WELD QUALITY 537

Table 13.1
Discontinuities Commonly Associated with Welding Processes
Discontinuity*
Incomplete
Incomplete Joint
Welding Process Porosity Inclusions Fusion Penetration Undercut Overlap Cracks
Arc Welding Processes
Stud welding (SW) — x x — x — x
Plasma arc welding (PAW) x x x x x — x
Submerged arc welding (SAW) x x x x x x x
Gas tungsten arc welding (GTAW) x x x x x x x
Gas metal arc welding (GMAW) x x x x x x x
Flux cored arc welding (FCAW) x x x x x x x
Shielded metal arc welding (SMAW) x x x x x x x
Carbon arc welding (CAW) x x x x x x x
Resistance Welding Processes
Resistance spot welding (RSW) †x† x x x — — x
Resistance seam welding (RSEW) †x† x x x — — x
Projection welding (PW) — — x x — — x
Flash welding (FW) — — x x — — x
Upset welding (UW) — — x x — — x
Percussion welding (PEW) — — x — — — x
Oxyfuel Gas Processes
Oxyacetylene welding (OAW) x x x x x x x
Oxyhydrogen welding (OHW) x — x x — — x
Pressure gas welding (PGW) x — x — — — x
‡Solid-State Processes ‡
Cold welding (CW) — — x — — — x
Diffusion welding (DFW) — — x — — — x
Explosion welding (EXW) — — x — — — —
Forge welding (FOW) — — x — — — —
Friction welding (FW) — — x — — — —
Ultrasonic welding (UW) — — x — — — —
Other Processes
Electron beam welding (EBW) x — x x — — x
Laser beam welding (LBW) x — x x — — x
Electroslag welding (ESW) x x x x x x x
Induction welding (IW) — — x — — — x
Thermite welding (TW) x x x — — — x
* The symbol “x” indicates that the type of discontinuity may occur in welds produced by the process. The symbol “—” indicates that the occurrence of this
type of discontinuity in these welds is very rare.
† In resistance welds, “porosity”” is more properly termed “voids.”
‡ As these are not fusion processes, the appropriate term for “incomplete joining” is “incomplete welding” rather than “incomplete fusion.”

Source: Adapted from American Welding Society (AWS) Committee on Methods of Inspection, 1999, Guide for the Nondestructive Examination of Welds, ANSI/AWS B1.10:1999,
Miami: American Welding Society, Table 2.