Weld Quality & Weld Testing

What is unique about the Eisenhower

Interstate Highway System?

One in every 5 miles is

straight, this can be used as
airstrips in times of war and
other emergencies
Each Weldment Should Be:
• Adequately Designed to meet the intended
service for the required life
• Fabricated with specified materials and in
accordance with the design concepts
• Operated and maintained properly
Welds are examined in regard to:
• Size
• Shape
• Contour
• Soundness
• Other Features as Specified
 Welding Code
Effect of Discontinuities on
Properties
• Discontinuities in a welded
joint can influence
mechanical properties
• Codes establish size limits
for acceptable
discontinuities
• Discontinuities
unacceptable by a given
code are called defects and
are subject to repair
Classification of Weld Joint Discontinuities

• Welding Process or Procedure Related Discontinuities

• Metallurgical Discontinuities
• Design Related Discontinuities
Classification of Weld Joint Discontinuities
Welding Process or Procedure Related Discontinuities

Geometric Other
•Misalignment •Arc Strikes
•Undercut •Slag Inclusions
•Concavity or Convexity •Tungsten Inclusions
•Excessive Reinforcement •Oxide Films
•Improper Reinforcement •Spatter
•Overlap •Arc Craters
•Burn-through
•Backing left on
•Incomplete Penetration
•Lack of Fusion
•Shrinkage
•Surface Irregularities
Classification of Weld Joint Discontinuities
Metallurgical Discontinuities

Cracks or Fissures Heat-Affected Zone

•Hot Microstructural Alterations
•Cold or Delayed
•Reheat
•Stress-Relief
•Strain-age Weld Metal & HAZ Segregation
•Lamellar Tearing

Porosity Base Plate Laminations

•Spherical
•Elongated
•Worm-hole
Classification of Weld Joint Discontinuities
Design Related Discontinuities

Changes in Section & Other Stress Concentrators

Weld Joint Type

 Open the web page under
“Demonstrations” and do the
exercise entitled “Discontinuities

http://www-iwse.eng.ohio-
state.edu/we300/Discontinuity/discontinuity.aam
Pages 364 through
367 of the Welding
Handbook list table
of Common Causes
and Remedies like the
one on the Right.
Review these tables to
gain insight about
Discontinuities
Turn to the person sitting next to you and discuss (1 min.):
• From a general point of view, how would you rank the
following discontinuities in their severity to weld properties:
Hot Cracks, Change in section size, Porosity, ? Why
 Welding Discontinuities

Porosity
• Porosity is the entrapment of small volumes
of gas in solidifying weld metal
• Prevention
– Drying consumables
– Cleaning, degreasing material being welded
– Electrode or filler metals with higher level of
deoxidants
– Sealing air leaks, reducing excess shielding gas
flow 0.1.1.4.2.T7.95.12
 Welding Discontinuities

Slag inclusions
• Slag inclusions are irregularly shaped, not
spherical like porosity
• Prevention
– Position work and/or change electrode/flux to
increase slag control
– Better slag removal between passes
– Dress weld surface smooth if it is likely to
cause slag traps
– Remove heavy mill scale on plate 0.1.1.4.2.T8.95.12
 Welding Discontinuities

Lack of Fusion
• Lack of fusion is caused by incorrect
welding conditions
• Prevention
– Procedure for complete fusion should be
verified by testing
– Increased energy input
– Correct electrode angle and work position

0.1.1.4.2.T9.95.12
 Welding Discontinuities

Incomplete Root Penetration

• Incomplete root penetration can be caused by
– Excessively thick root face, insufficient root gap
– Incorrect welding conditions
– Misalignment of second weld
• Prevention
– Improved joint preparation
– Test weld verifications for correct parameters
– Reassessment of back gouging

0.1.1.4.2.T10.95.12
 Welding Discontinuities

Overlap
• Overlap is an imperfection at the weld toe
or root caused by metal flowing onto the
surface of the base metal without fusing to
it
• Prevention
– Adjust electrode manipulation to ensure fusion
of base metal
– Limit size of fillet to 9-mm leg length
0.1.1.4.2.T11.95.12
 Welding Discontinuities

Undercut
• Undercut is an irregular groove at the weld toe in the
parent metal or previous pass caused by
– excessive weaving
– melting of top edge of fillet weld with high current
• Prevention
– Weld in flat position
– Change shielding gas to one which produces better wetting
– Terminate welds so they don’t finish at a free edge

0.1.1.4.2.T12.95.12
 Welding Discontinuities

Excessive Penetration
• Excessive penetration is caused by
– Incorrect assembly or preparation
• Edge preparation too thin to support weld underbead
• Excessive root gap
– Energy input too high
– Lack of operator skill
• Prevention
– Control of preparation, backing bars
0.1.1.4.2.T13.95.12
 Welding Discontinuities

Root Concavity
• Root concavity is caused by
– Excessively thick root face
– Insufficient arc energy for penetration
– Excessive backing gas pressure
• Prevention
– Reduce root face thickness, control backing gas
pressure
– Establish a procedure by test welding
0.1.1.4.2.T14.95.12
 Welding Discontinuities

Spatter
• Spatter consists of small droplets of
electrode material that land beside the weld
and may or may not fuse to the base
material
• Prevention
– Reduce energy input
– Shorter arc length
– Reposition current return clamp to reduce
magnetic arc blow or switch to AC current 0.1.1.4.2.T15.95.12
Turn to the person sitting next to you and discuss (1 min.):
• We have just looked at a list of discontinuities and
preventative measures. How does this information effect the
opinions of people involved in writing codes for proper
welding conditions?
Weld Test Samples Help Reveal
Discontinuities and Defects
 Fatigue Design

Fatigue Appearance
• Distinct fracture
surface has a
characteristic
texture
– Concentric line
multiple initiation sites
pattern
– Smooth portion
referred to as
clamshell texture