8/13/13 Handbook - Weld Defects

Variations-
Metal
Transfer

The atmospheric gases that are primarily responsible for porosity in steel are nitrogen and excessive
Equipment
oxygen. However, considerable oxygen can be tolerated without porosity in the absence of nitrogen. Oxygen
in the atmosphere can cause severe problems with aluminum because of its rapid oxide formation. The gas
supply should be inspected at regular intervals to insure freedom from leakage. In addition, excessive
Power
moisture in the atmosphere can cause porosity in steel and particularly aluminum. Care should be exercised
Supply
in humid climates. For example, a continuous coolant flow in water cooled torches can cause condensation
during periods of high humidity and consequent contamination of the shielding gas.
Shielding Excessive oxidation of the work pieces is an obvious source of oxygen as well as entrapped moisture.
Gases
Again, this is particularly true for aluminum where a hydrated oxide may exist. Anodized coatings on
aluminum must be removed prior to welding because they contain water as well as being an insulator.
Wire
Porosity can be caused by inadequate wire deoxidation when welding semi-killed or rimmed steels. The
Electrodes
oxygen in the steel can cause CO porosity if the proper deoxidizing elements are not present.
Foreign matter can be a source of porosity. An example is excessive lubricant on the welding wire. These
Safety hydrocarbons are sources of hydrogen which is particularly harmful for aluminum.
Other causes of porosity may be extremely fast weld solidification rates and erratic arc characteristics.
When solidification rates are extremely rapid, any gas that would normally escape is trapped. Extremely
Welding
Techniques high travel speeds and low welding current levels should be avoided.
Erratic arc characteristics can be caused by poor welding conditions (voltage too low or high, poor metal
transfer) and fluctuation in the wire feed speed. All these occurrences cause severe weld puddle turbulence.
Welding
Conditions This turbulence will tend to break up the shielding gas envelope and cause the molten weld metal to be
contaminated by the atmosphere.
Introduction
Economics
Incomplete
Penetration
Lack of
Weld Fusion
Defects Undercutting

Porosity
Mig Spot
Welding Longitudinal
Cracking

8
Tables

www.esabna.com/EUWeb/MIG_handbook/592mig10_8.htm 1/1