WELDING DEFECTS:

Welding defects refer to imperfections or irregularities that occur during the welding process,
resulting in a weld that does not meet the desired quality or specifications. These defects can
weaken the joint, compromise the structural integrity, and may lead to failures in the welded
components. the repair of welding defects should be done under the supervision of a
technician experienced in repair welding techniques.
Types of welding defects:
 Porosity and Blowholes: Porosity appears as small cavities or holes within the weld
metal caused by trapped gas (e.g., hydrogen, nitrogen) during solidification. This
defect weakens the weld and makes it more susceptible to corrosion. Porosity is a
result of weld metal contamination.

Fig: Porosity and Blowholes

 Weld Crack: A weld crack is a type of welding defect characterized by a fracture or
separation in the welded joint. Weld cracks can be problematic as they weaken the
weld and can lead to failure of the welded component or structure.

Fig: Weld Crack

There are different types of cracks, depending on the temperature at which they occur:
 Hot cracks: Hot cracks, also known as solidification cracks, occur during the
cooling process of the weld metal. They are often caused by the weld metal's
inability to withstand the stresses that arise during solidification. Hot cracks
typically form in the centre of the weld or along its fusion line. The
temperature at this point can rise over 10,000C.
 Cold cracks: Cold cracks, also called delayed cracks, form after the welding
process is completed and the metal has cooled down. They are caused by the
re-crystallization of the metal at low temperatures, often due to residual
stresses or hydrogen embrittlement.
  Crater cracks: Crater cracks occur at the end of the weld, in the weld crater.
They are caused by inadequate filling of the crater at the weld termination,
which creates stress concentration points. When the weld pool cools and
solidifies, it needs to have enough volume to overcome shrinkage of the weld
metal or it will form a crater crack.
 Undercut: Undercutting is the formation of grooves or depressions at the edges of the
weld due to excessive heat or incorrect welding techniques. It can lead to stress
concentration and potential failure under load. The result is the weakened weld and
workpiece.

Fig: Undercut
 Incomplete Fusion: Incomplete fusion occurs when there is a failure to properly bond
the weld metal with the base metal or between weld passes, leading to weak and
unreliable joints. It can also appear between adjoining weld beads. This creates a gap
in the joint that is not filled with molten metal.
 Slag Inclusion: Slag is a by-product of the welding process, and slag inclusions
happen when fragments of slag become trapped within the weld metal, reducing its
strength and promoting corrosion. It occurs due to improper cleaning, faster welding
speed, incorrect welding angle and when the welding current is too low.

Fig: Slag inclusion

 Spatter: Spatter refers to the small droplets of molten metal that may scatter around
the weld area, potentially causing surface contamination and affecting the weld
appearance. It’s a common occurrence in gas metal arc welding. No matter how hard
we try, it can’t be eliminated completely.

Fig: Spatter
 Incomplete Penetration: This defect happens when the weld does not penetrate
through the entire thickness of the joint, resulting in an insufficiently strong bond
between the materials.

Fig: Incomplete Penetration