Wis5 Defect

Welding Inspection
Defects/Repairs
Course Reference WIS 5
19 Sep 02 M.S.Rogers
Weld Defects
Defects which may be detected by visual
inspection can be grouped under five headings
Cracks
Surface irregularities
Contour defects
Root defects
Miscellaneous
Weld Defects
Other associated defects
Cavities
Solid inclusions
Set up irregularities
Parent material defects
Cracks
The four essential crack mechanisms
Hydrogen (HICC)
Solidification (Hot tears)
Reheat cracks
Lamellar tearing
Cracks
Longitudinal parent metal crack Transverse weld metal crack
Longitudinal weld metal crack Lamellar tearing
19 Sep 02
Transverse crack Center line crack M.S.Rogers
Surface Irregularities
Undercut
An irregular groove at the toe of a weld run in
the parent metal
 Excessive amps/volts
 Excessive travel speed
 Incorrect electrode angle
 Excessive weaving
 Incorrect welding technique
 Electrode too large
Cap Undercut
19 Sep 02
Root undercut Cap undercut M.S.Rogers
Overlap
An imperfection at the toe or root of a weld caused by
metal flowing on to the surface of the parent metal
without fusing to it
 Contamination
 Slow travel speed
 Incorrect welding
technique
 Current too low
Overlap
Crater Pipe
Crater pipe is a shrinkage defect and not a gas defect, it
has the appearance of a gas pore in the weld crater
 Too fast a cooling rate
 Deoxidization
reactions and liquid to
solid volume change
Crater crack
(Star crack)
 Contamination
Crater Pipe
Weld crater
Crater pipe
Contour Defects
Contour Defects
Incomplete filled groove Poor cap profile
Incomplete filled groove Excessive cap height

+ Lack of sidewall fusion
Excess cap reinforcement Incomplete filled groove
Root Defects
Root Defects
 Low Amps/volts
 Large Root face
Incomplete root fusion  Small Root Gap

 Fast Travel Speed
 Incorrect Electrode
Angle
Incomplete root penetration  Contamination
Root Defects
Lack of root fusion Lack of root Penetration
Lack of root penetration Lack of root fusion
Root Defects
A shallow groove, which may occur in the root of a butt weld
 Root faces too large

 Root gap too large
 Excessive back purge
pressure during TIG welding
Concave root
 Excessive root bead grinding
before the application of the
second pass
Concave Root
Root Defects
Root penetration bead in excess in accordance with the
relevant specification being used
 Root faces too small

 Root gap too large
 Excessive amps/volts
Excessive root penetration  Slow travel speed
Excessive Root Penetration
Concave root Excessive root penetration
Root Defects
A shallow groove caused by contraction in the weld
metal along each side of the penetration bead
 Insufficient weld metal

deposited in the root
pass
 Too fast a cooling rate
during the application of
Shrinkage groove the root bead pass
 Poor welding technique
Root Defects
A localized collapse of the weld pool due to excessive
penetration resulting in a hole in the root run
 High Amps/volts
 Small Root face
 Large Root Gap
 Slow Travel Speed

Burn through
Burn
Through
19 Sep 02
Burn through M.S.Rogers
Root Coking/Oxidized Root
 Loss or insufficient
back purging gas
 Most commonly
occurs when welding
stainless steels
 Purging gases
include argon, helium
and occasionally
nitrogen
Miscellaneous Defects
 Accidental striking of
the arc onto the parent
material
 Faulty electrode holder
 Poor cable insulation
 Poor return lead

clamping
Arc strike
 Excessive current
 Damp electrodes
 Contamination
 Incorrect wire feed

speed when welding
with the MAG welding
Spatter process
Inclusions
Gas Cavities
Gas pore Cluster porosity  Loss of gas shield
 Damp electrodes
 Contamination
Blow hole  Arc length too large
Herringbone porosity
 Damaged electrode flux
 Moisture on parent
material
Root piping
 Welding current to low
Gas Cavities
Porosity
19 Sep 02
Root piping M.S.Rogers
19 Sep 02
Cluster porosity Single gas pore M.S.Rogers
Solid Inclusions
Slag inclusions are defined as a non-metallic inclusion
caused by some welding process
 Slag originates from welding
flux
 MAG and TIG welding
process produce silica
Slag inclusions Lack of sidewall inclusions
fusion with
associated slag  Slag is caused by
inadequate cleaning
 Other inclusions include
tungsten and copper
inclusions from the TIG and
Parallel slag lines MAG welding process
Interpass slag inclusions Elongated slag lines
Set-up Irregularities
Plate/pipe Linear Misalignment

(Hi-Lo)
Poor fit-up
Angular Misalignment
Linear Misalignment
Parent Material Defects
A welding inspector should also inspect the parent
material for any visible defects
Mechanical damage Lap
Lamination
Segregation line
Plate Lamination
Weld Repairs
Weld Repairs
 A weld repair may be used to improve weld profiles
or extensive metal removal
 Repairs to fabrication defects are generally easier
than repairs to service failures because the repair
procedure may be followed
 The main problem with repairing a weld is the
maintenance of mechanical properties
 During the inspection of the removed area prior to
welding the inspector must ensure that the defects
have been totally removed and the original joint
profile has been maintained as close as possible
Weld Repairs
The specification or procedure will govern how
the defective areas are to be removed. The
method of removal may be
 Grinding
 Chipping
 Machining
 Filling
 Arc air gouging
 Oxy-gas gouging

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Welding Inspection

Parent material defects

Solidification (Hot tears)

Longitudinal parent metal crack Transverse weld metal crack

Longitudinal weld metal crack Lamellar tearing

 Excessive travel speed

 Incorrect electrode angle

 Incorrect welding technique

 Electrode too large

 Slow travel speed

 Too fast a cooling rate

Incomplete filled groove Poor cap profile

Incomplete filled groove Excessive cap height

Incomplete root fusion  Small Root Gap

Lack of root fusion Lack of root Penetration

 Root faces too large

 Root faces too small

Excessive root penetration  Slow travel speed

 Insufficient weld metal

 Small Root face

 Large Root Gap

 Slow Travel Speed

 Faulty electrode holder

 Poor cable insulation

 Poor return lead

 Incorrect wire feed

Plate/pipe Linear Misalignment

Mechanical damage Lap

 Arc air gouging

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