Erstellungsdatum: 24.01.

2000
Letzte Änderung: 23.01.2002
File-Name: e2202t1.fm

DVS – DEUTSCHER VERBAND Imperfections in thermoplastic Directive D

welded joints; DVS 2202-1
FÜR SCHWEISSEN UND V
VERWANDTE VERFAHREN E.V. features, descriptions, evaluation (December 1989) S 

Contents: 2 Evaluation groups

1 Purpose and range of application 2.1 Classification

2 Evaluation groups
3 Requirements for welding joints Specific requirements are laid down for the carrying capacity of a
4 Details in engineering data component particularly regarding the quality of the welding joints.
5 Testing and evaluation The following classification is used as a basis, so that the
6 Acceptance converter knows the extent of the measures required for quality
7 Other standards and guidelines applying control with regard to welding:
8 Appendix: diagram Evaluation group Requirement level
I High requirements
for safety and/or carrying capacity
1 Purpose and range of application
II Medium requirements
This guideline registers and describes faults in thermoplastic or safety and/or carrying capacity
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

welding joints with the aim of making possible a generally valid III Low requirements
evaluation with consideration being given to graded quality for safety and/or carrying capacity
requirements.
The description of the faults is based on the terminology The requirements to be laid down for the welding joints on a
regulated in DIN 32502. component should in each case be restricted to those which are
practicable with reference to the local situation or necessary
If specific faults are to be excluded or kept within limits when appropriate to the application.
welding joints are produced this can be emphasised by
classification into one of the evaluation groups.
2.2 Criteria for establishment
The application of the guideline and the measures necessary for
its fulfilment can, for example, be laid down by legal regulations In the establishment of the evaluation groups the following
or by generally recognised rules of engineering or be regulated factors, among others, should be taken into account:
on the basis of delivery agreements.
– type of stress
(for example static, dynamic)
1.1 Welding processes
Faults in the following welding processes are dealt with: – material
(for example viscous, brittle)
Abbreviation Table No. Page*
Heated tool butt welding HS 1 3+4 – operating conditions
Heated tool socket welding HD 2 4 ... 6 (for example stationary, changing)
Electro fusion welding HM 3 6 ... 8
– production
Hot gas fan welding WF 4 9 ...11 (for example workshop, construction site, welding in
Hot gas drawing welding WZ 4 10...12 constrained position)
Hot gas extrusion welding WE 5 11...13
– potential danger
* according to this paper/print (for example gases, water-endangering fluids)

1.2 Materials
The guidelines applies to welding joints on components and 3 Requirements for welding joints
systems, for example apparatus and pipelines, made from the
plastics listed below. 3.1 Quality features for carrying out of weld (Tables 1 to 5)
Abbreviation Material description
The requirements for keeping a welded joint within a particular
PE-HD High density polyethylene (rigid PE) quality grade are classified by the evaluation groups.
PP-B Polypropylene block copolymer
PP-H Polypropylene homopolymer In the majority of cases it concerns requirements for the carrying
PP-R Polypropylene random copolymer out with specific features and describing them with reference to
PVC-C Chlorinated polyvinyl chloride the internal and external state of the joint.
PVC-HI High-impact polyvinyl chloride By using Tables 1 to 5 it is possible to lay down specific
PVC-U Unplasticised polyvinyl chloride (rigid PVC) requirements for the quality of welding.
PVDF Polyvinylidene fluoride
Using the individual features, i. e. through the type and extent of
The application of the guideline for welding other thermoplastic the faults, an individual evaluation of welding joints can be
plastics must be agreed separately between the customer and undertaken as before (for example as part of the acceptance
the manufacturer. procedure for the component).

This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration is recommended. The user should
always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. The Deutscher Verband für Schweißtechnik
e.V. and those involved in preparing this publication are exempt from any liability.

DVS, Technical Committee, Working Group “Plastics, Welding and Bonding”

Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
Page 2 to DVS 2202-1

3.2 Requirements for characteristics Tests must be carried out on the welding joints of the component.
This covers all additional data such as: Specific characteristics can also be verified on test pieces which
– deformation resistance are manufactured under comparable conditions.
(for example welding factor) The nature and extent of the tests together with their timing are to
– plasticity be agreed between the customer and the manufacturer. The test
(for example bending angle to cracking) results are to be documented in suitable form.
– resistance against chemical attack
5.2 Evaluation
(for example resistance factor)
The test result forms the basis for the classification of welding
3.3 Requirements for after-treatment joints into one of the three evaluation groups, in accordance with
In certain cases, it can be necessary to process the completed Tables 1 to 5. The test reports should be used to determine
welding joints. points where the result does not correspond with the
requirements. Should the component or individual welding joints
This can take place, among other cases, in the event of not correspond to the evaluation group specified (Section 2.1.)
– dynamic stress then it or they may be touched up.
(for example notch-free transitions)
5.2.1 Touching up faulty welding joints
– to smooth weld surfaces
(for example lining) In so far as the inspector considers it possible, faulty welding
joints may be expertly touched up, as long as technical rules are
– to improve flow behaviour
adhered to. The purpose of touching up operations is finally to
(for example internal pipe beads)
obtain the welded joint quality laid down by the requirements. If
– for technical inspection reasons necessary, the results shall be determined by additional test
It is advisable to test and/or evaluate the weld both before and procedure.
after mechanical manipulation.
5.2.2 Overlapping faults

Should two or more types of faults arise simultaneously on

4 Details in engineering data
Requirements for welding joints are to be defined in the
documentation which is binding for manufacture (for example
working drawing, welding diagram), with reference to the DVS
guideline.
As a rule it is sufficient to identify a weld in accordance with
following example:
WZ-V-II
where
WZ = abbreviation for the welding process
V = welding symbol and dimensions
II = evaluation group code
Should all the welding joints on a component come under the
same evaluation group then it can be entered in a space provided
for this purpose on the drawing.
Example: All welding joints as per evaluation group II-DVS 2202,
Part 1.
Additional requirements for the carrying out or characteristics of
welding joints and for mechanical manipulation are also to be
noted in the engineering data.
welding joints, this can increase the effect of an individual fault.
Tests should then be carried out to ascertain whether the welded
joint still meets the requirements laid down or whether restrictions
have to be imposed as regards safety and quality standards
because of the accumulation of faults. Under certain
circumstances, the component or its welding joints should be re-
classified into another evaluation group.
6 Acceptance
If tests on the component confirm that it meets the requirements
laid down in the technical documentation the component shall be
considered as being accepted. A separate acceptance document
is to be drawn up.
Should the requirements not be met and should touching up not
be possible then the manufacturer has to produce a special
document on the usability of the component. The customer and
the manufacturer are to reach agreement in good time on the
nature, extent and evaluation of this document.
7 Other standards applying

DIN 1910*) Welding plastics; Processes, Part 3

5 Testing and evaluation
DIN 32 502*) Faults in welding joints on plastics – Classification,
5.1 Testing designation, clarifications
Visual inspection, measurements and, where necessary, suitable Also the guidelines and specifications of volume 68/IV of the DVS
non-destructive or destructive testing procedures are to be used notebook, together with any publications of the DVS 22.. series
to verify that the requirements for the individual welding groups which have been published in the meantime (all in the most
have been adhered to. recent versions).

*) Included in DVS notebook 68/IV

 Page 3 to DVS 2202-1

Table 1. Description of evaluation groups for heated tool butt welds.

No. Feature Description Evaluation groups

I II III
External state of joint
1 Cracks Cracks running length-wise Not permissible Not permissible Not permissible
or cross-wise to weld
They may be located
– in weld
– in base material
– in heat affected zone

2 Welding flash notches
Continuous or local notches Not permissible Not permissible Not permissible
length-wise to weld with
notch root in base material,
caused by, for example
– insufficient joint pressure
– warming-up time too short
– cooling time too short

3 Notches and flutes Notches in edge of base Locally permissible Locally permissible Permissible if
material, length-wise or if ending flat and if ending flat and ending flat and
cross-wise to weld, caused ∆s ≤ 0.1 s ∆s ≤ 0.1 s ∆s ≤ 0.15s
by, for example but max. 0.5 mm but max. 1 mm but max. 2 mm
– clamping tools
– incorrect transport
– fault in edge preparation
4 Mismatch of joint faces Joint faces are displaced Permissible if Permissible if Permissible if
relative to one another or e ≤ 0.1 s e ≤ 0.15 s e ≤ 0.2 s
thickness variations are not but max. 2s but max. 4 mm but max. 5 mm
adjusted

5 Angular deflection For example Permissible if Permissible if Permissible if

– machine fault e ≤ 1 mm e ≤ 2 mm e ≤ 4 mm
– layout fault

6 Narrow, excessive welding Excessive and sharp Not permissible Not permissible Not permissible
flash edged welding flash
over part or all of weld length
or weld girth due to wrong
welding parameters, especi-
ally caused by
– excessive joint pressure
with polyolefins only
7 Welding flash incorrectly Welding flash too wide or too Value range A see Value range B see Value range C see
formed narrow over part or all of diagram page 14 diagram page 14 diagram page 14
See note1) weld length, caused by, for
example
– incorrect warming-up time
– incorrect heated tool
temperature
– incorrect joint pressure

8 Non-uniform welding flash Non angular joint plane, Permissible if Permissible if Permissible if
See note2) leading to variations in form b1 ≥ 0.7 ⋅ b2 b1 ≥ 0.6 ⋅ b2 b1 ≥ 0.5 ⋅ b2
of welding flash over part or
all of weld length, caused by,
for example
– edge preparation faults
– incorrect welding unit
Page 4 to DVS 2202-1

Table 1. Fortsetzung.

No. Feature Description Evaluation groups

I II III
9 Thermal damage High-gloss welding flash with Not permissible Not permissible Not permissible
voids or nodules, usually
associated with faulty
welding flash formation and
marked bead notches
Internal state of joint
10 Lack of fusion No fusion or incomplete Not permissible Not permissible Not permissible
fusion on joint faces, over
part or the whole of weld
cross-section caused by, for
example
– contaminated joint faces
– oxidised joint faces
– excessive reversal time
– heated tool temperature
too low
– heated tool temperature
too high
11 Void Hollow space in joint planes Not permissible Not permissible Not permissible
caused by, for example
– insufficient joint pressure
– insufficient cooling time

12 Pores caused by inclusions Isolated, numerously disper- Small isolated Pores and rows of Pores and rows of
of foreign matter sed or locally concentrated pores permissible if pores permissible if pores permissible if
pores or inclusions caused ∆s ≤ 0.05 ⋅ s ∆s ≤ 0.10 ⋅ s ∆s ≤ 0.15 ⋅ s
by, for example
– vapour formation during
welding
– contaminated heated tool
1) Description and evaluation as per current knowledge on polyolefins. Amendments may be necessary after revision of guideline DVS 2207, Part 1 and
Part 2.
2) Applies only to welds which are produced using equipment as per DVS 2208, Part 1.

Table 2. Description of evaluation groups for heated tool socket welds.

No. Feature Description Evaluation groups

I II III
External state of joint
1
1.1 Faulty welding flash Variable welding flash Not permissible Not permissible Not permissible
formation formation or no welding flash
See note1) present on one or both sides
(over part or whole of weld
length) due to
– excessive heated tool
temperature
– excessive heating times
– impermissible tolerances
See note2)
1.2 Variable welding flash Not permissible Not permissible Not permissible
formation or no welding flash
present on one or both sides
(over part or whole of weld
length) due to
– insufficient heating time
– insufficient heated tool
temperature
– impermissible tolerances
 Page 5 to DVS 2202-1

Table 2. Fortsetzung.

No. Feature Description Evaluation groups

I II III
1.3 Variable welding flash Not permissible Not permissible Not permissible
formation or no welding flash
present on one or both sides
(over part or whole of weld
length) due to
– unprocessed joint faces
– contaminated joint faces
– heated tool temperature
too high
2 Angular deflection Pipe welded into fitting at Permissible if Permissible if Permissible if
(defect of form) angle on one or both sides, e ≤ 1 mm e ≤ 2 mm e ≤ 4 mm
or with slightly faulty grip-
ping, caused by, for example
– machine fault
– layout fault

3 Permissible deviation from average external pipe diameter

3.1 Lack of fusion due to Deformation or ovality of pipe 1.5% 2% 3%
deformation end or fitting with locally but max. 1.5 mm but max. 2 mm but max. 2 mm
insufficient welded pressure, from average from average from average
caused by, for example external pipe external pipe external pipe
– insufficient radii of curva- diameter diameter diameter
ture on collars
– faulty storage of pipe and/
or fitting
– unsuitable clamping
device
3.2 Lack of fusion due to Insufficient weld length with Permissible in Permissible up to Permissible up to
incomplete insertion of pipe fully or only partially fused cases of slight x ≤ 0.1 ⋅ d x ≤ 0.1 ⋅ d
joint faces, caused by, for undershooting of x ≤ 0.15 ⋅ socket x ≤ 0.2 ⋅ socket
example nominal weld depth depth
– insufficient warming-up length and notch-
time free, closed
– pipe ends not at right welding flash up to
angles x ≤ 0.05 ⋅ d
– heated tool temperature x ≤ 0.1 ⋅ socket
too low depth
– axial movement during
cooling period
– reversal time too long
Internal state of joint
3.3 Lack of fusion due to Local, extensive, axial or Not permissible Not permissible Not permissible
insufficiently closed form circular channel formation,
caused by, for example
– notches in pipe faces
– diameter tolerances on
pipe or fitting exceeded
– faulty mechanical manipu-
lation
– pipe not aligning in socket
3.4 Lack of fusion due to Local or extensive Not permissible Not permissible Not permissible
insufficient melting incomplete welding with
separation in the joint plane,
caused by, for example
– thermal damage
– contaminated joint faces
– wrong material pairing
– residues on heated tool
Page 6 to DVS 2202-1

Table 2. Fortsetzung.

No. Feature Description Evaluation groups

I II III
4 Compressed pipe cross- Pipe inserted too far in Not permissible Not permissible Not permissible
section during heating or joining,
caused by, for example
– excessive joint pressure
– welding of thin-walled
pipes
– excessive warming-up
time
– excessive welding
temperature
5 Pores caused by inclusion of Isolated, numerously Small isolated Pores and rows of Pores and rows of
foreign matter dispersed or locally pores permissible if pores permissible if pores permissible if
concentrated pores or ∆x ≤ 0.05 ⋅ x ∆x ≤ 0.10 ⋅ x ∆x ≤ 0.15 ⋅ x
inclusions, for example due
to
– vapour formation during
welding (water, solvent)
– dirty heated tool

1) As a rule in association with internal faults – dwell times too short

2) During heated tool socket welding a circular flash usually forms at the edge of the socket. This flash provides an initial indication that the welding has
been carried out properly.

Table 3. Description of evaluation groups for filament welds.

No. Feature Description Evaluation groups

I II III
External and internal state of joint connecting straight pipe sections, branches or tapping-tees
1 Angular deflection Pipe welded into fitting at an Permissible if Permissible if Permissible if
(defect of form) angle on one or both sides, e ≤ 1 mm e ≤ 2 mm e ≤ 4 mm
caused by, for example,
– layout fault
– change in position during
welding

2 Lack of fusion
2.1 Edge preparation fault Joint of faces on pipe Not permissible Not permissible Not permissible
– not mechanically treated
– too much removed by
rough machining,
insufficiently closed form
between socket and pipe
– too much removed in parts
by rough machining, with
flattening
2.2 Due to deformation Deformation or ovality of pipe Max. permissible deviations from average pipe diameter
end or fitting with locally
1.5% 2.5% 3%
insufficient welding pressure,
but max. 1.5 mm but max. 2 mm but max. 2 mm
caused by, for example
– use of collars
– wrong storage of pipe or
fitting
 Page 7 to DVS 2202-1

Table 3. Fortsetzung.

2.3 Due to faulty gripping Increased angular deflection Not permissible Not permissible Not permissible
with displacement of filament
and molten mass due to
variable welding pressure
with or without separation in
the joint plane, caused by, for
example
– pipe ends not aligning
– radii of curvature too small
in collars
– bending moment on sok-
ket
2.4 Due to incomplete insertion Pipe ends displaced in Specified insertion Permissible if the Permissible if the
of pipe socket or not resting against length may not be specified insertion specified insertion
one another or stop on one undershot at any length is slightly length is slightly
or both sides, for example point undershot undershot
due to
– insufficient insertion of
pipe
– pipe ends at an angle
Internal state of joints connecting straight pipe sections, branches or drilling fittings
2.5 Due to insufficiently closed Local, extensive, axial or Not permissible Not permissible Not permissible
form circular channel formation,
for example due to
– notches in pipe face
– ovality or deformation of
pipe or fitting
– diameter tolerances
exceeded on pipe or fitting
– faulty mechanical
treatment
– pipe ends dip
2.6 Due to insufficient fusion Local or extensive Not permissible Not permissible Not permissible
incomplete welding, with or
without separation in the joint
plane, for example due to
– filament embedded too
deeply in fitting with
insufficient heating of pipe
face
– insufficient welding power
– damaged heating
conductor
– dirty face
– material pairings which are
not as per processing gui-
delines
3 Thermal damage Locally occurring deposit, Not permissible Not permissible Not permissible
often on connecting bushes
or circular, on one or both
sides of the fitting, usually
with high-gloss or blistered
face, for example due to
– excessive welding time
– welding process repeated
immediately
– unit fault
4.1 Radial displaced filament Filament lying corrugated, Not permissible Slightly wavy Wavy filament
non-uniform, bunched or filament course course permissible
displaced in welding plane, permissible
for example due to
– weld overheating
– dirty weld faces
– faulty gripping
(as per Fig. 2.3)
Page 8 to DVS 2202-1

Table 3. Fortsetzung.

No. Feature Description Evaluation groups

I II III
4.2 Displaced filament Windings aggregated locally Not permissible Not permissible Not permissible
in axial direction, for example
due to
– tolerances on components
to be joint exceeded
– pipe inserted tilted

5 Inclusions of foreign matter
Concentration of pores in Not permissible Not permissible Not permissible
joint plane, filaments cut or
parted, for example due to
– dirty face
– water vapour or gas
formation during welding

Internal state of joints connecting straight pipes and tapping-tees

6
6.1 Lack of fusion due to Caused by Not permissible Permissible if total Permissible if total
insufficiently closed form in – concave shaped part ≤ 10% of welded ≤ 10% of welded
welding plane geometry surface surface

6.2 Caused by Not permissible Permissible if total Permissible if total

– insufficiently axially closed ≤ 10% of welded ≤ 10% of welded
form surface surface

6.3 Caused by Not permissible Permissible if total Permissible if total

– radial form error ≤ 10% of welded ≤ 10% of welded
surface surface

6.4 Lack of fusion at drilling point Caused by Not permissible Not permissible Not permissible
due to insufficiently closed – local or extensive channel
form in welding plane formation or cavity forma-
tion

7 Lack of fusion due to bent Local or extensive Not permissible Total ≤ 10% welded Total ≤ 10% welded
pipe incomplete welding, with or surface surface
without separation in joint
plane, caused by, for
example
– non-uniform application of
pressure
– one-side clamping tool use
– inadequate external
shaped part geometry
 Page 9 to DVS 2202-1

Table 4. Description of evaluation groups for hot gas welds.

No. Feature Description Evaluation groups

I II III
External state of surface of V-welds and double V-welds
1 Cracks Isolated cracks or groups of Not permissible Not permissible Not permissible
cracks with and without
branching, running
lengthwise or crosswise to
weld. They can lie in
– in the weld
– in the base material
– in the heat affected zone
2 Welding flash notches Marked deepening, which Not permissible Locally permissible Locally permissible
can be seen and felt, along if K > 0 if K > 0
or between individual
welding rods, caused by, for
example
– faults on die
– poor welding rod guidance
3 Edge notches Notches in base material Not permissible Locally permissible Continuously
along weld, caused by, for if ending flat permissible if
example ∆s ≤ 0.1 s ending flat
– penetration of die edge but max. 1 mm ∆s ≤ 0.1 s
– treatment of weld but max. 1 mm
– unsatisfactory edge zone
welding
4 Root not welded through Notch caused by incomplete Not permissible Not permissible Locally permissible
weld filling at root, due to, for in limited numbers
example if ∆s ≤ 0.1 s
– generating angle too small
during edge preparation
– root gap too small
– root rod too thick
– welding force too small
5 Incompletely welded cross- Due to, for example, Not permissible Not permissible Locally permissible
section inadequate edge preparation in limited numbers
if ∆s ≤ 0.1 s
but max. 1 mm

6 Weld root too high Caused by, for example Locally permissible Permissible if Permissible if
– root gap too big in limited numbers ∆s ≤ 0.2 s ∆s ≤ 0.25 s
– compressed stringer bead if ∆s ≤ 0.15 s but max. 3 mm but max. 4 mm
but max. 2 mm

7 Weld too high Caused by, for example Continuously Continuously Continuously
– too many individual rods or permissible if permissible if permissible if
passes 0.1 s ≤ ∆ s ≤ 0.4 s 0.05 s ≤ ∆ s ≤ 0.5 s 0 s ≤ ∆ s ≤ 0.6 s
– wrong edge preparation

8 Weld undershot Inadequate weld filling Not permissible Not permissible Not permissible

9 Mismatch of joint faces For example Permissible if Permissible if Permissible if

– different wall thickness are e1 ≤ 0.1 s e1 ≤ 0.15 s e1 ≤ 0.2 s
not compensated e2 ≤ 0.15 s e2 ≤ 0.2 s e2 ≤ 0.25 s
– equal wall thickness are but max. 2 mm but max. 4 mm but max. 5 mm
displaced
Page 10 to DVS 2202-1

Table 4. Fortsetzung.

No. Feature Description Evaluation groups

I II III
10 Angle deflections Permissible if Permissible if Permissible if
(errors of form) e ≤ ± 1 mm e ≤ ± 2 mm e ≤ ± 4 mm

11 Weld intersections Not permissible Not permissible Not permissible

12 Wavy weld surface Waviness running vertical to Locally permissible Continuously Continuously
weld in finishing pass, permissible permissible
caused by, for example
– welding force and speed
non-uniformly distributed
13 Rough weld surface Fine open bubbles, streaks Isolated cases Limited areas Permissible
or nodules and the like, permissible permissible
caused by, for example
– dirty welding shoe
– hot gas temperature too
high
14 Start fault Incomplete welded cross- Not permissible Small reduction in Permissible
section at start or end of cross-section
weld permissible without
sharp transitions
15 Heat damage Discoloration, nodule Not permissible Isolated cases Limited areas
formation, high-gloss weld permissible permissible
faces and the like
External state of weld surface of fillet welds
16 Weld too high Exceeds standard fillet weld Permissible if Permissible if Permissible if
thickness of b ≤ 0.4 a b ≤ 0.5 a b ≤ 0.6 a
a = 0.7 ⋅ s but max. 6 mm but max. 9 mm but max. 12 mm

17 Weld too low Exceeds standard fillet weld Not permissible Permissible if Permissible if
thickness of nominal dimension nominal dimension
a = 0.7 ⋅ s a is slightly under- a is undershot
shot locally locally
b ≤ 0.15 a b ≤ 0.3 a

18 Incompletely welded cross- Weld geometry not to Not permissible Permissible if Permissible if
section standard z ≤ 0.15 a z ≤ 0.3 a
 Page 11 to DVS 2202-1

Table 4. Fortsetzung.

No. Feature Description Evaluation groups

I II III
Internal state of V-welds and fillet welds
19 Pores and foreign matter Numerously dispersed, Small isolated Pores and pore Pores and pore
inclusions isolated or locally pores permissible if rows permissible if rows permissible if
concentrated pores or ∆ s ≤ 0.05 ⋅ s ∆ s ≤ 0.10 ⋅ s ∆ s ≤ 0.15 ⋅ s
inclusions, for example due
to
– vapour formation during
welding (water, solvent)
– dirty heated tool
20 Lack of fusion Lack of fusion running Not permissible Not permissible Not permissible
horizontally or vertically in
the weld edges, caused by,
for example
– welding temperature too
low
– dirty joint faces

Table 5. Description of evaluation groups for hot gas extrusion welds.

No. Feature Description Evaluation groups

I II III
External state of surface of V-welds or double V-welds
1 Cracks Isolated cracks or groups of Not permissible Not permissible Not permissible
cracks with and without
branching, running
lengthwise or crosswise to
weld
They can lie
– in the weld
– in the base material
– in the heat affected zone
2 Welding flash notches Continuous or local flat Not permissible Locally permissi- Locally permissi-
deformation lengthwise to ble if ble if
weld, caused by, for example K>0 K>0
– faults in welding shoe
– faults in welding unit
guidance

3 Edge notches Notches in base material Locally permissible Continuously Continuously

along weld, caused by, for if ending flat and permissible if permissible if
example ∆s ≤ 0,1 s ending flat and ending flat and
– penetration of weld shoe but max. 1 mm ∆s ≤ 0.1 s ∆s ≤ 0.2 s
edges but max. 2 mm but max. 3 mm
– processing of edge zone
4 Inadequate edge zone Inadequate covering of Not permissible Locally permissible Continuously
welding welding groove edge on one with notch-free permissible with
or both sides transition and notch-free
Nominal dimension: ∆b ≥ 2 mm transition and
∆b ≥ 3 mm ∆b ≥ 1 mm

5 Root gap Notches caused by Not permissible Locally permissible Permissible if

inadequate weld filling on in limited numbers ∆s ≤ 0.1 s
root, caused by, for example if ∆s ≤ 0.1 s but max. 1 mm
– bent up and unwelded joint but max. 1 mm
faces
– root opening too small
– welding force too small
– root falling back due to
shrinkage
Page 12 to DVS 2202-1

Table 5. Fortsetzung.

No. Feature Description Evaluation groups

I II III
6 Incompletely welded cross- Caused by, for example Not permissible Not permissible Locally permissible
section – inadequate edge in limited numbers
preparation if ∆s ≤ 0.1 s
but max. 1 mm

7 Weld root too high Description Permissible if Permissible if Permissible if

Caused by, for example ∆s ≤ 0.15 s ∆s ≤ 0.2 s s ≤ 0.25 s
– root opening too big but max. 2 mm but max. 3 mm but max. 4 mm
– welding force too great

8 Welding flash too high Finish pass too high, caused Continuously Continuously Continuously
by, for example permissible if permissible if permissible if
– inadequately formed 0,1 s ≤ ∆s ≤ 0.4 s 0,05 s ≤ ∆s ≤ 0.5 s 0 ≤ ∆s ≤ 0.6 s
welding shoe but max. 6 mm but max. 9 mm but max. 12 mm
– welding force too small

9 Welding material overflow Welding material overflow on Not permissible Locally permissible Continuously
one or both sides, usually in small numbers if permissible if
without sufficient fusion to ∆b ≤ 5 mm ∆b ≤ 5 mm
base material

10 Weld underarching Weld cross-section is not Not permissible Not permissible Locally permissible
obtained, caused by, for in limited numbers
example if ∆s ≤ 0.1 s
– shrinkage of welding filler but max. 1 mm
– inadequately formed
welding shoe
– welding speed too high
11 Mismatch of joint faces For example Permissible if Permissible if Permissible if
– different wall thickness are e1 ≥ 0.1 s e1 ≤ 0.15 s e1 ≤ 0.2 s
not compensated e2 ≥ 0.15 s e2 ≤ 0.2 s e2 ≤ 0.25 s
– equal wall thickness are but max. 2 mm but max. 4 mm but max. 5 mm
displaced

12 Angle deflections Length, L, of shorter side is Permissible up to Permissible up to Permissible up to

(defects of form) decisive for permissible e ≤ ±1 e ≤ ±2 e ≤ ±4
deflection

13 Weld intersections Not permissible Not permissible Not permissible

14 Asymmetrical weld cover Welding shoe has been Not permissible Permissible if the Locally permissible
guided outside weld centre required weld in limited numbers
cross-section is not if ∆s ≤ 0.1 s
undershot but max. 1mm

15 Wavy weld surface Caused by, for example Locally permissible Continuously Continuously
– welding force non- permissible permissible
uniformly applied
– welding speed non-
uniformly applied
 Page 13 to DVS 2202-1

Table 5. Fortsetzung.

16 Rough weld surface Fine open bubbles, streaks Isolated spots Limited areas Permissible
or nodules and the like, for permissible permissible
example
– noisture in form mass
– form mass temperature
too low
17 Start fault Incompletely welded cross- Not permissible Not permissible Low reduction in
section at start or end of cross-section with-
weld out sharp
transitions
permissible
18 Heat damage Discoloration, formation of Not permissible Isolated spots Limited areas
nodules, high-gloss welded permissible permissible
surface and the like
External state of weld surface of fillet welds
19 Weld too high Exceeding of standard fillet Permissible if Permissible if Permissible if
weld thickness of b ≤ 0.4 a b ≤ 0.5 a b ≤ 0.6 a
a = 0,7 ⋅ s but max. 6 mm but max. 9 mm but max. 12 mm

20 Weld cross-section under- Required weld cross-section Not permissible Permissible if Permissible if
shoot is not obtained, caused by, nominal dimension nominal dimension
for example a slightly undershot a under shot locally
– shrinkage of welding filler locally b ≤ 0.3 a
– inadequately formed b ≤ 0.15 a
welding shoe

21 ncompletely welded weld Weld geometry not to Not permissible Permissible if Permissible if
cross-section standard z ≤ 0.15 a z ≤ 0.3 a

Internal state of V-welds, double V-welds and fillet welds

22 Pores due to inclusions of Isolated, numerously Small isolated Pores and pore Pores and pore
foreign matter dispersed or locally pores permissible if rows permissible if rows permissible if
concentrated pores or ∆s ≤ 0.05 ⋅ s ∆s ≤ 0.10 ⋅ s ∆s ≤ 0.15 ⋅ s
inclusions, for example due
to
– vapour formation during
welding (water, solvent)
– dirty heated tool
23 Lack of fusion No fusion, or incomplete Not permissible Not permissible Locally permissible
fusion on opposite position, in limited numbers
fastening points and weld
sides, caused by, for
example
– dirty joint faces
– welding force too small
– inadequate heating
Page 14 to DVS 2202-1

8 Appendix

The range s > 15 mm will be etablished after revision of DVS 2207 Parts 1 and 2