WELD DEFECTS-

REMEDIES
 REASONS FOR DEFECTS

 Lack of know-how.

 Welding process characteristic.

 Base metal defects or base metal composition, with an

inherent susceptibility towards cracking.

 Defective welding filler metals.

 Joint environment

 Welding environment
 CLASSIFICATION OF DEFECTS

1. Defects involving inadequate bonding:

 Lack of fusion in fused weld
 Incomplete penetration

2. Foreign inclusion:
 Slag Inclusion
 Oxide film in fusion weld
 Tungsten Inclusion
3. Geometric defects:
 Undercut
 Excessive Reinforcement
 Burn through or excessive penetration
 Distortion
 Improper weld profile
4. Metallurgical Defects:
 Cracks, Gas porosity, Arc strike, Embitterment
 DEFECTS OF WELDING

 1. Lack of penetration
 2. Lack of fusion
 3. Undercut
 4. Porosity
 5. Overlap
 6. Cracks
 1. LACK OF PENETRATION

Weld Metal fails to fill up to the root or fails to fuse

completely with the root face of the parent metal.
 1. LACK OF PENETRATION

Causes:
• Dirty Surface
• Improper cleaning
• Too low current
• Excess Welding Speed
• Unfavourable Heat input
 2. LACK OF FUSION

A discontinuity in a weld between weld metal

and parent metal
 2. LACK OF FUSION

Causes:
 Dirty Surface
 Improper Cleaning
 Too –low Current
 Excess Welding Speed
 Unfavourable Heat Input
 3. UNDERCUT

Groove in the parent metal along the toe of

the weld
3. UNDERCUT
 3. UNDERCUT

Causes:
o High current
o Higher dia of electrode
o Wrong electrode angle
o Wrong polarity in case of DC
 4. POROSITY

Entrapment of gases in the weld metal

 4. POROSITY

Cause:
 Contamination of Work Piece
 Excessive Moisture Pickup in Electrode

Covering
 Moisture on work surface
 Long arc
 Excessive Current
 High Travel Speed
5. OVERLAP

Imperfection at the
toe of the weld
caused by
overflow of weld
metal on the
surface of parent
metal without
fusing
 5. OVERLAP

Causes:
• Wrong angle of electrode
• Too large deposit in a single run
• Faulty electrode manipulation
6. CRACKS
6. CRACKS
 6. CRACKS

Example of Longitudinal Cracking

 6. CRACKS

Causes:
 High Rigidity of Joint
 High carbon Content of Weld Metal
 High Sulphur Content in Base or weld metal
 Hot Cracking
 Higher Hardenability
 Hydrogen Induced Cracking
 High residual Stresses
CRATER
CRATER
General Welding Discontinuities
General Welding Discontinuities
General Welding Discontinuities
General Welding Discontinuities

CONVEX FILLET WELD

General Welding Discontinuities

CONCAVE FILLET WELD

General Welding Discontinuities

Cold lap
General Welding Discontinuities

Cluster porosity
General Welding Discontinuities

Slag inclusions
General Welding Discontinuities

Incomplete penetration or lack of penetration

General Welding Discontinuities

Incomplete fusion
General Welding Discontinuities

Internal concavity or suck back

General Welding Discontinuities

Internal or root undercut

General Welding Discontinuities

External or crown undercut

General Welding Discontinuities

Offset or mismatch
General Welding Discontinuities

Inadequate weld reinforcement

General Welding Discontinuities

Excess weld reinforcement

General Welding Discontinuities

Cracks
General Welding Discontinuities

Tungsten inclusions
General Welding Discontinuities

Oxide inclusions
General Welding Discontinuities

Burn-Through
General Welding Discontinuities

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Porosity
Summary of Weld Defects
Cause Type of Defect

Lack Lack of Slag Under cut Porosity Blow Overlap Crack

of penetra inclusion holes
fusion tion

Dirty Surface, improper √ √ √ √

cleaning of weld beads

Current too low √ √ √ √

Current too high √ √

Unfavorable /low heat input √ √

Excess/High weld speed √ √ √ √

Wrong size (high dia) of √ √

electrode

Wrong angle of electrode √ √

Faulty electrode manipulation √ √

Wrong arc length, wrong √ √

polarity

Inadequate joint preparation √

Defective weld design √

Rapid cooling √
Ways to achieve Quality in Welding

 Select the electrode type which has been approved

for the job and has been used successfully.
 Re-dry the electrodes in electric oven and use them
fresh from oven.
 Use DC. If AC is to be used, make sure there are no
fluctuations in the welding current and also that the
machine has at least 70 OCV.
 Ensure that joints are correctly prepared and fitted up
accurately.
 Ensure that surfaces to be welded are free from rust,
oil, grease, paint and moisture.
 Lay sound and well fused tack welds.
 Lay each pass methodically so that it fuses well with the
joint faces without undercut or overlap. Clip the slag
thoroughly.
 Do not make weld beads too convex. Choose
electrodes which give a flat or concave bead.
 Make sure the craters are well fused, sound and free
from porosity and slag. Inspect each crater closely.
Chip out bad or defective craters.
 Inspect each weld pass for porosity, slag inclusions
and cracks. Use a magnifying glass. If you suspect
a defect, chip or gouge it out.
 Do not hurry up with the job. Do not use very high
currents or very high welding speeds.
 Welders have to possess training, skill and vigilance.

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