Welding Defects

INTRODUCTION
Background:
Quality Manager request Welding Engineer to conduct welding
defects training to Quality Personnel
Purpose:

Visual Inspection of welds

Identification of welding defects
Weld Quality Awareness
Reference Specification

OUTLINE PER DEFECT

1.
2.
3.
4.

Definition of welding defect

Visual Indication of the defect
Possible Causes
Corrective Action

LIST OF DEFECTS TO BE COVERED

1. Porosity
2. Lack of Penetration
3. Lack of Fusion
4. Lack of Inter run fusion(Capping)
5. Undercutting
6. Cracking
7. Excessive Spatter
8. Burn through
9. Arc Strike
10.Pinhole

Any physical irregularity in the weld or HAZ, which may or may not affect
the usefulness of a part.
Porosity
A cavity caused by entrapped gases of molten metal

WELDING DEFECT

Possible Causes
Low/high shielding gas flow
Draft conditions
Contaminated weld preparation

Corrective Action
Ensure sufficient gas flow
Check workshop condition
before welding
Pre-clean weld area

The failure of metal to extend into the root of a joint

LACK OF ROOT
PENETRATION
Possible Causes
Corrective Action
Root face too large/small
Use correct gap (WPS)
Incorrect electrode angle
Gun manipulation
Travel speed too high for current Use correct travel
speed(WPS)

Lack of union between:

Weld metal and parent metal
Parent metal and parent metal
Weld metal and weld metal

LACK OF FUSION

Possible Causes
Corrective Action
High/too low welding currents Remove all oxide before welding
Contaminated weld preparation
Ensure correct parameters are
Travel speed too low
used

Lack of union between the runs visible in capping or filler.

LACK OF INTER RUN

FUSION

Possible Causes
Incorrect parameter settings
Welder technique

Corrective Action
Use correct parameters
Avoid weaving where possible

An irregular groove at the toe of a run in the parent material

Appears at the edge of the weld

UNDERCUTTING
Possible causes
Travel speed too high
Welding voltage too
high
Excessive welding
current

Corrective action
Decrease travel
speed
Use leading torch
angle

A linear discontinuity produced by fracture

CRACKS

Possible Causes
Corrective Action
Incorrect wire chemistry
Use correct welding
Poor quality of material being welded
consumables
Weld bead too small
Weld as per WPS instruction

Molten metal droplets that are thrown out from the fusion zone

EXCESSIVE SPATTER
Possible Cause
Arc voltage too low
Excessive arc length
Damp electrodes

Corrective Action
Use Anti spatter
Use correct voltage(WPS)

A localized collapse of the molten pool resulting in a hole in the weld run

BURN THROUGH
Possible Causes
Excessive Penetration
Excessive amperage
Excessive root grinding

Corrective Action
Use correct root gap as
specified on WPS

Damage on the parent material resulting from accidental striking of an arc

from the weld

ARC STRIKE
Possible Causes
Electrode straying onto parent
material
Poor contact of the earth clamp
Electrode holder with poor
insulation

Corrective Action
Ensure the correct condition
of welding equipment

A welding defect caused by high welding temperatures

PINHOLE

Possible Causes
Corrective Action
Unclean base metal surface
Preclean surfaces before
Rusted wire
welding
Insufficient or damp shielding gas
Use correct and sufficient
welding consumables

WELDING GUN ANGLE

CONCLUSION
Importance of inspection
Defect Identification
WPS to be followed at all times
Transnet Welding defect specification
PD_WE_NAT_SPEC_003
EN acceptance standard
ISO 5817
ASME acceptance standard
ASME B31.3

Thank you