Welding Defects

Objectives
The

student will have a Knowledge of the basic weld defects The Student will have an understanding of the cause of the basic defects The student will be able to understand how to rectify the defect.

What are welding defect?

Welding defects are excessive conditions, that are outside the parameter of the required weld, the defect will compromise the stability and functionality of the weld.

How can you prevent defects from happening?

Correct preparation of the weld. Materials free from dirt and correctly prepared. Use the correct tools, equipment and settings. Correct storage of the Electrodes. Welder correctly trained in weld position. Correct electrode being used

Types of Welding Defects.

Dimensional Undercut Inclusions Cracks Incomplete Fusion Lack of Penetration

Dimensional Defects
A Dimensional defects are any defect that cause the weld metal. Parent metal, work piece to be out of specification or tolerance. Dimensional defects are mainly caused by improper set up or distortion. This should be managed before the welding process.

Precaution that can be taken to prevent this: Off setting This is were the base material is tack off centre to allow for the distortion of the weld will create. Strong backs These are an aid to prevent distortion. They are tack to the work piece to strengthen the welding area. Jigs Hold the work in place until the welding process has been done Spiders (round work pieces ) Place inside cylinders and pipe to keep their roundness when welded.

Concave and convex weld profiles

The concave defect cause the weld to be weak across the throat of the weld (Middle). The cause of this are: Travel speed is to quick Amps are to high Poor electrode Manipulation

Concave and convex weld profiles

The convex defect cause the weld to become weak at the toes of the weld (outer edges). This is caused by :Travel speed being to slow Amps to low Poor electrode manipulation.

Undercut
Undercut is a groove formed into the base metal adjacent to the weld bead. It is caused by: Incorrect torch or electrode manipulation (slope & tilt angles). Welding current too High Travel speed to Fast Insufficient dwell at the edge of the weld bead

Slag Inclusion Defects

Slag Inclusion defect are mainly associated with flux welding processes. This is caused by: Poor cleaning of weld beads during multi runs. Incorrect electrode size for joint. Scale & Rust not removed from Base metal.

Hydrogen Cracking
Hydrogen cracking may also be call cold/delayed cracking. Hydrogen is given off by the flux during the welding process. These type of Cracks mainly appear during or just after welding, The cracks can be caused by :-

Tensile pressures affecting the weld joint after the weld has cooled.
The weld bead being to small for the weld joint. High heat input then rapid cooling of the material.

Hot Cracking
Hot cracking is when the weld material is pulled apart or cracked before it has time to solidify. It is caused by: External stresses before the weld metal has fully solidified Impurities being force out of the solidifying weld and becoming trapped inside

Incomplete fusion and Penetration

Incomplete root fusion is when the weld fails to fuse one side of the joint in the root. Incomplete root penetration occurs when both sides of the joint are unfused. Some of the causes are:a) b) c) d) e)
a) b)

Excessively thick root gap. Too small a root gap Misaligned welds Power input to low Arc (heat) input to low

c)

d)

These defects can be reduced in MMA welding by Using the correct welding parameters and Electrode size, This will give the correct arc energy Input.

e)

What can happen if welding defects arent found.