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Prior to welding
- Lack of Penetration
- Lack of fusion
- Undercut
- Slag inclusion
- Porosity
- Crack
- Distortion
Welding Defects
Lack of Penetration: Defect occurs a the root of the joint when the weld metal fails to reach it or weld metal fails to fu
If incorrect size of electrode is used, low welding current & Faulty fit-up and inaccurate joint preparation.
Lack of Fusion: lack of fusion is defined as a condition were boundaries of un-fused metal exist between the weld me
This occurs mainly due to presence of scale, dirt, oxide, slag and other non metallic substance which prevents the wel
Undercut: This defect appears as a continuous or discontinuous groove at the toes of a weld pass and is located on th
Cause:
Slag inclusion: Improper cleaning of slag between the deposition of successive passes. Presence of heavy mill scale, lo
Note: To avoid slag inclusion, clean the slag thoroughly between the weld pass. Keep the joint surface and bare filler w
The presence of gas pores in a weld caused by entrapment of gas during solidification is termed as porosity.
Cause of Porosity?
3.Presence of oil, grease, moisture and mill scale on the weld surface.
Crack:
What is Crack?
Fracture of metal is called crack, there are two types of cracks: cold crack & Hot crack.
Cold crack usually occur in HAZ of the base metal when this zone becomes hard and brittle due to rapid cooling after
Precaution: Use of low carbon equivalent materials, Higher heat input during welding, preheating, use of low hydroge
A weld is considered faulty if it has lack of reinforcement, excessive reinforcement or irregular profile.
Distortion: Due to weldment is locally heated, the temperature distribution in the weldment is not uniform and chang
Distortion is cause when the heated weld region contacts non uniformly, causing shrinkage in one part of the weld to
Distortion in fillet welds, is similar to that in butt welds: transverse and longitudinal shrinkage as well as angular distor
o reach it or weld metal fails to fuse completely in the root faces of the joint.
metal exist between the weld metal and base metal or between the adjacent layers of weld metals.
substance which prevents the weld to reach melting temperature. Improper deslagging between the weld pass.
of a weld pass and is located on the base metal or in the fusion face of a multi pass weld. It occurs prominently on the edge of a fillet weld d
es. Presence of heavy mill scale, loose rust, dirt, grit and other substances present on the surface of base metal.
p the joint surface and bare filler wire perfectly clean, avoid undercut and gaps between weld pass and use proper welding consumables.
on is termed as porosity.
brittle due to rapid cooling after the weld metal has been deposited and sufficient hydrogen has been absorbed by the weld metal form th
r irregular profile.
eldment is not uniform and changes take place as welding processes, Typically, the wd metal and the base metal heat affected zone immed
rinkage in one part of the weld to exert eccentric forces on the weld cross section. The distortion may appear in butt joints as both longitu
shrinkage as well as angular distortion results from the unbalanced nature of the stresses in the welds.
ntly on the edge of a fillet weld deposited in the horizontal position.
metal heat affected zone immediately adjacent to it are at a temperature substantially above that of the unaffected base metal.
ear in butt joints as both longitudinal and transverse shrinkage or contraction, and as angular change ( rotation) when the face of the weld
naffected base metal.
tion) when the face of the weld shrinks more than the root.
PWHT
Why it is required?
This is done to remove residual stress left in the joint which may cause brittle fracture
Released for blasting and painting at painting yard after spool fabrication:
Primer: Thickness (DFT) dry film thickness to be check (DFT Gauge Elcometer)
After completion of Primer, First, Second, and Final coat, DFT to be check according to the project specification.
Material handling: Proper protection / care to be taken at the time of transporting to construction site.
to the project specification.
o construction site.
API 5L
24"
Sch. XS 12.7 mm
Tolerances
1.905 14.605
1.5875 11.1125
11.1125 ~ 14.605