Weld Defects

WELD DEFECTS
Root Defects.
Internal Defects.
Surface Defects.
Copyright © 2005, TWI Ltd World Centre for Materials Joining Technology
CLASSIFICATION OF DEFECTS
STRESS CONCENTRATION FACTOR SCALE.
LOW SIGNIFICANCE MEDIUM SIGNIFICANCE HIGH SIGNIFICANCE

1- 4 5-7 8- 10
EQUIAXED LINEAR VOLUMETRIC PLANAR

Rounded and Slag lines Linear from at
Non linear Elongated porosity least one direction
Gas pores Slag inclusions Cracks, lack of fusion
ROOT DEFECTS.
• INCOMPLETE ROOT PENETRATION.
• LACK OF ROOT FUSION.
• ROOT CONCAVITY.
• BURN THROUGH.
• EXCESS PENETRATION.
INCOMPLETE ROOT PENETRATION
DEFINITION:
Failure of weld metal to
extend into the root of a
joint.
CAUSES:
Root faces too large
Root gap too small
Electrode dia too large
Incorrect electrode angle
Arc length too long
Travel speed too high for
current
INCOMPLETE ROOT FUSION
DEFINITION:
Lack of union at the
root of the weld.
CAUSES:
Amperage too low / too
high
Contaminated weld preps
ROOT CONCAVITY
DEFINITION:
A shallow groove that may
occur in the root of a butt
weld.
CAUSES:
Root face too large
Low arc energy
Excessive back purge
Excessive root grinding
EXCESS PENETRATION
DEFINITION:
Excessive weld metal
protruding through the
root of a fusion weld made
from one side only.
CAUSES:
Excessive amperage
Excessive root gap
Small root face
Incorrect welding
technique
Type of electrode
ROOT HAZ CRACK
INTERNAL DEFECTS
• LACK OF SIDE WALL FUSION.
• LACK OF INTER RUN FUSION.
• POROSITY.
• SLAG INCLUSIONS.
LACK OF SIDEWALL FUSION
DEFINITION:
Lack of union in a weld.
CAUSES:
Contaminated weld prep
Amperage too low / high
LACK OF INTERUN FUSION
POROSITY
• DEFINITION:
A group of gas pores,
formed by entrapped gas
during the solidification
of molten metal.
Blowhole - a cavity
generally over 1.5mm.
Wormhole (piping) -
elongated or tubular
cavity.
GAS PORE
SLAG INCLUSION
DEFINITION:
A fused, non-metallic
residue produced from
some processes.
CAUSES:
Insufficient cleaning
Contamination
Arc length too long
Welding over irregular
profile
SURFACE DEFECTS.
• ARC STRIKES.
• SURFACE CRACKS.
• SPATTER.
• POROSITY.
• EXCESS WELD METAL.
• CRATER PIPE.
• UNDERCUT.
• INCOMPLETELY FILLED GROOVE.
• OVERLAP.
• POOR WELD PROFILE.
ARC STRIKE (STRAY FLASH)
DEFINITION:
Damage on the parent
material resulting from the
accidental striking of an
arc from the weld.
CAUSES:
Electrode straying onto
parent material
Electrode holder
Poor contact of return /
earth clamp
SURFACE CRACKS
DEFINITION:
A linear discontinuity
produced by fracture.
Cracks may be
longitudinal,transverse,
edge, centreline, fusion
zone, underbead, weld
metal or parent metal.
Weld metal cracks.
Heat affected zone cracks
Parent material/HAZ
SPATTER
DEFINITION:
Small droplets of electrode
material which have
strayed away from the
arc which may or may not
have fused to the parent
plate.
CAUSES:
Excessive arc energy
Arc - blow
Damp electrodes
GAS PORES/POROSITY
DEFINITION:
A gas pore is a cavity
generally under 1.5mm in
dia. Porosity is a group of
gas pores.
CAUSES:
Moisture on prep / flux
Contamination
Arc length too long
Damaged electrode flux
Loss of gas shield
SURFACE BREAKING POROSITY.
EXCESS WELD METAL
DEFINITION:
Additional weld metal, at
either the root or the face,
which may or may not
be acceptable. Excess
weld metal can cause a
poor toe blend.
CAUSES:
Slow travel speed
Incorrect welding
technique
CRATER PIPE
DEFINITION:
A depression due to
shrinkage at the end of
a weld run, where the
source of heat was
removed.
CAUSES:
Deoxidation reaction
Liquid to solid volume
change
Rapid cooling rate
UNDERCUT
DEFINITION:
An irregular groove at
the toe of a weld run
in the parent material,
or in previously
deposited weld metal,
due to welding.
CAUSES:
Excessive welding current
High welding speed
Wrong electrode angle
Excessive weaving
INCOMPELTELY FILLED GROOVE
DEFINITION:
A continuous or
intermittent channel in the
surface of a weld running
along its length, due to
insufficient weld metal.
CAUSES:
Incorrect welding
technique
Travel speed too high
OVERLAP
DEFINITION:
An imperfection at the toe
or root of a weld caused
by metal flowing onto the
surface of the parent plate
without fusing to it.
CAUSES:
Contamination
Slow travel speed
High amperage
Welding technique
OVER LAP AT TOE OF FILLET WELD
POOR WELD PROFILE / BULBOUS
CONTOUR
DEFINITION:
A non uniform/irregular
appearance at either
the weld face or root.
Can include excessive root
penetration/cap height
and poor cap profile.
CAUSES:
Poor welding technique.
Too slow/fast travel speed
Arc blow

Weld Defects

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Weld Defects

Uploaded by

Copyright:

Available Formats

WELD DEFECTS

LOW SIGNIFICANCE MEDIUM SIGNIFICANCE HIGH SIGNIFICANCE

EQUIAXED LINEAR VOLUMETRIC PLANAR

• LACK OF ROOT FUSION.

• LACK OF INTER RUN FUSION.

You might also like