that
Power which does occur can be one of two types: hot cracks and cold cracks. Typical hot cracks are shown in
Supply Figure 10-5. Hot cracks are those that occur while the weld bead is between the liquidus (melting) and
solidus (solidifying) temperatures. In this temperature range the weld bead is ”mushy”. Hot cracks usually
result from the use of an incorrect wire electrode (particularly in aluminum and stainless steel alloys). The
Shielding chemistry of the base plate can also promote this defect (an example would be any high carbon stainless
Gases
steel casting). Any combination of the joint design, welding conditions and welding techniques that results in
a weld bead with an excessively concave surface can promote cracking.
Wire
One form of this defect which may often be encountered, particularly with any 5000 series aluminum, is
Electrodes
called a crater crack. These are small cracks which appear at the end of the weld where the arc has been
broken. Although small, these cracks are troublesome since they can propagate into the weld bead. A crater
crack is shown in Figure 10-6. The major reason for this defect is the incorrect technique for ending the
Safety
weld. To properly end a weld, the crater should be filled. This is done by reversing the arc travel direction
before breaking the arc. This technique is depicted in Figure 10-7. In addition, if the welding control is
designed to supply gas for a short time after the arc is broken, the crater should be shielded until it is
Welding
completely solidified.
Techniques
Figure 10-6 - Example of Crater Cracking

Welding
Conditions

Introduction
Economics
Incomplete
Penetration
Lack of
Weld Fusion
Defects Undercutting
Figure 10-5 - Example of Longitudinal
Porosity Cracking
Mig Spot
Welding Longitudinal
Cracking

9
Tables

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