Lack of fusion is one of the most serious weld defects. It produces the notch effect.

There are, however, no efficient non-destructive methods available for its detection.
These types of defects occur when the welding procedures are not adhered to; possible causes include the current setting, arc length, electrode angle, and electrode manipulation.
Lack of fusion (Topic: 18502) Lack of fusion is a very common type of weld defects. With lack of fusion means an area without sufficient mechanical binding between weld metal and base metal. Lack of fusion may be caused by: Insufficient welding current Insufficient edge preparation Too long weld arc Attempts to weld over heavily oxidised joint surfaces Welding in too narrow joints Insufficient oxide removal Wrong position of the welding torch. Welding speed.

Avoid lack of fusion by: Brushing the joint surfaces Machining the joint surfaces before welding Increase joint angle or

Lack of fusion are usually not acceptable weld defects, as they are characterised as planar defects and treated in the same way as cracks. Use of fracture mechanics may, if relevant fracture toughness parameters are available, be used to evaluate the severity of lack of fusion. NDT-detectability: Lack of fusion is normally not detectable by radiographic examination, and may often be difficult to detect by ultrasonic, as the two surfaces are pressed closely together and reflects only limited amount of ultrasonic waves. Lack of fusion is caused by the following conditions: a. Failure to raise to the melting point the temperature of the base metal or the previously deposited weld metal. b. Improper fluxing, which fails to dissolve the oxide and other foreign material from the surfaces to which the deposited metal must fuse. c. Dirty plate surfaces. d. Improper electrode size or type. e. Wrong current adjustment.