Defects 01
Defects 01
Definition
Influence
Types
Causes
Remedies
Discontinuity & Defect
WM
PM
t t
Weld Strength
Lack of penetration
Surface discontinuity
Internal discontinuity
Voluminar discontinuity
Planar discontinuity
Common surface Discontinuities
P
Excess Penetration
Proper Penetration
Excess Penetration
Root Concavity
Weld Size & Reinforcement
R = max 3 mm
Shallow Obtuse
angle > 100
High level of SC
Acute angle > 90
Weld Size & Reinforcement
L T –Throat Size
T R
T L – Leg size
R- Reinforcement
L L
Weld bead Profile Definitions
L2
L1
Concave bead with Convex bead with un-
under sized weld equal sized weld
Undercut &
Bead Off-set
Undercut -causes
Mis-alignment
Surface Porosity & Slag
Porosity Common Internal
Discontinuities
Blow Holes / Aligned / distributed /
Cluster / worm hole Porosities
Lack of fusion/ Lack of Penetration
Lack of side wall fusion / Inter run
fusion / lack of fusion at root
Cracking
Under-bead cracking / delayed
cracking / Delayed cracking
/Hydrogen induced cracking
Hot cracking, shrinkage cracks,
Fatigue cracking
Porosity - Cause /Source
Cavities / voids formed due to entrapment of gases when the
molten metal solidifies from liquid state when more gases get
dissolved into molten metal
Gas Pores
Internal Porosity
10 mm
Types of Porosity – Cluster & distributed
Types of Porosity – Aligned
Aligned Porosity
20 mm
Pin-hole Porosity
10 mm
Slag Inclusion
Slag Inclusion
1-Incomplete fusion
2-Linear slag Inclusion
3-Crack
Mis-alignment
Lack of fusion
Lack of Penetration
Incomplete Fusion - Causes
LOP
1-Lack of penetration
between runs
2-LOP at side wall
Cold Cracking (Under bead cracking)
HAZ
0.5 mm
0.2 mm
Lamellar
Tearing
Weld Metal
cracking
10 mm
Hot Cracking
10 mm
Discontinuities commonly associated with
welding Processes
Incomplete Incomplete
Weld Process Porosity slag fusion Penetration
undercut cracks
SMAW X X X X X X
GMAW X X X X X X
SAW X X X X X X
GTAW X X X X
RES. spot X X
Solid State X X
EBW O X X X
LW X X X
ESW X X X X X X
Applicable Inspection Methods for weld Joints
Joints RT UT PT MT VT ET
Butt A A A A A A
Corner O A A A A O
Tee O A A A A O
Lap O O A A A O
A – Applicable Method
O – Marginal applicability depending upon factors such as material
thickness, discontinuity size orientation and location
RT – Radiographic testing, UT – Ultrasonic testing
PT – Penetrant testing, MT – Magnetic particle testing,
VT – Visual testing, ET – Eddy current testing
Applicable Inspection Methods Vs Discontinuities
Discontinuities RT UT PT MT VT ET
Porosity A O A O A O
Slag Inclusion A A U O U O
Incomplete fusion O A U O U O
Incomplete Penetration A A U O U O
Undercut A O O O A O
Overlap U O A A O O
Cracks O A A A A A
Laminations U A A A A U
A – Applicable Method
O – Marginal applicability depending upon factors such as material
thickness, discontinuity size orientation and location
RT – Radiographic testing, UT – Ultrasonic testing, PT – Penetrant testing, MT – Magnetic
particle testing, VT – Visual testing, ET – Eddy current testing
Causes of Discontinuities
Porosity X X -- XX X XXX
Slag Inclusion XXX X X X X
Incomplete fusion X XX XX X X X
Incomplete Penetration XX O X X XXX
Undercut XXX X XX
Overlap XXX X
Cracks --- XXX XX XX -- -- X
Laminations -- -- -- XX -- -- XX
Location of discontinuity
Significance
Characterization of defects
Discontinuity Size & Number
Diameter, length, width etc
Location of the Discontinuity
Weld, HAZ, Toe region, Root, Face of weld
Surface / sub-surface / Interior of weld
Significance
Modes of failures
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