Welding Processes

Shielded Metal Arc Welding

Gas Metal Arc Welding
Tungsten Arc Welding
Submerged Arc Welding
Problems Associated With
Incorrect Weld Joint Fit Up
Root Problems
Gap size too large:

a) excess penetration b) burnthrough

c) shrinkage grooves d) gas entrapment

Root Problems
Gap size too small:
1) incomplete penetration

2) incomplete root fusion 3) incomplete side wall fusion

4) slag inclusions 5) root concavity

 Root Problems
Root face too large:

a) incomplete root penetration b) incomplete root fusion

Root Problems
Root face too small:

1) excessive penetration 2) burnthrough

3) root concavity 4) root undercut

Included Angle Too large

a) excess penetration b) incomplete filled groove

 Fillet Welds
Gap size too large:

1) reduced root penetration

2) slag inclusions

3) gas inclusions

5) cracking
4) reduced vertical
leg length size
 Included Angle Too Small
2) incomplete interun fusion

1) incomplete root penetration 4) incomplete sidewall fusion

3) incomplete root
fusion 6) poor toe blend

5) excessive cap

7) slag inclusions
Visual Inspection of Welds
Butt Weld Size
a) excess weld metal height

b) root penetration

c) weld width

d) root bead width

Fillet welds (size)
Consider:

a) z minimum (and maximum) leg length

size

b) a minimum design throat

thickness
Shape (Butt Welds)
Consider:

Ideally, (a) is the most desirable but

very often it may be difficult to
achieve. Because of this, one should
assess the excess weld height in
conjunction with the weld profile and
perhaps the toe blending.
Shape (Fillet Welds)
Consider:
In normal practice, (a) is the most desirable
but, again, in many instances it is difficult to
achieve. Acceptance levels, therefore, allow
tolerances on weld shape.
Toe Blend (Butt Welds)
For butt welds, consider:
In normal practice, (a) is the most
desirable but, again, in many
instances it is difficult to achieve.
Acceptance levels, therefore, allow
tolerances on weld shape.

Depending on the service conditions

of the product, the toe blend may be
of greater importance than the size
and shape of the weld. A poor toe
blend may reduce service life by a
considerable margin if the product is
under a cyclic load.
Toe Blend (Fillet Welds)
For fillet welds, consider:

In normal practice, (a) is the most

desirable but, again, in many
instances it is difficult to achieve.
Acceptance levels, therefore,
allow tolerances on weld shape.
Root Defects

Incomplete root penetration

Failure of weld metal to extend into the root of a joint

Lack of root fusion

Lack of union at the root of a joint

Excess penetration bead

Excess weld metal protruding through the root of
a fusion weld made from one side only
Root Defects
Root concavity
(suck-back; underwashing - non-standard terms)
A shallow groove which may occur in the root of a
butt weld, but full fusion is evident
Shrinkage groove
A shallow groove caused by contraction in the metal
along each side of a penetration bead or along the
weld centreline

Burnthrough
(melt through)
A localised collapse of the molten pool due to
excessive penetration, resulting in a hole in the
weld run
Contour Defects

Incompletely filled groove

A continuous or intermittent channel
in the surface of a weld, running
along its length, due to insufficient
weld metal. The channel may be
along the centre or along one or
both edges of the weld
Bulbous Contour

Bulbous contour
A non-standard term used to
describe poor appearance
Unequal Legs

Unequal legs
(non standard term)
Variation of leg length on a fillet weld
Note: Unequal leg lengths may be
specified as part of the design - in which
case they are not imperfections
Undercut

Undercut
An irregular groove at a toe of a run in the
parent metal or in previously deposited
weld metal
The inspector must determine if the
undercut is continuous or intermittent, or
sharp or smooth
Overlap

Overlap
An imperfection at the toe or root of a
weld caused by metal flowing on to the
surface of the parent metal without fusing
to it
Gas Pore

Gas pore
A cavity, generally under
1.5mm in diameter, formed by
trapped gas during the
solidification of molten metal

Porosity
A group of gas pores
Crater Pipe

Crater pipe
A depression due to shrinkage at the end of a
run where the source of heat was removed.
Crater pipes may also lead to micro-cracking
Surface Cracks
Crack
A linear discontinuity produced by fracture Cracks may be ...

a) ... longitudinal, in the weld metal, i.e. centreline

b) ... longitudinal, in the parent metal or heat affected zone

c) ... transverse

d) Crater crack
(star cracking)
Arc Strike

Stray flash/arc burn/arc strike

(stray arcing)
1. The damage on the parent material
resulting from the accidental striking of an
arc away from the weld
2. The accidental striking of an arc away
from the weld
Note that the same term is used for both
the action and the result
Weld Width
Weld width and consistency of weld width

For butt welds and fillet welds,

consider:
Weld Defects
Lack of Side Wall Fusion
Lack of Inter Run Fusion
Porosity
Slag Inclusions
Incomplete Root Fusion
/Penetration
Solidification Cracking
Overlap
Excess Weld Metal
Excess Penetration
Root Concavity
Slag Inclusion
Surface Breaking Porosity
Cracking
Arc Strikes
Crater Pipe
Using Welding Inspection Tools
 Weld Profile Gauge
Scale in
inches or mm Measuring
Fillet Welds

Measuring Cap
Reinforcement/ Measuring
Misalignment Bevel Angle
Hi Lo Gage

Measures Hi Lo…
Pipe Thickness…
Bevel Angle…
Using the tools…
Throat Thickness (WPG)
Fillet Weld
Cap Reinforcement (WPG)

Measuring
the height
of the cap
Bevel Angle (WPG)
Readout

Measuring
the pipe
bevel
angle
Misalignment (WPG)
Shown
on scale
Misalignment (Hi Lo)
Pipe Misalignment