Welding Defects

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 Weld Defects
Defects which may be detected by visual
inspection can be grouped under five headings
Cracks

Surface irregularities

Contour defects

Root defects

Miscellaneous
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 Weld Defects
Other associated defects

Cavities

Solid inclusions

Set up irregularities

Parent material defects

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 Welding Defects
Cracks
Classified by Shape Classified by Position
• Longitudinal • HAZ
• Transverse • Centreline
• Branched • Crater
• Chevron • Fusion zone
• Parent metal

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 Cracks

Longitudinal parent metal crack Transverse weld metal crack

Longitudinal weld metal crack Lamellar tearing

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 Surface Irregularities

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 Undercut
An irregular groove at the toe of a weld run in
the parent metal
 Excessive amps/volts

 Excessive travel speed

 Incorrect electrode angle

 Excessive weaving

 Incorrect welding technique

 Electrode too large

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 Cap Undercut

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 Overlap
An imperfection at the toe or root of a weld caused by
metal flowing on to the surface of the parent metal
without fusing to it

 Contamination

 Slow travel speed

 Incorrect welding
technique
 Current too low

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 Overlap

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 Crater Pipe
Crater pipe is a shrinkage defect and not a gas defect, it
has the appearance of a gas pore in the weld crater

 Too fast a cooling rate

 Deoxidization
reactions and liquid to
solid volume change
Crater crack
(Star crack)
 Contamination

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 Crater Pipe

Weld crater

Crater pipe

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 Contour Defects

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 Contour Defects

Incomplete filled groove Poor cap profile

Incomplete filled groove Excessive cap height

+ Lack of sidewall fusion
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 Root Defects

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 Root Defects
 Low Amps/volts
 Large Root face

Incomplete root fusion  Small Root Gap

 Fast Travel Speed
 Incorrect Electrode
Angle
Incomplete root penetration  Contamination

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 Root Defects

Lack of root fusion Lack of root Penetration

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 Root Defects
A shallow groove, which may occur in the root of a butt weld

 Root faces too large

 Root gap too large
 Excessive back purge
pressure during TIG welding
Concave root
 Excessive root bead grinding
before the application of the
second pass
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 Concave Root

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 Root Defects
Root penetration bead in excess in accordance with the
relevant specification being used

 Root faces too small

 Root gap too large
 Excessive amps/volts

Excessive root penetration  Slow travel speed

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 Excessive Root Penetration

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 Root Defects
A localized collapse of the weld pool due to excessive
penetration resulting in a hole in the root run

 High Amps/volts

 Small Root face

 Large Root Gap

 Slow Travel Speed

Burn through

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 Miscellaneous Defects

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 Miscellaneous Defects
 Accidental striking of
the arc onto the parent
material

 Faulty electrode holder

 Poor cable insulation

 Poor return lead

clamping
Arc strike

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 Miscellaneous Defects
 Excessive current

 Damp electrodes

 Contamination

 Incorrect wire feed

speed when welding
with the MAG welding
Spatter process

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 Inclusions

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 Gas Cavities
Gas pore Cluster porosity  Loss of gas shield
 Damp electrodes
 Contamination
Blow hole  Arc length too large
Herringbone porosity
 Damaged electrode flux
 Moisture on parent
material

Root piping
 Welding current to low
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 Gas Cavities

Porosity

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 Solid Inclusions
Slag inclusions are defined as a non-metallic inclusion
caused by some welding process
 Slag originates from welding
flux
 MAG and TIG welding
process produce silica
Slag inclusions Lack of sidewall inclusions
fusion with
associated slag  Slag is caused by
inadequate cleaning
 Other inclusions include
tungsten and copper
inclusions from the TIG and
Parallel slag lines MAG welding process
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 Set-up Irregularities

Plate/pipe Linear Misalignment

(Hi-Lo)

Poor fit-up

Angular Misalignment
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 Parent Material Defects
A welding inspector should also inspect the parent
material for any visible defects

Mechanical damage Lap

Lamination

Segregation line

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 Plate Lamination

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