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PELATIHAN PLATE WELDER SMAW 3G
K3 PENGELASAN
Alvinura Fajrin, 2022
OUTLINE
• Weld Defect Classification
• Fault in Fusion Weld
• Mechanical Damage
• Set Up Irregularities
TUJUAN INSTRUKSIONAL
1. Mengenal potensi bahaya dan
RISIKO aktivitas pengelasan,
pemotongan dan penggerindaan
2. Melakukan pengendalian RISIKO
3. Bekerja aman sesuai dengan
Standard Operational Procedure
(SOP)c
REFERENSI
1. Welding Imperfections, The Welding
Institute, 2005
Weld Defect Classification
Defects can be grouped under three main
classifications
Planar Defects: linear from at least one dimension
• Cracks
• Lack of fusion
Linear Volumetric Defects: Linear in length with volume
• Slag lines
• lack of fusion with associated slag
• Piping.
Non-planar defects: rounded indications without significat length
• Slag inclusions
• Gas pores/blow holes.
• Other matallic and non-metallic inclusions
Faults in Fusion Welds
Defects which may be detected by visual inspection
can be grouped under the following headings
Cracks Lack of fusion
Solid inclusions Mechanical damage
Surface and profiles Parent material damage
Misalignment (set-up Miscellaneous
irregularities)
Gas pores and porosity
Cracks
Copyright © 2005 TWI Ltd World Centre for Materials Joining Technology
Cracks
Weld Metal Hydrogen Cracking HAZ Hydrogen Cracking
Solidification Cracking Lamellar Tearing
Cracks
Cracks that may occur in welded materials are caused
generally by many factors and may be classified by
shape and position, cracks are classed as planar.
Classified by Shape Classified by Position
Longitudinal HAZ
Transverse Centreline
Branched Crater
Chevron Fusion zone
Parent metal
Transverse crack Longitudinal crack
Inclusions
Gas Cavities
Gas pore <1.5mm Blow hole.>1.6mm
Gas pore Cluster porosity
Loss of gas shield
Damp electrodes
Contamination
Blow hole
Herringbone porosity Arc length too large
Damaged electrode flux
Moisture on parent material
Welding current too low
Root piping / wormholes
Gas Cavities
Porosity
Root piping
Cluster porosity Herringbone porosity
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 Lack of interun
fusion + slag MAG welding process
Solid Inclusions
Lack of interun fusion + slag
Lack of sidewall fusion + slag
Interpass slag inclusions Elongated slag lines
Lack of Fusion
Lack of Fusion
Poor welder skill
Incorrect electrode
manipulation
Incomplete filled groove
+ Lack of sidewall fusion Arc blow
Incorrect welding
1 current/voltage
2
Incorrect travel speed
1. Lack of sidewall fusion Incorrect inter-run cleaning
2. Lack of inter-run fusion
Lack of Fusion
Lack of sidewall fusion + incomplete filled groove
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
Overlap
Toe Overlap
Butt weld
Toe Overlap
Fillet weld
Weld Root Defects
Low Amps/volts
Large Root face
Small Root Gap
Lack of root fusion
Fast Travel Speed
Incorrect Electrode Angle
Contamination
Incomplete root penetration
Arc blow
Weld Root Defects
Lack of root fusion Incomplete root
Penetration
Lack of root penetration Lack of root fusion
Surface & Profile
Weld Profile Defects
Incomplete filled groove Poor cap profile
Poor cap profiles and excessive
cap reinforcements may lead to
stress concentration points at
the weld toes and will also
contribute to overall poor toe
blend Excessive cap height
Weld Profile Defects
Poor Cap Profile & Poor Toe Blend
Excess cap reinforcement Incomplete filled groove
Weld Profile Defects
Poor stop/starts
Miscellaneous Defects
Miscellaneous Defects
Spatter
Excessive current
Damp electrodes
Contamination
Incorrect wire feed speed
when welding with the MAG
welding process
Arc blow
Miscellaneous Defects
Accidental striking of the arc
onto the parent material
Faulty electrode holder
Poor cable insulation
Poor return lead clamping
Arc strike
Cap & Root 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
Cap Undercut
Intermittent Cap Undercut
Root undercut Cap undercut
Weld Root Defect
A shallow groove caused by contraction in the weld
metal along each side of the penetration bead
Insufficient weld metal
deposited in the root pass
Too fast a cooling rate during
the application of the root
bead pass
Shrinkage groove Poor welding technique
Weld Root Defect
A shallow groove, which may occur in the root of a butt weld
Root gap too large
Excessive back purge pressure
during TIG welding
Excessive root bead grinding
before the application of the
Concave root
second pass
Weld Root Defect
Concave Root
Weld Root Defect
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
Weld Root Defect
Excessive root
penetration
Concave root Excess root penetration
Weld Root Defect
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
Weld Root Defect
Burn Through
Oxidized Root (Root Coking)
Loss or insufficient back
purging gas
Most commonly occurs
when welding stainless
steels
Purging gases include
argon, helium and
occasionally nitrogen
Crater Pipe
Weld crater
Crater pipe
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
Crater cracks Too fast a cooling rate
(Star cracks)
Deoxidization
reactions and liquid to
solid volume change
Contamination
Crater pipe
Mechanical Damage
Mechanical Damage
Mechanical damage can be defined as any surface material
damage cause during the manufacturing process.
This can included damage caused by:
Grinding
Hammering
Chiselling
Chipping
Breaking off welded attachments (torn surfaces)
Using needle guns to compress weld capping runs
Mechanical Damage
Chipping Marks
Mechanical Damage/Grinding Mark
Set-up Irregularities
Unequal Leg Lengths
A variation of leg lengths on a fillet weld
Note: Unequal leg lengths on a fillet weld may be specified
as part of the design, in which case it will not be
considered as a defect.
Set-up Irregularities
Linear misalignment is
measured from the lowest
plate to the highest point.
Plate/pipe Linear Misalignment
(Hi-Lo)
Angular misalignment is
measured in degrees
Angular Misalignment
Set-up Irregularities
Linear Misalignment
Set-up Irregularities
Linear Misalignment
Any Questions
Questions
Weld Defects
QU 1. Give two main causes for the occurrence of a burn through
QU 2. Give two main causes for the occurrence of excessive root
penetration on a single-V butt weld
QU 3. Give five defects, which may occur when welding carbon
steel using the MMA welding process with the current
setting to low
QU 4. Give three possible causes for the occurrence of lack of
side wall fusion
QU 5. Sketch the following defects
a. Lack of root wall fusion b. Lack of root penetration
c. Incomplete filled groove d. Concave root
