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7/30/2019 Defects on Weld BEAD
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Root bead width
Excess weld metalheight
Root penetration
Weld cap width
Butt weldsButt welds -- SizeSize
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x
x
x
Butt weldsButt welds --ProfileProfile
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Butt weldsButt welds -- Toe BlendToe Blend
x
x
x
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Butt weldsButt welds -- Weld WidthWeld Width
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Excess Weld MetalExcess Weld Metal
Excess capExcess capreinforcementreinforcement
Under FillUnder Fill
IncompleteIncompletefilled groovefilled groove
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Incompletely Filled GrooveIncompletely Filled Groove
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Poor RestartPoor Restart
Poor stop/starts
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Cap undercutCap undercut
Cap UndercutCap Undercut
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OverlapOverlap
OverlapOverlap
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DEFINITION:
An imperfection at the toe
or root of a weld caused
by metal flowing onto the
surface of the parent platewithout fusing to it.
CAUSES:
Contamination
Slow travel speed
High amperage
Welding technique
OverlapOverlap
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OverlapOverlap
OverlapOverlap
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CausesCauses
Improper welding techniqueImproper welding technique
Insufficient weld metal depositedInsufficient weld metal deposited
Lack of FusionLack of Fusion
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`Inter run Incompletely Filled GrooveInter run Incompletely Filled Groove
CausesCauses
Improper welding techniqueImproper welding technique Insufficient weld metal depositedInsufficient weld metal deposited
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Slag InclusionsSlag Inclusions -- CapCap
CausesCauses
Insufficient cleaning between passesInsufficient cleaning between passes
Contaminated weld preparationContaminated weld preparation
Welding over irregular profileWelding over irregular profile
Incorrect welding speedIncorrect welding speed
Arc length too longArc length too long
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Gas pores / PorosityGas pores / Porosity
CausesCauses
Low welding currentLow welding current
Arc length too longArc length too long
ExcessiveExcessive moisture in flux or preparationmoisture in flux or preparation ContaminatedContaminated preparationpreparation
Damaged electrode fluxDamaged electrode flux
Removal of gas shieldRemoval of gas shield
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CausesCauses
Excessive arc energyExcessive arc energy
Excessive arc lengthExcessive arc length
Damp electrodesDamp electrodes Arc blowArc blow
SpatterSpatter
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Arc Str ikesArc Str ikes
CausesCauses
Electrode straying ontoElectrode straying onto
parent metalparent metal
Electrode holder with poorElectrode holder with poorinsulationinsulation
Poor contact of earthPoor contact of earth
clampclamp
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Chisel MarksChisel MarksChisel Marks Pitting Corrosion Grinding Marks
Mechanical damage can be defined as any surfaceMechanical damage can be defined as any surface
material damage cause during the manufacturingmaterial damage cause during the manufacturing
process. This can included damage caused by:process. This can included damage caused by:
GrindingGrinding HammeringHammering ChisellingChiselling ChippingChipping
Breaking off welded attachments (torn surfaces)Breaking off welded attachments (torn surfaces)
Using needle guns to compress weld capping runsUsing needle guns to compress weld capping runs
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CraterCraterCrackCrackandandpipepipe
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PorosityPorosity
Cluster porosityCluster porosity
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Gas poresGas pores
PorosityPorosity
PorosityPorosity
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Cluster PorosityCluster Porosity
ClusterCluster
porosityporosity
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Worm Hole
HerringboneHerringbone
porosityporosity
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Lack of FusionLack of Fusion
Causes Amperage too low Contaminated weldpreparation Amperage too high(welder increasesspeed of travel)
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Slag inclusionsSlag inclusions Lack of sidewallLack of sidewallfusion withfusion with
associated slagassociated slag
Lack of interun fusionLack of interun fusion
+ slag+ slagParallel slag linesParallel slag lines
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Lack of side Wall FusionLack of side Wall Fusion
Lack ofLack ofsidewall fusionsidewall fusion
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Slag InclusionSlag Inclusion
Interpass slagInterpass slaginclusionsinclusions
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Slag InclusionsSlag Inclusions
CausesCauses
Arc length too longArc length too long
Incorrect welding speedIncorrect welding speed
Insufficient cleaning between passesInsufficient cleaning between passes
Contaminated weld preparationContaminated weld preparation
Welding over irregular profileWelding over irregular profile
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Wagon TrackWagon Track
ElongatedElongatedslag linesslag lines
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Tungsten InclusionsTungsten Inclusions
CausesCauses
Contamination of weld Caused by tungsten touchingContamination of weld Caused by tungsten touchingweld metal or parent metal during welding using theweld metal or parent metal during welding using the
TIG welding processTIG welding process
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CausesCauses
Excessive amperage duringExcessive amperage during
welding of rootwelding of root
Excessive root gapExcessive root gap
Poor fit upPoor fit up Excessive root grindingExcessive root grinding
Improper welding techniqueImproper welding technique
Excess PenetrationExcess Penetration
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CausesCauses
Too small a root gapToo small a root gap
Arc too longArc too long
Wrong polarityWrong polarity
Electrode too large for jointElectrode too large for joint
preparationpreparation
Incorrect electrode angleIncorrect electrode angle
Too fast a speed of travel for currentToo fast a speed of travel for current
L.O.PL.O.P
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Root L.O.FRoot L.O.F
Lack of rootLack of root
fusionfusion
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Lack ofLack of
fusionfusion
IncompleteIncomplete
PenetrationPenetration
Root Welding DefectsRoot Welding Defects
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Root L.O.FRoot L.O.F
CausesCausesToo small a root gapToo small a root gap
Arc too longArc too longWrong polarityWrong polarity
Electrode too large for jointElectrode too large for joint
preparationpreparation
Incorrect electrode angleIncorrect electrode angle
Too fast a speed of travel forToo fast a speed of travel for
currentcurrent
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Root Concavity
Roo t concav it yRoo t con cav i t y
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Root ConcavityRoot Concavity
CausesCauses
Root gap too largeRoot gap too large
Insufficient arc energyInsufficient arc energy Excessive back purge TIGExcessive back purge TIG
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Burn ThroughBurn Through
CausesCauses
Excessive root grindingExcessive root grinding
Excessive amperage during welding of rootExcessive amperage during welding of root Improper welding techniqueImproper welding technique
Slow travel speedSlow travel speed
Large root gap/small root face (irregular fit up)Large root gap/small root face (irregular fit up)
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Burn Through
A h l l d b i i h ldA h l l d b t t i i t h ld
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Shrinkage grooveShrinkage groove
I n su f f i ci en t w e ld m e ta l I n su f f i ci en t w e ld m e ta l
deposi t ed i n t he roo tdeposi t ed i n t he roo t
passpass
Too fas t a coo l ing ra t eToo fas t a coo l ing ra t e
du r i ng t he app l icat i on o fdu r i ng t he app l icat i on o f
t he roo t bead passt he roo t bead pass
Poo r w e ld i ng techn i quePoo r w e ld i ng techn i que
A sha l low g roove caused by con t ract i on i n th e w e ldA sha l low g roove caused by con t ract i on i n th e w e ld
m e ta l al ong each si de o f t h e pene t ra t i on b ead o rm e ta l a long each s i de o f t he pene t ra t i on bead o r
can occu r i n t he cen te r o f t he w e ld beadcan occu r i n t he cen te r o f t he w e ld bead
Shrinkage grooveShrinkage groove
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Root pipingRoot piping
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Root undercutRoot undercut
CausesCauses Root gap too largeRoot gap too large
Excessive arc energyExcessive arc energy
Small or no root faceSmall or no root face
Root undercutRoot undercut
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NonNon--alignment of two abutting edgesalignment of two abutting edges
Also Known as: Hi Low. Mismatch. or MisalignmentAlso Known as: Hi Low. Mismatch. or Misalignment
2mm
Alignment ImperfectionAlignment Imperfection
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50mm
3mm
Angular distortion.
Measure the distance to the edge of the plate (50mm).
Use a straight edge (rule) to find the amount of distortion
then measure the space (3mm).
This reported as Angular distortion 3mm in 50mm
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