Welding Defects

WELD DEFECTS

• EXTERNAL • INTERNAL
> Distortion > Crack
> Overlap > Internal porosity
> Undercut > Lack of fusion
> Excessive Penetration
> Inclusions
> Surface Cracks
> Incomplete penetration
> Crater
> Porosity (surface)
> Underfill
> Incomplete penetration

2
DISTORTION

• Heat input in the job results in

uneven expansion &
contraction thus changing
original shape / dimensions

3
DISTORTION -REMEDY
• Reduce effective force

• Avoid over welding

• Proper welding sequence

• Peening

• Preheating

• Jigs & fixtures

• Tack weld

4
UNDERCUT

• Excessive arc length

• Excessive current

• Excessive speed of travel

• Side manipulation

• Damp electrode

• Presence of scale

5
OVERLAP

• Incorrect welding technique

• Incorrect electrical conditions

• Slow speed of travel

• Use of oversize electrode

6
 EXCESSIVE PENETRATION

• Incorrect joint preparation

• Excessive current

• Excessive arc length

• Improper welding technique

7
CRATER

• Incorrect welding technique

• Long arc

• High current

8
 POROSITY

• Due to dissolved gases in

molten metal

• Incorrect polarity

• Dirty base metal

• Damp electrode

• Excessive arc length

9
LACK OF FUSION

• Insufficient welding current

• Speed of travel too fast

• Improper sequence of runs

10
INCLUSIONS

• Insufficient current
• Incorrect electrode manipulation
• Lack of cleaning
• Long arc length
• Incorrect electrode size
• Undercut

11
UNDERFILL

• Incorrect welding technique

• Incorrect edge preparation

• High Arc Length

12
INCOMPLETE PENETRATION

• Incorrect polarity
• Incorrect root gap
• Large root face
• Improper joint
• Oversize Electrode
• Excessive travel speed
• Less current

13
SPATTER

• High current

• Long arc

• Incorrect polarity

14
 ARC BLOW

• This defect occurs in DC welding. Arc stream

tends to deviate from its intended path This is
caused due to DC being unidirectional setting
magnetic field around work station

• Avoid by using backing strip or breaking &

restarting the arc/AC Machine

15
CRACK

Discontinuity caused by tearing

of the metal(Hot crack) or by
fracturing of the metal when
cold. Can occur in weld metal,
at the fusion line or in
basemetal. Longitudinal cracks
& transverse cracks.

• Restrained cracking
• Crater Cracking
• HAZ cracking or Hydrogen induced
cold cracking
• Corrosion cracking
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