Miscellaneous faults Causes: Accidental contact of electrode or ‘welding torch with plate surface remote om weld. These ‘usually result in small hard spots just beneath ‘the surface which may contain cracks, and are ‘thus to be avelded, Causes: inconect ‘welding conditions, such as too hich a ‘welding current, andor contaminates consumables or preparations, giving 1s@ to explosions, ‘within the are and ‘weld pool. GloDules of ‘molten metal are thrown out, and adhere to the parent metal remote from the weld, Copper pick up Causes: Melting of ‘copper contact tube in gas-shiolded motal-are ‘welding because of inconet welding conditions. Surface poekdug ‘Alternative tart ~ Surface depression on. face of submergedeare weld Causes: Bix ‘inadequately dried or containing insufficient SoorsdantsImperfect shape Causes: correct Alternative term- assembly andor R ment istortion during ‘Weld metal normally fabrication, extends above the parent metal surface: only @ fault if exceeding, specification, Causes: Deposition of too much weld meta, often associated with ‘unsuitable wold preparation, incorrect —— ian, ‘welding parameters, or sat too large an electrode. Causes: Poor Results ftom washing ‘manipulative techniaue aay of the edge or insufficient heat preparation when Input, with current or molten, voltage too low. Causes: Poor welding technique and/or “unbalanced welding conditionsInclusions (Causes: Incomplete removal of sag Semis pase welds often sssocted ‘yntn the prosance of undoteut or Jegula surface n underlying ‘The adiograph shows to slag nes Eavwols ot sono Gaus: ormaly caused the Drocenee of mil cal andor ut on Drepared surlaces, or cloeuodes ‘with coverings which are creckod or Aamagea for exemple by 29 ap frying. May aloe aris from eared ‘undercut in underiing passes of rmult-pase veldLack of fusion and penetrationReeuting Hon ennaponntof a otison etdiying Genie ct ‘waldmotl, often showing “Hagan arta an saalogaph bao ‘Causes: Te gas ay ais tom ‘tamination ol saraon tobe ‘elda,o be provatea fem ‘tesping om benauth the weld by contamination fom te tomas esuking fem entrpmentof asi. thie wing wire van conning ‘ollied wea metal 1 Geaudarteis ase Scala ieee ows eatbon mei to Supecsor reson consumniee SUS" POA ‘x otipiese oy nuogesCauses: Unstable arc conditions at ‘weld pool, where protection may be incomplete and temperature gradients have not had time to equilibrate, coupled writh inadequate manipulative tochnique to allow for this instability. ‘The radiograph shows internal restart porosity, Causes: Hxcessive contamination rom grease, dampness, or atmospheric entrainment Occasionally caused by oxcossivo sulphur in consumables or paront metal,Cracks Solidification eracking Gauses: Excessively deep or wide Dead, High curent andor welding spoed. Latge root gap. Carbon, sulphur, or phosphorus pici-up from parent steel Hydrogen induced HAZ cracking (Causes: Hardened HAZ - heat affected zone of the parent metal ~ ouplad with presance of hydrogen Giffused from weld metal. Susceptibility increases with Increasing thickness of section fespacilly in stools with high carbon ‘equivalent, Increased heat input Deneficlal Pre heating sometimes nogessary, Control of moisture in consumables and cleanliness of ‘wold preparations essential.Bydroge: ed weld metal cracking, Causes: Wold metal more highly alloyed than parent steel, usually in thick soctions with insullicient ‘consumable drying or prohoat. May bbe transverse, at 90° or 45" to surface, or longitudinal. Contol as for HAZ cracking. Lamellar tearing Causes: Poor ductility in ‘rough-thiekness direction because ‘of non-metallic inclusions. Only {ound in rolled plate, Occurs mainly ‘where weld metal is deposited an plate surface, such as T, comer, and ‘cruciform joints, void by specifying plata with sufficient through: thickness (short transverse) ductility, om, Facto eutaonReheat cracking Occurs in creep resisting and some ‘thick section structural low alloy steals during post weld hoat treatment Causes: Foor creep ductility in HAZ coupled with thermal stress. Accentuatod by cavero notches such as pre-existing cracks, or tears at ‘Weld toes, or unfused root of partial ‘Penetration weld. ‘Heat treatmont may need to include low temperature soaking, Grinding or peening of weld toes after ‘welding can be beneficial Can be avoided by ‘two-layer’ ‘welding technique and use of ‘non-susceptible weld metal,Offset or Mismatch High-lowOffset or Mismatch with lack of Root FusionCap concavity or insufficient fill 6essive root penetrationrernal Undereut = #2Root UndereutRoot Concavity (suck back)Root burn-through 8Incomplete or lack of root penetration Ti), Ae aInter—pass Slag InclusionsElongated Slag lines (wagon tracks)Lack of side wall fusionInter-pass cold lap-lack of side wall fusionSeattered PorosCluster PorosityRoot aligned porosityTransverse cracksLongitudinal crackTungsten inclusions