WELD DEFECTS

CAUSES AND REMEDIES

WHICH IS GOOD AND WHICH IS BAD?
WHAT IS A DEFECT IN WELD?

 Welding defects can be defined as weld surface irregularities, discontinuities,

imperfections, or inconsistencies that occur in welded parts.
 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.
 Defects in weld joints could result in the rejection of parts and assemblies, costly
repairs, significant reduction of performance under working conditions and, in
extreme cases, catastrophic failures with loss of property and life.
PICK A PIC!
PATCH IT UP!

POROSITY UNDERCUT INCOMPLE INCOMPLE BURN SPATTERS SLAG

S TE FUSION TE THROUGH INCLUSION
PENETRATI
ON
POROSITIES

 Porosity is the presence of cavities in the weld metal caused by the freezing in of
gas released from the weld pool as it solidifies. The porosity can take several forms:
 Distributed
 Surface breaking pores
 Wormhole
 Crater pipes
PROBABLE CAUSES

 Uncleaned work base/ base metal

 High wind velocity
 Low shielding gas production
 Welding over trapped slags
INCOMPLETE FUSION / INCOMPLETE PENETRATION

 Incomplete root fusion is when the weld fails to fuse one side of the joint in the
root. Incomplete root penetration occurs when both sides of the joint are
unfused.
PROBABLE CAUSES

 Excessively thick root face

 Travel speed too fast
 Too small a root gap
 Misplaced welds
 Power input too low
 Arc (heat) input too low
SLAG INCLUSION

 Slag is normally seen as elongated lines either continuous or discontinuous

along the length of the weld. This is readily identified in a radiograph.
PROBABLE CAUSES

 inadequate overlap
 excessive undercut
 uncleaned weld passes
 poor weld bead
 Welding current too low
THINKING OUT LOUD!!!

 What do you notice about the causes of the different weld defects?
 As a welder, how will you avoid or lessen these defects?
 Why should we identify the causes of theses defects?
VIDEO PRESENTATION
WORK IT OUT!!!
Category 5 points 3 points 1 point
Product outcome Welding product shows Welding product shows Product shows a lot of
no weld defect little defect defects

Application of remedy Remedies applied are Remedies applied are Remedies applied are not
very effective effective effective

Proper use of tools and Used tools and Used tools and Unable to use tools and
equipments equipments with equipments with less equipments properly
confidence confidence

Safety work habits Observed safety all the Observed safety Observed safety once or
time sometimes none at all