To assure quality of weld workmanship

the welds are examined with the factors

listed above in mind.

Welds are examined in regard to:

• Size
• Shape
• Contour
• Soundness
• Other Features as Specified
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
 Cracks:
Cracks may occur in various location and direction in the weld area.
The typical types of cracks are longitudinal, transverse, crater, under
bead and toe cracks. When joint is at elevated temperature then a
crack occurs and it is known as hot crack. When it occurs after
solidifying weld metal, it is known as cold crack.

Causes:
It is due to the welding ended far too adruptly. The cracks begins at a
void in welding crater, caused by the solidification shrinkage.

Remedies:
When finishing move back the electrode to fill up the crack.
With root pass welding, quickly move the arc form welding pool to
the plate edge.
Increase crater fill time by power source.
 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
 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
 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
Causes:
Heat input is too low.
Weld pool is too large and running ahead of the arc.
Joint included angle is too low.
Electrode and torch angle is incorrect.
Unfavorable bead position.

Remedies:
Increase welding current and decrease the travel speed.
Reduce deposition rate.
Increase joint include angle.
Position electrode or plate angle such a way so the plate
edges will melt.
Position bead in such a way that the sharp edges with other
bead or plate are avoided.
 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
 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
 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
Causes:
Arc voltage too high or arc too long.
Incorrect electrode use or incorrect electrode angle.
The electrode is too large.
High electrode speed.

Remedies:
Lower arc voltage or reduce arc length.
Apply electrode angle form 30 degree to 45 degree with the
standing leg.
Use a smaller diameter electrode.
Reduce travel speed.
 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
 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
 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
Causes:
Welding current too high.
Arc is too long.
Incorrect polarity.
Insufficient gas shielded.

Remedies:
Reduce welding current and arc length.
Use correct polarity according to the welding
condition.
Increase torch to plate angle and use correct gas
shielding.
 Arc blow:
Causes:
Arc deflection as a result of magnetic effects into the opposite
direction of the earth lead clamp.
Arc deflection as a result of magnetic effects in the direction of
heavy part of work piece especially at corner and edges.

Remedies:
Use AC electrode where possible.
Try welding away from earth clamp connection. Try splitting
the earth clamp and correct to both side of the joint.
Keep arc as short as possible.