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Identification
Lack of fusion imperfections can occur when the weld metal fails to fuse completely with the sidewall of the joint (Fig. ! to penetrate ade"uately the previous weld bead (Fig. #!.
Causes
The principal causes are too narrow a joint preparation$ incorrect welding parameter settings$ poor welder techni"ue and magnetic arc blow. %nsufficient cleaning of oily or
scaled surfaces can also contribute to lack of fusion. These types of imperfection are more likely to happen when welding in the vertical position.
Joint preparation
Too narrow a joint preparation often causes the arc to be attracted to one of the side walls causing lack of side wall fusion on the other side of the joint or inade"uate penetration into the previously deposited weld bead. Too great an arc length may also increase the risk of preferential melting along one side of the joint and cause shallow penetration. %n addition$ a narrow joint preparation may prevent ade"uate access into the joint. For e&le$ this happens in ''( welding when using a large diameter electrode$ or in '%G welding where an allowance should be made for the si)e of the no))le.
Welding parameters
%t is important to use a sufficiently high current for the arc to penetrate into the joint sidewall. *onse"uently$ too high a welding speed for the welding current will increase the risk of these imperfections. +owever$ too high a current or too low a welding speed will cause weld pool flooding ahead of the arc resulting in poor or non-uniform penetration.
Welder technique
,oor welder techni"ue such as incorrect angle or manipulation of the electrode-welding gun$ will prevent ade"uate fusion of the joint sidewall. .eaving$ especially dwelling at the joint sidewall$ will enable the weld pool to wash into the parent metal$ greatly improving sidewall fusion. %t should be noted that the amount of weaving may be restricted by the welding procedure specification limiting the arc energy input$ particularly when welding alloy or high notch toughness steels.
Fig. 4. Weld bead deflection in D !!" welding caused b# welding past t$e current return connection
cceptance standards
The limits for incomplete fusion imperfections in arc welded joints in steel are specified in 56 78 #9: ; (%64 9: ;! for the three "uality levels (see Table!. These types of imperfection are not permitted for <uality Level 5 (stringent! and * (intermediate!. For <uality level 3 (moderate! they are only permitted providing they are intermittent and not surface breaking. For arc welded joints in aluminium$ long imperfections are not permitted for all three "uality levels. +owever$ for "uality levels * and 3$ short imperfections are permitted but the total length of the imperfections is limited depending on the butt weld or the fillet weld throat thickness. cceptance limits for specific codes and application standards
"pplication Steel
"cceptance limit Level B and C not permitted. Level D intermittent and not surfa e !rea"in#.
$luminium
Levels B' C' D. Lon# imperfe tions not permitted. ISO 1%%&2:1992 Levels C and D. S(ort imperfe tions permitted. *ot permitted *ot permitted .l. not #reater t(an 15mm /dependin# on ,all t(i "ness0 .l. not #reater t(an 25mm /less ,(en ,eld len#t( 1-%%mm0
)ressure vessels BS55%%:1997 Stora#e tan"s )ipe,or" Line pipe BS2+5&:1989 BS2+--:1987 $)I 11%&:198-