SPATTERS
UNDERCUT
POROSITY / BLOW HOLES
LACK OF FUSION
LACK OF PENETRATION
SLAG INCLUSION
EXCESSIVE REINFORCEMENT
COMMON WELDING DEFECTS
-CONTD
END CRATER
ARC STRIKES
BURN THROUGH
CRACKS
DISTORTION
Definition
Small Metal Particles Thrown Out Of The Arc
During Welding
CAUSES
Current too high
Long arc
Wrong polarity
Arc blow
Uneven flux coating
UNDERCUT
DEFINITION
A groove cut into the base metal
along the toe of a weld and left
unfilled by the weld metal.
UNDERCUT
CAUSES
REMEDIES
Current too high
Ensure proper
High Welding speed
current
Faulty electrode
Correct welding
manipulation
Wrong electrode
angle
speed
Correct arc length
Correct manipulation
of electrode
POROSITY/BLOW HOLES
Group of pin holes on the surface of the weld
due to gas entrapment.
CAUSES
Presence of contaminants on job or electrode
Presence of high sulphur in the job or electrode
materials
Trapped moisture
Fast freezing of weld metal
Improper cleaning of the edges
POROSITY/BLOW HOLES
CONTD
REMEDIES
Remove oil, grease, rust, paint, moisture
Use fresh and dried electrodes
Use good flux coated electrodes
Avoid long arcs
LACK OF FUSION
DEFINITION
Lack of union in a weld between
- deposited metal and parent
metal, or
parent metal and parent metal,
or
deposited metal and deposited
metal
LACK OF FUSION
CAUSES AND REMEDIES
CAUSES
Insufficient welding
current
REMEDIES
Ensure Correct welding
current
Incorrect electrode angle
Correct welding angle
Too high welding speed.
Optimum welding
speed
Improper joint
preparation
Proper joint preparation
Improper cleaning
Good cleaning
LACK OF FUSION
LACK OF PENETRATION
CAUSES
REMEDIES
Incorrect joint design
Correct edge preparation is
required. Ensure correct angle
of bevel & required root gap
Improper welding
parameters.
particularly current
Correct welding speed,
Correct current setting
Incorrect electrode size Use correct size electrode
Incorrect polarity
where DC is used
Ensure correct polarity.
Maintain key-hole throughout
the run
LACK OF PENETRATION
SLAG INCLUSION
DEFINITION
Entrapment of oxides and non
metallic solid material in the weld
deposit or in between the weld
metal.
SLAG INCLUSION
CAUSES
Improper cleaning of
weld metal between
passes
REMEDIES
Proper cleaning of the
slag between passes
Stirring action of arc
Weld metal not hot
enough to flow properly
Rapid solidification of
weld metal
Preheating the base
metal
Use of large size
electrode for root pass
welding
Excessive Reinforcement
DEFINITION
WELD DEPOSIT OVER AND
ABOVE THE
REQUIORED SIZE OF
THE WELD
SIGNIFICANCE
THE WEIGHT, WIDTH, RADIUS AND
REINFORCEMENT ANGLE IS
MORE IMPORTANT.
Excessive Reinforcement
Excessive Reinforcement
CAUSES
Poor Fit Up
Excessive welding
current
Low welding speed
REMEDIES
Proper fit up
Correct welding
current
Optimum welding
speed
Improper welding
technique
Correct welding
technique
BURN THROUGH (OR)
EXCESSIVE PENETRATION
Definition
Holes burned through the parent
metal in single pass weld or the
root run in multi run welds.
Creates an opening at the root.
BURN THROUGH (OR)
EXCESSIVE PENETRATION
CAUSES
REMEDIES
Excessive root gap
Correct root gap
Insufficient root
Sufficient root
face
face
Excessive welding
Correct welding
current
current
Low welding speed
Optimum welding
speed
ARC STRIKES
Definition
Defect caused when the welder
accidentally or in advertently strikes the
electrode or the electrode holder against
the work, adjacent to the weld causing
unwanted arc.
Also happened between a faulty ground
clamp and work
EFFECT OF ARC STRIKES
--Create a hard and brittle condition on
materials
--Arc strikes initiate failure in cyclic loading
ARC STRIKES
CRACKS
DEFINITION
Cracks are the linear ruptures of the metal
under stress.
Classification : hot, cold, base metal, crater,
micro fissuring
CRACKS
CAUSES
Presence of
localized stress
Fast cooling
Improper welding
techniques
Poor Ductility
Absence of preheating and
post heating on
High Carbon steels
REMEDIES
Pre-heating and
Post heating to
be done on high
carbon
steel
Uniform cooling
Use fewer passes
Adopt proper
welding
technique
DISTORTION
DEFINITION
Deviation from the desired shape due to
residual stresses.
Resistance created by surrounding cold
metal to the cooling weld metal is the
cause for residual stresses and distortion
DISTORTION
CAUSES
REMEDIES
Presence of
residual stresses
Absence of pre &
post heating
Design
Accuracy of
manufacture
Assembly procedure
Counter allowance
Welding sequence
