WELDING SECTION WELDING DEFECT Under cut Lack of penetration Porosity Cracks Excessive spatter Slag in fusion Distortion

UNDER CUT This can be defined as the irregular groove at a toe of a rod in the parent metal Causes Poor angle of electrode Poor manipulation of electrode Prevention Maintain a good control of electrode or blow pipe Use the correct handle of blow pipe or electrode LACK OF PENETRATION This is the failure of weld metal to extend to the root of a joint Causes bad preparation of joint insufficient heat or current Prevention Ensure the correct preparation of a joint Use an adequate current or heat input in gas welding ` POROSITY This can be defined as a group of gas in the weld metal Causes Oil or grease Damp electrode (wet electrode) Rust in parent metal

Prevention Re dry electrode before use Plate must be wire brush before welding commence Plate and electrode should be free from oil or grease LACK OF PENETRATION This is defined as lack of union between weld metal and parent metal Causes Insufficient heat of current Poor preparation of job Use of bare wire electrode Prevention Good preparation of job Use coated electrode (flux coated) Use adequate current or heat.

Note Bare wire electrode is used in welding pipe in breweries industries Angle of electrode 60o -70o Welding symbol Single V Single U Double V Double U SLAG IN FUSION This is an entrapment between a rod, it cause by. Too much welding current Poor surface of plate Poor manipulation of electrode or blow pipe Carelessness in slag deliver

Prevention Ensure good manipulation of weld Make sure slag are properly removed and clean through chipping EXCESSIVE SPATTERS This can be found in an arc welding process only, its causes are Entrapment of gases Damp electrode Using high current Prevention Re-dry electrode before use Use a minimum arc length CRACKS This is the line in discontinuity produce by fracture; it may be longitudinal, transverse and edge. Causes uneven expansion uneven contraction Prevention Use blow hydrogen electrode with less sulphur content Pre heat joints and post heat DISTORTION This is the alteration or sprinkage welded fabrication brought by the heating of welding. Cause amount of heat input internal stress uneven expansion and contraction Prevention use a good welding sequence pre heating of job post heating of job

 ensure maximum of heat input

Note Moving fast when welding will result into excessive spatters. When using welding symbol or before one can use welding symbol the thickness of the material has to be taken into consideration, that is when the of the parent metal is beyond 40mm then welding symbol can be use but if not the other way round should be the case