Welding Engineering

Merchanical Rotating
LNG Academy VI
2017 1
Welding Defects
-Ж-
G.T.A.W

2
 Introduction
1 Before starting

SHE-Q Moment
2 Safety, Health and Environment Quality

Contents 3 Kinds of Welding Defects

Welding defect in GTAW

Causes of Welding Defects

4 Welding defect in GTAW

Prevention of Welding Defects

5 Welding defect in GTAW

3
 M. Ghiyats. M
Mush’ab. I. U. Introduction
Afdhal

4
SHE-Q
Moment

5
 Tungsten Inclusion
Causes :
1. Exceeding the maximum current for a given electrode size or
type.
2. Letting the tip of the electrode make contact with the molten
weld puddle.
3. Letting the filler metal come in contact with the hot tip of the
electrode.
4. Using an excessive electrode extension.
5. Inadequate gas shielding or excessive wind drafts which
result in oxidation.
6. Using improper shielding gases such as argonoxygen or
argon-CO2 mixtures, which are used for gas metal arc welding.

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 Prevention of Tungsten Inclusion

Ж 5. Using inert gas only.

3. Reducing the electrode extension. Ж 4. Increasing gas flow or shielding arc from wind drafts.

2. Maintaining a distance between the tungsten electrode and weld

1. Reducing the current. Ж
puddle and the tungsten electrode and filler metal.

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 Causes
These inclusions occur when welding those metals that
have surface oxides with very high melting points. This
problem is mainly associated with welding aluminum
and magnesium, but some problems will also occur
when welding stainless steel. Oxide inclusions weaken

Oxide the weld and can serve as initiation points for cracking.

Inclusion

Prevention
The best method of preventing this problem is to wire
brush the joint and weld area and clean the area
thoroughly before welding.

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 Causes :
1. Inadequate shielding gas flow.
2. Excessive welding current.
3. Rust, grease, oil, moisture, or dirt on the surface of the base metal or filler
metal, including moisture trapped in aluminum oxide.
4. Impurities in the base metal, such as sulfur and phosphorus.
5. An excessive travel speed, which causes freezing of the weld puddle
before gases can escape.

Porosity 6. Contaminated or wet shielding gas.

Prevention :
1. Increasing the shielding gas flow.
2. Lowering the welding current.
3. Cleaning the surface of the base metal.
4. Changing to a different base metal with a different composition.
5. Lowering the travel speed.
6. Replacing the shielding gas.
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 Causes
Sulphur in the steel or moisture
on the surface of the base metal
that becomes trapped in the weld
joint. Wormhole porosity can
seriously reduce the strength of
Wormhole Porosity the weld.

(Piping Porosity)

Prevention
Clean the surfaces of the joint and
preheat to remove moisture. If
sulphur in the steel is the problem,
a more weldable grade of steel

10 should be selected.
 Causes :
1. Excessive welding current.

Undercutting 2. Arc voltage too high.

3. Excessive travel speed
4. Not enough filler metal added.
5. Excessive weaving speed.
6. On vertical and horizontal welds, undercutting
may also be caused by incorrect electrode
Prevention :
angles.
1. Reducing the welding current.
2. Holding a short arc length.
3. Using a travel speed slow enough so the weld
metal can completely fill all of the melted out
areas of the base metal.
4. Using more filler metal.
5. Pausing at each side of the weld bead when
a weaving technique is used.

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 Causes :
1. Excessive travel speed.
2. Welding current too low.
3. Poor joint preparation.
4. Letting the weld metal get ahead of the arc.

Prevention :
1. Reducing the travel speed.
Incomplete 2. Increasing the welding current.
Fusion 3. Preparing the joint better.
4. Using proper electrode angles.

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 Overlapping
Overlapping is produced by one or more of the following:
1. Too slow a travel speed which permits the weld puddle to
get ahead of the electrode.
2. Arc welding current that is too low.
3. Addition of too much filler metal.
4. Incorrect electrode angle that allows the force of the arc to
push the molten weld metal over unfused sections of the base
metal.

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 Prevention of Overlapping

Ж 5. Grinding off the excess weld metal

3. Reducing the amount of filler metal added Ж 4. Using the correct electrode angles.

1. Using a higher travel speed. Ж 2. Using a higher welding current.

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 Prevention :

1. Reducing the welding current.

2. Increasing the travel speed.
3. Reducing the width of the root
opening, using a slight weaving
motion, or increasing the electrode
extension.
Melt-Through
Causes :

1. Excessive welding current.

2. Travel speed that is too slow.
3. Root opening that is too wide or a
root face that is too small.

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Crater
Causes :
The solidification of the metal after the arc has been
broken. The weld crater often cracks and can serve as
an origin for linear cracking back into the weld metal or
into the base metal. These craters can usually be

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Crater
Prevention :
1. Reverse the travel of the electrode a little way
back into the weld bead from the end of the
weld bead, before breaking the arc.
2. Use a foot rheostat to control the welding
current.
3. Removed by chipping or grinding.

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 Causes :
Carelessness

Arc Strikes Prevention :

In difficult areas, adjacent areas
can be protected using fire
blankets

Repair :
Where applicable, arc strikes must
be sanded smooth and tested for
crack. if found, they must be
remove and repaired using
qualified repair procedure and

18 inspected as any other weld

Thank you for watching!
Any questions?

Mechanical Rotating
LNG Academy VI
2017