WELDMENT DISCONTINUITY

By: JAMES F. PORTER, JR.

WELDMENT

DISCONTINUITY
An interruption of the typical structure of a material, such as a lack of homogeneity in its mechanical, metallurgical, or physical characteristics. A discontinuity is not necessarily a defect.
3

DEFECT
A discontinuity or discontinuities that by nature or accumulated effect (for example, total crack length) render a part or product unable to meet minimum applicable acceptance standards or specifications. This term designates rejectability.
4

WELDMENT DEFECTS
A. DEFECTIVE PROPERTIES

B.
C.

DIMENSIONAL DEFECTS
STRUCTURAL DEFECTS

DEFECTIVE PROPERTIES
A. BASE METAL

B.

WELD METAL

DIMENSIONAL DEFECTS
A. B. DISTORTION INCORRECT JOINT PREPARATION C. INCORRECT WELD SIZE D. INCORRECT WELD PROFILE E. INCORRECT FINAL DIMENSION
7

AVOID OVERWELDING

EDGE PREPARATION

EDGE PREPARATION

10

INTERMITTENT WELDING

11

MINIMUM WELD PASS

12

WELD NEAR NEUTRAL AXIS

13

BALANCE WELD AROUND NEUTRAL AXIS

14

PRE-SET PARTS

15

BACKSTEP WELDING

16

WELD SEQUENCE

17

WELD SEQUENCE

18

PRE-BENDING

19

BACK-TO-BACK CLAMPING

20

Weld Profile/Size

21

Weld Profile/Size

22

Weld Profile/Size

23

Weld Profile/Size

24

ACCEPTABLE GROOVE WELD PROFILE

25

ACCEPTABLE GROOVE WELD PROFILE

26

UNACCEPTABLE GROOVE WELD PROFILE

27

UNACCEPTABLE GROOVE WELD PROFILE

28

UNACCEPTABLE GROOVE WELD PROFILE

29

UNACCEPTABLE GROOVE WELD PROFILE

30

DESIRABLE FILLET WELD PROFILE

31

ACCEPTABLE FILLET WELD PROFILE

32

UNACCEPTABLE FILLET WELD PROFILE

33

UNACCEPTABLE FILLET WELD PROFILE

34

UNACCEPTABLE FILLET WELD PROFILE

35

STRUCTURAL DEFECTS
1.

2. 3. 4. 5. 6. 7. 8. 9.

Porosity Slag Inclusion Tungsten Inclusion Incomplete Fusion Undercut/Overlap Incomplete Penetration Underfill Crack Distortion
36

Porosity

Porosity gas pores formed by entrapped gas during solidification of molten metal Worm-hole An elongated or tubular cavity formed by entrapped gas during the solidification of molten metal.
37

Porosity
CAUSES: 1. 2. 3. 4. 5. 6. Inadequate cleaning Moisture Inadequate shielding Damaged/contaminated flux Windy Wrong polarity

38

Slag Inclusion

nonmetallic solid material entrapped in weld metal or between weld metal and base metal
39

Slag Inclusion
CAUSES: 1.Inadequate cleaning 2.Improper electrode manipulation

40

Incomplete Fusion

A weld discontinuity in which fusion did not occur between weld metal and fusion faces or adjoining weld beads.
41

Incomplete Fusion
CAUSES: 1.Low current 2.Improper electrode manipulation 3.Inadequate cleaning 4.Inadequate preheating

42

Incomplete Fusion at Weld Face

43

Incomplete Fusion of Flare Bevel Groove Welds

44

Incomplete Fusion Between Weld & Base Metal

45

Undercut/Overlap

1. Undercut - A groove melted into the base metal adjacent to the weld toe or weld root and left unfilled by weld metal. 2. Overlap - The protrusion of weld metal beyond the weld toe or weld root.

46

Undercut/Overlap
CAUSES: 1.Undercut high current - Improper electrode manipulation 2. Overlap - low current Improper electrode manipulation

47

Incomplete Penetration/Underfill

1. Underfill - A condition in which the weld face or root surface extends below the adjacent surface of the base metal. 2. Incomplete Joint Penetration - A joint root condition in a groove weld in which weld metal does not extend through the joint thickness

48

Partial Penetration

Partial joint penetration groove welds are commonly specified in lowly loaded structures. Partial penetration joint above without discontinuities is an acceptable condition where appropriate.

49

Incomplete Penetration
CAUSES:
1. Wrong edge preparation Included angle Root face Root gap or root opening 2. Large electrode 3. Fast travel speed
50

Crack

Fracture-type discontinuity characterized by a sharp tip and high ratio of length and width to opening displacement. Above are several different representations of weld cracking.

51

Crack
CAUSES:
1. Inadequate preheating 2. Wrong electrode 3. Too much restraint on joint

52

Longitudinal Crack

53

Transverse Crack

54

Throat Crack

55

Toe Crack

56

Closeup of Crater Cracks in Aluminum Weld

57

Propagation of Crater Crack in Aluminum Weld

58

Underbead Cracks

59

Radiograph of Longitudinal Crack

60

Radiograph of Transverse Crack

61