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TLE - IA - SMAW
Quarter 4 - Module 31Week 5-6
Marking/Locating Weld Defects
What I Need to Know
This module was designed and written for the learners. After going through
this module, the learner is expected to:
1. identify the different welding defects; and
2. recommend welding defect remedies.
TLE_IAAW9-12RW-IVa-1
What I Know
Directions: Read each question carefully. Write your letter of your answer on
your activity notebook.
1. Which of the following defects occurs due to flux employed and electrode
coating?
A. inadequate penetration C. slag inclusion
B. incomplete fusion D. porosity
2. A discontinuity in the weld metal, which exceeds applicable weld limit?
A. high rate of weld C. repair defect
B. insufficient current D. weld defect
3. The temperature to which a metal is heated before an operation is performed
on the metal is called ___________.
A. brazing C. preheating
B. post heating D. reverse polarity
4. Which of the following defects occurs due to filler material having a different
rate of contraction compared to parent metal?
A. cracking in weld metal C. spatter
B. cold cracking D. undercut
5. Hot cracks can be prevented by _________.
A. by using low hydrogen electrode C. slower cooling
B. faster cooling D. pre-heating
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Lesson
Marking/Locating Weld
1 Defects
Defects are common in any type of manufacturing, welding including.
In the process, there can be deviations in the shape and size of the metal
structure. It can be caused by the use of incorrect welding process or wrong
welding technique. In this lesson we’ll learn about the different types, causes
and remedies of welding defects.
What’s In
Directions: Read each statement carefully. Write True if the statement is
correct and False if not. Write your answers on your activity notebook.
____1. Overlap is caused by improper preparation of the base metal.
____2. Undercut is generally associated with improper welding techniques.
____3. Incomplete fusion means correct welding technique.
____4. Slag inclusion is non-metallic material trapped in the weld metal.
____5. Porosity is the result of gas being entrapped in solidifying weld material.
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What’s New
Directions: Study the illustration below and answer the following questions.
Write your answer on your activity notebook.
Question:
1. Identify what possible defects can be found in the illustration.
2. Give the remedies on how to fix it.
What Is It
Today, we will learn about welding defects, their types, causes and
remedies. Defects are common phenomenon in any manufacturing process.
This is due to process limitation and human behavior. It is impossible to form
a defected welding joint but it can be reduced to some extent by taking some
precaution.
Welding defects are generated in a welding job due to the faulty or poor
technique used by the inexperienced or unskilled welder or due to
fundamental difficulties in the welding operation.
According to the American Society of Mechanical Engineers (ASME),
causes of welding defects can be broken down as follows: 41 percent poor
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process conditions, 32 percent operator error, 12 percent wrong technique,
10 percent incorrect consumables, and 5 percent bad weld grooves.
Any discontinuity (or irregularity) in the weld metal, which exceeds the
applicable code limit, is termed as a WELD DEFECT (or Welding
Defect). Please note that a discontinuity can be called as a defect only when if
it exceeds the specified code limit, hence we can say that every defect present
in the weld metal is a discontinuity but every discontinuity present in the weld
metal may not necessarily be a defect. A defect can be macroscopic or
microscopic.
(Note: Discontinuity is also termed as “reflector” in some codes and texts)
Defects may occur due to the following reasons;
1. Incorrect welding parameters.
2. Inappropriate welding procedures.
3. Poor process condition.
4. Inappropriate selection of filler metal and parent metal.
5. Unskilled welder or welding operator.
6. Incorrect job preparations.
A weld defect is any discontinuity in the weld metal, which exceeds the
applicable code limit. Please note that a discontinuity can be termed as a
defect only when, if it exceeds the specified code limit, hence we can say that
every defect present in a weld metal is a discontinuity but every discontinuity
present in the weld metal may not necessarily be a defect.
Weld defect, how to check? Visual examination reveals surface
discontinuities and is a valuable method for evaluating weld quality. It is
simple, accessible, low cost examination method, but it requires a trained
examiner. Workmanship standards may address such items as surface
roughness, weld spatter and arc strikes. Many of these discontinuities can be
found by visual examination of a completed weld as specified in the
illustration below.
WELD DEFECTS
External Defect Internal Defect
(Surface or visual defect) (Subsurface or hidden defect)
- surface cracks - lack of fusion
- overlaps - lack of penetration
- undercut - internal porosity
- underfill - internal blowholes
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- excessive penetration - slag inclusion
- surface porosity - tungsten inclusion
- spatter - internal crack
- arc strike
CAUSES REMEDIES
WELD DEFECTS
access to welding should be
1. Arc strike accidentally strikes with the work easier.
piece.
periodically check the
wrong laying electrode holder. electrode holder.
the clamp at base metal is not provides a place to put
good. electrode holder.
2. Burn through too fast travel speed reduce heat input
too high current
poor electrode manipulation
3. Cracks wrong electrode make sound welds with good
root fusion
weld and part sizes unbalanced
heat parts before welding
faulty welds
weld from center towards
faulty preparation - rigid joint edges
avoid welding on string
beads
4. Concavity or too fast travel speed observe proper parameters
convexity and techniques
too high current - poor electrode
manipulation grind off or weld on
a great number of passes with use the proper amount of
5. Distortion small diameter electrodes weld metal as per the
requirement of the joint. It will
slow arc travel speed reduce the contraction
forces.
high residual stresses in the plate
to be welded use an appropriate number
of weld passes.
using improper welding sequences
place the weld near the
neutral axis.
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use proper welding
sequences.
6. Incomplete too short arc length, properly clean the base
fusion metal
very high travel speed,
ensure that there is enough
too low welding amperage heat input to coalesce
the base metal
7. Poor speed too fast weld slowly enough
penetration
electrode too large select electrode properly
current too low use sufficient current
faulty preparation leave proper free space at
the bottom of weld
8. Porosity short arc hold longer arc
insufficient puddling time allow sufficient puddling -
remove impurities in base
impaired base metal - incorrect metal
current
use correct current - use
improper welding technique weaving motion to eliminate
pin holes
9. Slag inclusion low amperage increase amperage
- improper welding technique -observe proper welding
techniques
- too tight welding area
grind off tight areas/ re-weld
10. Spatter longer arc length adjust current properly
severe electrode angle pick suitable electrode
high amperage adjust voltage
faulty electrode clean parts in welding area
11. Undercut faulty electrode manipulation avoid using overly large
electrodes
improper electrode
use moderate current and
current too high weld slowly
use uniform weave
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12. Underfill improper welding technique apply proper welding
technique
faulty preparation
may require grinding
preparation
13. Overlap too slow speed longer arc - large deposits in
a single run
current is too low
observe proper welding
longer arc techniques - grind off excess
deposits
large deposits in a single run
proper welding technique
use small electrode
What’s More
A. Directions: Look for words related to weld defects from the word hunt
puzzle below. List down 5 words that you’ve found on your activity
notebook.
E U Q Y D B S L A G S G B X
C N R W U U N D E R F I L L
O D T E W R O N D R U B Q M
N E A U G N O V E R L A P S
C R D I S T O R T I O N Q A
A C C S U H E T U I O P L V
V U R G O R C O N V E Y O R
I T A J P O Q R Y U I O D B
T A C K F U P O R O S I T Y
Y B U R N T H R O U G H K O
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B. Directions: Enumerate at least five causes of welding defects.
1. __________________
2. ________________
3. ________________
4. ________________
5. ________________
C. Complete the following sentences using the words inside the box.
cracks distortion slag inclusion spatter
undercut underfill porosity concavity
1. ______________ occurs when internal stresses exceed the strength of
the weld metal, the base metal or both.
2. ______________ is a fillet weld which exceeds the allowable limit.
3. ______________ is a weld defect caused by the expansion and
contraction of the weld metal and adjacent base metal during the
heating and cooling cycle of the welding process.
4. ______________ are nonmetallic particles trapped in the weld metal
or at the weld interface.
5. ______________ when the weld reduces the cross-sectional thickness
of the base metal.
What I Have Learned
Directions: To test your mastery in this module, answer the following
questions. Write your answer on your activity notebook.
1. How do you prevent welding defects?
2. Why do you need to determine the location of weld defects?
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What I Can Do
Directions: Mark an arrow and name the five (5) defects in the drawing
below then recommend appropriate remedies. Write your answer on your
activity notebook.
Assessment
Directions: Read each items carefully. Choose the letter of the correct answer
and write it on your activity notebook.
1. Which of the following defects occur due to melting or burning away of
base metal?
A. crack in weld metal C. spatter
B. cold cracking D. undercut
2. Incorrect welding technique, improper preparation of the materials for
welding or wrong joint design is referred to as _________.
A. incomplete Fusion C. lack of fusion
B. inclusions D. undercut
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3. It is important for a beginner to know the different weld defects produced
during the welding process caused by incorrect welding procedure, wrong
selection of materials or improper preparation of base metal can cause
______.
A. slag C. underfill
B. undercut D. welding defects
4. The types of welded joints do not depend on _________.
A. area available for welding C. size of weld
B. size of members connected at joint D. type of loading
5. Which of the following is not true regarding poor penetration?
A. faulty preparation C. too low current
B. too fast speed D. too small electrode
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What’s more What's In What I know
A. Answers may vary 1. True 1. C
B. 1. Incorrect welding 2. True 2. D
parameters 3. False 3. A
2. Inappropriate welding
procedures
4. True 4. A
3. Poor process 5. True 5. C
condition
4. Inappropriate
selection of filler metal
and parent metal
5. Unskilled welder or
welding operator
6. Incorrect job
preparation
C. 1. Cracks
2. Concavity
3. distortion
4. slag inclusion
5. undercut
Assessment What I can do (in any order) What I have learned
1. D 1. cracks
2. incomplete fusion Answers may vary.
2. D 3. overlap
4. porosity
3. D 5. underfill
4. C .
5. D
Answer Key
