Welding Defects

WELDING INSPECTION

FLAWS/DISCONTINUITIES / DEFECTS

WHY IS IT IMPORTANT FOR YOU TO LEARN THIS SKILL?

UPON COMPLETION OF THIS MODULE YOU WILL BE ABLE TO:

1. DIFFERENTIATE FLAWS, DISCONTINUITIES AND DEFECTS.

2. DEFINE THE MAJOR CLASSIFICATION OF WELD DEFECTS
3. IDENTIFY DEFECTS, ITS CAUSES AND ITS REMEDIES
4. ACCEPTANCE STANDARDS
 Discontinuity
• All Welds have flaws.
• Another name for a flaw is a discontinuity
• Discontinuities are interruptions in the normal crystalline
structure (or grain) of the metal.
• Discontinuities are NOT always defects

Defect
• A flaw or flaws that by nature or accumulated
effect render a part or product unable to meet
minimum applicable acceptance standards or
specifications. The term designates rejectability.
 Acceptance Standards
a. Client requirements
b. CODE requirements
c. Users standards

Sample of Codes and Standards

1. AWS – American Welding Society
2. API – American Petroleum Institute
3. ASME – American Society of Mechanical Engineers
4. BIS – Bureau of Indian standard
• The purpose of welding inspections is to locate and
determine the size of any discontinuities
• Discontinuities that are too large or repeated too often
within the weld become defects
• Defects will compromise the welds overall strength
 What are some common defects?

CLASSIFICATION SYSTEM AND TYPES

A. DRAWING AND DIMENSIONAL
B. STRUCTURAL DISCONTINUITIES IN WELDS
C. PROPERTIES(Mechanical and Chemical) of weld metal
and or base metal.

A. Dimensional
1. Warpage-Longitudinal Distortion-Angular
b. Causes of warpage / distortion –
1. shrinkage of weld metal and overheating of joint,
2. faulty preparation
3. faulty clamping or weak tacking
c. Controlling methods
1. proper bead sequence
2. correct preparation
3. intermittent welding
4. correct clamping, proper tack size, prewarp
d. Correction method – straightening operation, heating,
removal of welds and subsequent re-welding
e. Effects
1. builds stress
2. failure to meet design dimensions
Joint Preparation

• Correct Bevel Angle

• Correct Root Gap
• Correct Root Face
• Proper Tack Weld
• Proper Alignment
 Incorrect Joint Preparation
a. Types
1. bevel angle
2. groove angle
3. root opening or root gap
4. root face
b. Causes
1. improper methods used
2. failure to issue proper instructions
3. failure to follow instructions
4. use of improper symbols
c. Controlling methods
1. use proper instructions
2. use of correct symbols
3. use correct techniques
d. Corrections methods
1. prepare again using proper methods
e. Effects–warpage/trapped slag/incomplete fusion/improper bead shape
Incorrect Joint Preparation
Incorrect Joint Preparation
Incorrect Joint Preparation
Excessive Concavity or Convexity
 Concavity

Fillet weld

Corner joint
 Convexity

Fillet weld

Corner joint
 Incorrect weld size
Excessive Concavity or Convexity
a. Types
1. excessive convexity/incorrect length
2. excessive concavity / excessive root reinforcement
b. Causes
1. improper welding technique
2. failure to follow instruction
3. insufficient or excessive welding current
c. Controlling Methods
1. use proper technique
2. follow instruction
d. Correction Methods
1. removal of welds and subsequent welding
e. Effects
1. notch effect
2. concentration of stress under load
3. insufficient throat thickness
EXCESSIVE CONVEXITY
EXCESSIVE CONCAVITY
 Incorrect Weld Profile
a. Type
1. excessive root reinforcement
2. excessive face reinforcement
b. Causes
1. slow travel speed
2. excessive heat
3. incorrect root face
4. improper electrode angle
c. Controlling methods
1. increase travel speed
2. reduce heat
3. use correct preparation
4. use correct electrode angle
d. Correction methods
1. removal of excessive reinforcement
2. possible removal of welds and subsequent re-welding
e. Effects – concentration of stress under load/notch effect
 Incorrect weld profile
EXCESSIVE WELD REINFORCEMENT

Tie end
Excessive Face Reinforcement
Excessive Root Reinforcement

Insufficient penetration

Burn through
Narrow root gap
 Incorrect Final Dimension
a. Types
1. Too long / Too short
b. Causes
1. incorrect tolerance on drawings or specifications
2. shrinkage of welds
3. incorrect joint preparation
c. Controlling methods
1. inspect for correct dimensions or tolerances prior to
fabrication
d. Correction methods
1. possible removal of welds and subsequent re-welding
e. Effects
1. will change dimensions of entire product
 Structural Discontinuities

• Porosity
• Slag inclusion
• Tungsten Inclusion
• Poor penetration
• Undercut
• Cracks
• Lack of Fusion
• Burn Through
• Rollover or “Cold Lap”
 Porosity
a. Types
1. uniformly scattered porosity
2. cluster porosity
3. linear porosity
b. Causes
1. dirt, grease, rust, oil, moisture on base metal
2. excessive current
3. moisture in shielding gas
4. moisture in filler metals
c. Controlling methods
1. clean base metal properly
2. dry base metal and/or filler materials
3. proper welding technique
d. Corrective methods
1. removal of defective area and subsequent re-welding
e. Effect
depending on nature and type can propagate into a crack
Structural Discontinuities in Weld

POROSITY- Gas entrapment

Sample of Defective Welds

• Porosity would
likely to occur at
starting the weld,
Tie Ins.

• Over
reinforcement
Sample of Defective Welds

A. Porosity
• Causes:
1.Welding speed too
rapid
2.Current too low
3.High sulphur or
other impurities
4.Faulty electrodes
 Slag Inclusions
a. Type
1. slag at root of joint
2. slag at bond area
3. scattered slag inclusions
b. Causes
1. improper joint preparation
2. improper cleaning of welds
3. improper techniques – wrong current setting
- wrong travel or speed
c. Controlling methods
1. proper joint preparation
2. proper cleaning before welding another bead
3. use proper technique – adjust current setting,
- adjust travel or speed
d. Corrective methods
1. removal of defective area and subsequent re-welding
e. Effect – weld is weak and cause cracking
Sample of Defective Welds
Slag Inclusion
Causes:
• 1.Joint design:
sharp V-shaped
recess
• 2.High viscosity
of molten metal,
rapid chilling,
too low a weld
temperature
• Slag are not
complete
remove before
depositing
another bead.
 Tungsten Inclusions
Type
1. Scattered inclusions
Causes
1. touching the electrode to the work or molten weld metal
2. incorrect current type and or current setting
3. incorrect type and or size of tungsten electrode
Controlling methods
1. use proper welding technique
2. use correct type and current setting
3. use correct type and size of tungsten electrode
Correction method
1. removal of defective area and subsequent re-welding
Effects
1. creates brittle area
2. can cause cracking

ote: can be seen as white image in x-ray film.

Tungsten Inclusions
 Incomplete Fusion- Lack of Fusion
a. Type
1. incomplete fusion at the root of the weld or adjacent
layers of weld metal
b. Causes
1. inadequate amount of heat (low current setting)
2. incorrect electrode angle
3. travel speed too fast
4. incorrect joint preparation
c. Controlling Methods
1. increase amount of heat (increase current setting)
2. reduce travel speed
3. use correct electrode angle
4. use proper joint preparation
d. Correction methods
1. possible back gouge and re-weld
2. removal of defective area and subsequent re-welding
e. Effect – weak joint and can cause cracking
4. Incomplete fusion at the root of the weld

Corner edge of the joint is not melted

4. INCOMPLETE FUSION at adjacent of the weld
 Incomplete joint penetration-Lack of Penetration
a. Type
1. lack of complete fill at the root of the joint / either butt joint or
tee joint.
b. Causes
1. groove design not suited for the process
2. root face dimension is too great (thick)
3. root opening is too small
4. fast travel speed
5. insufficient welding current
c. Controlling methods
1. use proper joint design
2. reduce travel speed
3. increase current setting
d. Correction method
1. possible back gouge and re-weld
2. removal of defective area and subsequent re-welding
e. Effects – notch effect possible start cracks
Inadequate joint penetration
Defective Root Penetration
Defective Root Penetration

keyhole
• Keyhole = root
gap + 1/16” on
both sides is the
recommended
size.

• Burn Through /
Melt through
Defective Root Penetration

Lack of Penetration In tie

ins
 Insufficient Fill on the Root Side
(suckback)
• Definition: The weld surface is below the adjacent
surfaces of the base metal at the weld root.
• Cause: Typically improper joint preparation or
excessive weld pool heat.
• Prevention: Correct cause.

• Repair: Backweld to fill. May require removal of weld

section by grinding for access to the joint root.
EXCESSIVE PENETRATION&INCOMPLETE
PENETRATION
 Undercut
• Definition: A groove cut at
the toe of the weld and left
unfilled.
• Cause: High amperage,
electrode angle, long arc length,
rust
• Controlling methods
Set machine on scrap metal. Clean metal before
welding.
• Repair: Weld with smaller electrode, sometimes must
be low hydrogen with preheat. Sometimes must gouge
first.
 Undercut
a. Types
1. side wall undercut
2. surface toe line undercut
b. Causes
1. excessive current (too high current)
2. too long arc length
3. magnetic arc blow (DC welding)
4. excessive travel speed (travel too fast)
5. incorrect electrode angle
c. Controlling methods
1. reduce current
2. adjust arc length
3. use AC welding
4. reduce travel speed
5. observe electrode angle
d. Correction methods
1. grinding or removal of defective area and subsequent re-
welding.
e. Effects
1. reduces strength of the joint
2. can cause slag inclusion
UNDERCUT
Undercut
Undercut typically has an allowable limit.
Different codes and standards vary greatly
in the allowable amount.
Plate - the lesser of 1/32” or 5% (typical)
 Cracks
a. Types
1. transverse and longitudinal weld cracks
2. crater cracks
3. base metal cracking
b. Causes
1. localized stress exceeds the ultimate strength of the material
2. lack of pre heat
3. poor crater fill technique
c. Controlling methods
1. use pre heating
2. use low hydrogen electrodes
3. sequence welds to balance shrinkage
4. use proper crater fill technique
5. avoid quenching and cooling conditions
 Cracks- Contd

d. Correction method
1. grinding / removal of defective area and subsequent re-
welding
e. Effects
1. weld failure
2. cracks progress in length (increase of crack length)
Cracks
CRACK
CRATER CRACKS

INSUFFICIENT FILLING AT THE END OF THE WELD

 Surface irregularities
Types
1. depressions
2. varying surface welds
3. varying reinforcement
4. non uniform weld ripples
5. spatter
Causes
1. inexperienced welder
2. restricted positioning while welding
Controlling methods
1. proper training of welders
2. workmanship samples
Correction methods
1. grinding or chipping before depositing succeeding welds
Effects
1. could result in slag entrapment or other discontinuities
OVERLAP
 Insufficient Fill

• Definition: The weld surface is below the adjacent surfaces

of the base metal
• Cause: Improper welding techniques
• Controlling methods
• : Apply proper welding techniques for the weld type
and position. Use stripper beads before the cover
pass.
• Correction methods
Simply weld to fill. May require preparation by
grinding.
UNDERFILL
Surface Irregularities

SPATTER
POOR APPEARANCE

• Crater
1. Incomplete
Termination of
Weldment
UNACCEPTABLE WELD PROFILES
 Properties (Mechanical and Chemical) of Welded Metal and/or
Base Metal

1. Tensile strength – ultimate strength of a material subjected to a

tensile load
2. Yield strength – indication of maximum stress that can be
developed in a material without with out plastic deformation.
3. Ductility – extent to which a material can sustain palstic
deformation without rupture
4. Hardness – measure of a materials resistance to localized
plastic deformation
5. Impact – energy required to fracture a part subjected to shock
loading
6. Chemical Composition – the structure and properties of
substances and of the changes they undergo.
How would you find these faults ?
TWO METHODS OF DETERMINING WELD FAULTS
1. Non Destructive Examination
a. Visual
b. Dye Penetrant Examination
c. Magnetic particle Examination
d. Ultrasonic Examination
e. Radiographic Examination
2. Destructive Testing
a. Tensile Test
f. Bend test
g. Impact test
h. Hardness test
ASME SEC.VIII DIV.1- Acceptance Norms
(1) any indication characterized as a crack or zone of incomplete
fusion or penetration;
(2) any other elongated indication on the radiograph which has
length greater than:
(a) 1⁄4 in. (6 mm) for t up to 3⁄4 in. (19 mm)
(b) 1⁄3t for t from 3⁄4 in. (19 mm) to 21⁄4 in. (57 mm)
(c) 3⁄4 in. (19 mm) for t over 21⁄4 in. (57 mm)
Where
t is the thickness of the weld excluding any allowable
reinforcement. For a butt weld joining two members having
different thicknesses at the weld, then the thinner of these two
thicknesses.
ASME SEC.VIII DIV.1- Acceptance Norms
(3) any group of aligned indications that have an aggregate length
greater than t in a length of 12t, except when the distance
between the successive imperfections exceeds 6L where L is the
length of the longest imperfection in the group;
(4) rounded indications in excess of that specified by the
acceptance standards given in Appendix 4.
 AWS D 1.1 STRUCTURAL WELDING CODE
Static load, Cyclic load & Tubular connections

(a) Crack Weld shall have no crack

(b) Weld / Base Thorough fusion shall exist bet’ WM/BM
metal fusion and adjacent layers of WM
(c ) Crater Crater to be filled to full cross section except for
stitch welds outside eff. Len.
(d) Weld profile In conformance with Drawing
(e) Inspection VT to start after weld cools to room temp
(f) Underrun Underrun in fillet weld nominal size 1.6 mm
provided it is < 10% length. In Web to
flange welds, it is not permitted
AWS D 1.1 STRUCTURAL WELDING CODE

Undercut In static loading, 1 mm permitted for t<25

and 1.6 mm in t>25mm. For t<25 mm, Max 1.6 mm
permitted for accumulated l of 50 mm in 305 mm.
In cyclic loads and tubular connections,
undercut < 0.25 mm deep when weld is transverse to
tensile stress. For other cases, 1 mm is permitted

Porosity In complete joint penetration butt joints

transverse to tensile stress, no visible piping porosity
permitted in static, cyclic & tubular connection
AWS D 1.1 STRUCTURAL WELDING CODE
Porosity
In static loading, for other grooves and
fillets sum of porosity with dia > 1mm,
should be < 10 mm in any linear inch of
weld and < 19 mm in any 305 mm weld

For cyclic loading and tubular connection,

the frequency of piping porosity in other
cases should be < one in 100 mm weld
length and max dia < 2 mm.

In cyclic loading and tubular connections,

for fillet welds connecting stiffeners to
web, the sum of dia of piping porosity<10
mm in any linear inch of weld and shall
be < 19 mm in any 305 mm weld
AWS D 1.1 STRUCTURAL WELDING
CODE
RADIOGRAPHY FOR STATICALLY LOADED STRUCTURE
• Elongated indication and spacing as per chart
• Rounded indications > E/3 not to exceed 6 mm (except for
t>2” it is 10 mm) and gap should be > 3 L
• Isolated discontinuities like clusters with sum of
dimensions not to exceed chart and gap < 3 L
• Sum of individual discontinuities each having max
dimension < 2 mm, shall not exceed 2 E /3 (10 mm max) in
any linear inch of weld.
• In line discontinuities with sum of greatest dimension < E
in any 6E length of weld
Thank
You