Welding Defects

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KAMA 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
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M.S.Rogers

Weld Defects
Other associated defects

Cavities
Solid inclusions
Set up irregularities

Parent material defects

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KAMA M.S.Rogers

Welding Defects
Cracks
Classified by Shape
Longitudinal
Transverse
Branched
Chevron

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Classified by Position
HAZ
Centreline
Crater
Fusion zone
Parent metal

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Cracks

Longitudinal parent metal crack

Longitudinal weld metal crack

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Transverse weld metal crack

Lamellar tearing

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Surface Irregularities

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KAMA M.S.Rogers

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
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KAMA M.S.Rogers

Cap Undercut

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KAMA 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
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KAMA M.S.Rogers

Overlap

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KAMA M.S.Rogers

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)

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Contamination

KAMA M.S.Rogers

Crater Pipe
Weld crater

Crater pipe

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KAMA M.S.Rogers

Contour Defects

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KAMA M.S.Rogers

Contour Defects

Incomplete filled groove

Poor cap profile

Incomplete filled groove

+ Lack of sidewall fusion

Excessive cap height

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KAMA M.S.Rogers

Copyright 2003 TWI Ltd

M.S.Rogers

Root Defects

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KAMA M.S.Rogers

Root Defects
Low Amps/volts

Large Root face

Incomplete root fusion

Small Root Gap

Fast Travel Speed

Incorrect Electrode
Angle
Incomplete root penetration
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Contamination
KAMA M.S.Rogers

Root Defects

Lack of root fusion

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Lack of root Penetration

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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

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Excessive root bead grinding

before the application of the
second pass
KAMA M.S.Rogers

Concave Root

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KAMA M.S.Rogers

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

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Slow travel speed

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Excessive Root Penetration

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KAMA M.S.Rogers

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

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KAMA M.S.Rogers

Miscellaneous Defects

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KAMA M.S.Rogers

Miscellaneous Defects
Accidental striking of
the arc onto the parent
material
Faulty electrode holder

Poor cable insulation

Arc strike
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Poor return lead

clamping
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Miscellaneous Defects
Excessive current
Damp electrodes

Contamination

Spatter
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Incorrect wire feed

speed when welding
with the MAG welding
process
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Inclusions

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KAMA M.S.Rogers

Gas Cavities
Gas pore

Cluster porosity

Loss of gas shield

Damp electrodes
Contamination

Blow hole
Herringbone porosity

Arc length too large

Damaged electrode flux

Moisture on parent
material
Root piping
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Welding current to low

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Gas Cavities

Porosity

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Root piping

KAMA M.S.Rogers

Solid Inclusions
Slag inclusions are defined as a non-metallic inclusion
caused by some welding process
Slag originates from welding
flux

Slag inclusions

Lack of sidewall
fusion with
associated slag

Parallel slag lines

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MAG and TIG welding

process produce silica
inclusions
Slag is caused by
inadequate cleaning
Other inclusions include
tungsten and copper
inclusions from the TIG and
MAG welding process
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Set-up Irregularities

Plate/pipe Linear Misalignment

(Hi-Lo)

Poor fit-up

Angular Misalignment
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KAMA M.S.Rogers

Parent Material Defects

A welding inspector should also inspect the parent
material for any visible defects

Mechanical damage

Lap

Lamination

Segregation line

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KAMA M.S.Rogers

Plate Lamination

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KAMA M.S.Rogers