Welding Defects

TWI
CSWIP 3.1
WIS 5
WELDING INSPECTION
PRACTICAL VISUAL
INSPECTION OF WELDS
Copyright © 2004, TWI Ltd World Centre for Materials Joining Technology
Features to Consider
Butt welds - Size
Weld cap width

Excess weld
metal height
Root
penetration
Root bead width
Butt welds - Profile
x
x x
Butt welds - Toe Blend
x
x x
Butt welds - Weld Width
Welding Defects
Incomplete root penetration
Causes
• Too small a root gap
• Arc too long
• Wrong polarity
• Electrode too large for joint
preparation
• Incorrect electrode angle
• Too fast a speed of travel for
current
Welding Defects
a) Excessively thick root face
b) Too small a root gap
c) Misplaced welds
d) Power input too low
e) Arc (heat) input too low
Welding Defects
Too large diameter

electrode
Smaller (correct)
diameter electrode
Lack of sidewall
fusion due to arc
deflection
Welding Defects
Incomplete root Fusion
Causes
• Too small a root gap
• Arc too long
• Wrong polarity
• Electrode too large for joint
preparation
• Too fast a speed of travel for
current
Welding Defects
Root concavity
Causes
• Root gap too large
• Insufficient arc energy
• Excessive back purge TIG
Welding Defects
Excess Root Penetration
Causes
• Excessive amperage during
welding of root
• Excessive root gap
• Poor fit up
• Excessive root grinding
• Improper welding
technique
Welding Defects
Root undercut
Causes
• Root gap too large
• Excessive arc energy
• Small or no root face
Welding Defects
Cap Undercut
Causes
• Excessive welding current
• Welding speed too high
• Excessive weave
• Electrode too large
Welding Defects
Overlap
Excess weld
metal
Welding Defects
Lack of fusion
Causes
• Contaminated weld preparation
• Amperage too low
• Amperage too high (welder increases speed of
travel)
Welding Defects
Incompletely Filled Groove
& Lack of Side wall Fusion
• Causes
• Insufficient weld metal deposited
• Improper welding technique
Welding Defects
Inter run Incompletely Filled Groove
Causes
• Insufficient weld metal deposited
Welding Defects
Incompletely Filled Groove
Welding Defects
Gas pores / Porosity
Causes
• Excessive moisture in flux or preparation
• Contaminated preparation
• Low welding current
• Arc length too long
• Damaged electrode flux
• Removal of gas shield
Welding Defects
Gas pores / Porosity
Welding Defects
Inclusions - Slag
Causes
• Insufficient cleaning between passes
• Welding over irregular profile
• Incorrect welding speed
Welding Defects
Inclusions - Slag
Causes
• Insufficient cleaning between passes
• Welding over irregular profile
• Incorrect welding speed
Welding Defects
Poor (convex) weld bead

profile resulted in pockets
of slag being trapped
between the weld runs
Smooth weld bead

profile allows the slag
to be readily removed
between runs
Welding Defects
Inclusions - Tungsten
Causes
• Contamination of weld Caused by tungsten touching
weld metal or parent metal during welding using the
TIG welding process
Welding Defects
Burn Through
Causes
• Excessive amperage during welding of root
• Excessive root grinding
Welding Defects
Spatter
Causes
• Excessive arc energy
• Excessive arc length
• Damp electrodes
• Arc blow
Welding Defects
Arc Strikes
Causes
• Electrode straying onto

parent metal
• Electrode holder with

poor insulation
• Poor contact of earth

clamp
Welding Defects
Mechanical Damage
Chisel
Chisel Marks
Marks Pitting Corrosion Grinding Marks
Welding Defects
Non-alignment of two abutting edges
2mm
Also Known as: Hi Low. Mismatch. or Misalignment
Welding Defects
50mm
3mm
Angular distortion.
Measure the distance to the edge of the plate (50mm).
Use a straight edge (rule) to find the amount of
distortion then measure the space (3mm).
This reported as Angular distortion 3mm in 50mm
Welding Defects
Linear
Excess weld metal height
Lowest plate to highest point
3 mm
Excess penetration Lowest Linear misalignment
plate to highest point measured in mm
Angular
3mm
Angular misalignment measured in mm

Welding Defects

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Welding Defects

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TWI

Weld cap width

Root bead width

b) Too small a root gap

d) Power input too low

e) Arc (heat) input too low

Too large diameter

Poor (convex) weld bead

Smooth weld bead

• Electrode straying onto

• Electrode holder with

• Poor contact of earth

Also Known as: Hi Low. Mismatch. or Misalignment

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