By:- Zanjbeel

Course:
Manufacturing Process

Topic:
Defects of Welding & Welding joints

By:- Zanjbeel

Welding:
In engineering, any process in which two or more pieces

of metal are joined together by the application of heat,

pressure, or a combination of both

By:- Zanjbeel

By:- Zanjbeel

Welding Defects:

Welding defects may classify into following four classes:

Shape Defects (fig. 1) Cracks & Cavities (fig. 2) Lack of fusion, insufficient through weld (fig. 3)

Solid inclusions (fig. 4)

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(fig. 1)

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(fig. 2)

(fig. 3)

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(fig. 4)

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Common weld defects include:

i. Lack of fusion

ii. Lack of penetration or excess penetration

iii. Porosity iv. Inclusions v. Cracking vi. Undercut

vii. Lamellar tearing

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Lack of fusion & Lack of penetration or excess penetration: Lack of fusion results from too little heat input an or too rapid
traverse of the welding torch (gas or electric)

Excess penetration arises from too high a heat input or too slows transverse of the welding torch (gas or electric)
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Porosity:
This occurs when gases are trapped in the solidifying weld metal May arise, from dirt, particularly oil or grease, on the metal in

the vicinity of the weld

Avoided by ensuring all consumables are stored in dry conditions and work is carefully cleaned
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Inclusions:
Can occur when several runs are made along a V join

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Cracking:

This can occur due to thermal shrinkage or due to a combination of strain accompanying phase change and thermal shrinkage

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Undercutting:
In this case the thickness of one (or both) of the sheets is reduced at the toe of the weld There is already a stress concentration at the toe of the weld and any undercut will reduce the strength of the join.

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Lamellar tearing:
This is mainly a problem with low quality steels. It occurs in plate that has a low ductility

These problems can be overcome by using better quality steel,

'buttering' the weld area with a ductile material and possibly by redesigning the joint

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Welding Joints:
the manner in which materials fit together. As shown in
Figure, There are five basic types of weld joints: Butt joint. T-joint.

Lap joint.
Corner joint. Edge joint.

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Joint types:
There are various types of welds that can be made in
each of the basic joints. They include:

Butt joint: (Shown in fig. a)

Square-groove Bevel-groove

V-groove
J-groove U-groove Flare-V-groove Flare-bevel-groove
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fig. a
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T-joint: (as shown in fig. b)

Fillet weld Plug weld Slot weld Bevel-groove weld

J-groove weld
Flare-bevel-groove weld

fig. b
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Lap joint : (as shown in fig. c)

Fillet

weld

Plug weld

Slot weld
Spot weld Bevel-groove weld J-groove weld
fig. c

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Corner joint : (in fig. d)

Fillet weld
Spot weld V-groove weld J-groove weld Flare-V-groove weld Edge weld Corner-flange weld

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fig. d

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Edge joint: (in fig. e)

Square-groove weld Bevel-groove weld V-groove weld J-groove weld

U-groove weld
Edge-flange weld Corner-flange weld
fig. e

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