Weld Defects

Significance of defects

Incomplete fusion can influence brittle

fracture in either static or dynamic loads.
The effect of lack of fusion is almost same
as Lack of penetration
Arc strikes consist of un annealed
martensite and contains a number of small
fissures. These small fissures can lead to
brittle fracture when remaining load bearing
material has been sufficiently reduced in
cross section.

A Defect is Rejactable discontinuity

A defect is a discontinuity but a discontinuity
need not be a defect.
Acceptance of a discontinuity is based on
different factors. Few examples are as
follows:
Stresses to which the parts will be subjected
during service
Type of Material Used
The environment
Consequence of failure

Acceptance Standards Dictate the type of

Inspection and testing.
The weld defects can be broadly classified
into two types.
Planer defects / two dimensional defects
(Crack, Lack of Fusion, Lack of
Penetration, Severe Undercut These are
not acceptable defects)
Volumetric Defects / Three Dimensional
defects.(Slag inclusion, cavities, Porosities
are acceptable to certain extent)

General Reasons for Defects

Lack of Know-how
Welding Process Characteristics
Base metal Composition
Defective welding filler metal
Joint design
Welding Environment (Wind, fit-up,
Temperature etc.)

Defects involving inadequate bonding

Lack of Fusion

Due to improper manipulation of electrode

Incorrect position of electrode
Low welding current
Too rapid arc advance
Improper joint fit-up

INCOMPLETE PENETRATION
Incorrect Joint design
Improper welding parameters specifically
current
Incorrect electrode size
Incorrect polarity where DC is used
Un fused root can cause stress
concentration that could lead to brittle
failure

Inclusions

Slag Inclusion
Because of the string action of the arc slag
may be forced down to the molten metal
and the high viscosity of weld metal, rapid
solidification at a low temperature leads to
entrapment.
Preheating the base metal to control the
rate of solidification will ensure release of
slag from molten metal

Oxide Films
In MIG welding oxides in the form of
Globules are found in weld metal. The
presence of such films seriously impairs
the ductility of weld metal.
This defect is rarely detectable except with
the aid of a microscope

Tungsten Inclusions
These are particles deposition in the weld
metal from a tungsten electrode in TIG
welding
These inclusions are not generally
considered harmful unless their size and
number become excessive.
Superimposed high frequency current for
arc starting tends to minimize these
inclusions

Geometric Defects
Undercuts represents a depression into
the base metal adjacent to the toe of the
weld and it form a notch.
A small amount of undercut under
pulsating stress often acts as a starting
point for fatigue cracks.
Correct choice of current range and good
manipulation of electrode during welding
will avoid undercut

Burn through or excess penetration

Occurs because of very high current and
low travel speed.
It is also called as icicles and are found at
the root of the weld.
Consumable inserts may be used to avoid
excess penetration

Improper weld profile

This occurs more in the case of fillet joints
Excessive concave or convex beads are
examples of this.
These are caused because of improper
weld parameters, electrode size &
weaving.
Visual examination is sufficient to decide
these defects.

METALLURGICAL DEFECTS

CRACKS
Hot cracking
Caused because of restraint on the joint
and the presence of higher carbon and
sulfur.
Segregation of weld metal due to bead
shape also is a reason for these defects.
MPI or LPI are used to detect surface
defects while UT is suitable for internal
cracks.

Cold cracking
Cold cracking starts in the HAZ of the
parent metal
It is associated with combined effects of
hydrogen, restraint and martensite
formation
Low hydrogen electrode and preheating
minimizes cold cracking.

Crater cracks
Cracks formed from a circular surface with
a depression either in the weld or at the
end of a weld.
It is caused by a volume concentration of
molten metal during solidification usually
the result of abrupt interruption of the
welding arc in the root run.

Gas porosity

Porosity is the presence of gas pockets of

voids caused by the entrapment of gases
evolved during weld metal solidification
Porosity is caused due to improper shielding,
rust on the weld face, too much generation of
gas in the weld pool.
Porosity is considered to be the least
dangerous defect but is often an indication of
damp electrodes having been used.

Arc Strikes

Localized heat affected zone caused by an

arc is known as arc strikes
Arc strikes produce hardening particularly in
high carbon steels and alloy steels.

Embrittlement

The carbon and alloy steels containing 0.18%

carbon tends to form brittle martensite
structure in HAZ.
This is avoided by controlled cooling rate.

Quality Of Welding
Welding Defects
(Root Cause Analysis)

Why These Defects Occur?

Porosity
Lack of supervision
Incompetent welder / operator
Poor performance of welding
equipment
In-proper handling / use of
welding
consumables
Poor joints fit-ups
Weather condition
Quality & characteristic of base
metal & etc

Incomplete Penetration
Lack of supervision
Incompetent welder / operator.
Poor joints fit-ups
Welding current too low
Wrongly use of electrode size (too
big)
Arc length too long
Melting filler rod instead of
welding
Insufficient gas shielding (GTAW
SUS)

Slag / Tungsten Inclusions

Lack of supervision
Incompetent welder / operator
Poor performance of welding
equipment
In-proper handling / use of
welding tools
In-proper handling / use of
welding
consumables
Poor joints fit-ups & etc

Cracks
Lack of supervision
Incompetent welder / operator.
In-proper use of welding
consumables.
Weather condition.
Quality & characteristic of base
metal.
In-proper control of preheating &
post heating
process & etc

Incomplete Fusions
Lack of supervision
Incompetent welder / operator
Poor performance of welding
equipment
In-proper handling / use of
welding tools
In-proper handling / use of
welding
consumables
Poor joints fit-ups & etc

Undercut, Excess Penet. Root

Concavity
Lack of supervision
Incompetent welder / operator
Misalignment
Welding current too high
Poor joints fit-ups
Wrong electrode angle

What Are The Possible Root Causes

Lack Of Supervision
Inadequate Knowledge And Awareness In Quality
Control At All Levels
Poor Discipline and Negative Working Attitude
Lack Of Responsibility Toward Quality Control At
Supervisory Level
Inefficient Quality Monitoring & Surveillance Plan
Work Environment Poor Work Site Management &
Control

Areas Of Concern
Quality Is Client Driven, Company Has Not Set Clear
Quality Goals & Targets And Communicate To Shop
Floor
Ineffectiveness Of Implementation Of QMS
Expectations And Deliverables Are Not Clearly
Defined At Supervisors, QA Personnel And QC
Personnel Levels
Quality Is A QA/QC Function, Supervisors are more
Concern In Timely Delivery Of Projects
Subcontractors Management Has No Commitment
Toward Quality Goals

CAUSE EFFECT (FISHBONE) DIAGRAM

WELD DEFECT ROOT CAUSE ANALYSIS
BASE MATERIAL
QUALITY

WELDING
CONSUMABLES

WELDER / OPERATOR
SKILLS

Using of contaminated
electrodes/fluxes

Welding unkilled
steels

Using of cold w elding

consumables

Welding of pitting
corroded plates

Poor house keeping

Welding at dusty
environment

Using of too
narraow groove

Using of unqualified
w elder for tack w elding

Not using w ind

protectors.

Welding on w et
/ oily surfaces

Poor accessibility
for w elding

Not grinding rusted

/mill scales and
gouged surfaces

Not using proper run

and run off plates

Large gps

JOINT FITUPS

Poor control and

guiding w elders

Lack of Quality
aw areness/ targets
Lack of prcess
controlls

SUPERVISOR ROLE

Non uniform
travel speed

POROSITY
Wrong selection of
w elding process
Using of SMAW w here
more appropriate
GTAW process

Lack of responsibility
and commitment
tow ards quality

Poor organizing
of site protection
from w ind

Exocentric or over
loading on rotators.

No calibration of
equipment

Engaging of
unqualified w elders

Lack of job / WPS

know ledge

Poor controls on
electrode baking
and handling

Unstable current

Using of damaged
gas hoses

Using of w rong size

and clod electrodes

Poor in keeping of
w elders records
and repair rates

Using of tack w elds

in the groove for
single side joints

Unstable arc voltage

Non uniform
rotation of
w elding rotators

Poor eye sight,

over fatigue and
personal reasons

Welding on w et
/ oily surfaces

Using of unskilled gas

cutters, gougers and
grinders

Gas cutting notches on

edge preoeration

Not keeping joint for

easy w elding position

WELDING ENVIRONMENT

Using of
contaminated
filler metals

Improper aligning
of rotators

Using of high or
low flow gasses

Using of long arcs

Welding at w indy
environment

Storing of
electrodes and filler
metals together
w ith oils, paints.

Using of w rong
w elding parameters

Using of excessive
electrode stickout

Not using HF units for

GTAW w elding

Frequent
pow er tripping

Lack of commitment
tow ards quality

Lack of w elding/
WPS know ledge

Using of w rong
size electrode

Poor storage and

handling of w elding
consumables

Using of plates oily/

greased

Not using of w eather

protectors

Poor attitude of
w elder/ operator

Using of
unbaked w elding
consumables

Using of poor
quality shielding /
purging gasses

Welding of old and

already used materials
in the process

Lack of skillness

Wrong selection of
type of electrodes
/ fluxes

Using of rusted plates

WELDING
EQIPMENT

Using of GMAW w here

FCAW can be used
Using of SMAW w here
more appropriate SAW
process
Lack of understanding on
application of process

WELDING PROCESS

CAUSE EFFECT (FISHBONE) DIAGRAM

WELD DEFECT ROOT CAUSE ANALYSIS

CAUSE EFFECT (FISHBONE) DIAGRAM

WELD DEFECT ROOT CAUSE ANALYSIS

CAUSE EFFECT (FISHBONE) DIAGRAM

WELD DEFECT ROOT CAUSE ANALYSIS

CAUSE EFFECT (FISHBONE) DIAGRAM

WELD DEFECT ROOT CAUSE ANALYSIS

CAUSE EFFECT (FISHBONE) DIAGRAM

WELD DEFECT ROOT CAUSE ANALYSIS