Quality Of Welding

Welding Defects
(Root Cause Analysis)

Aug 25 2004 (v 00)

Why Weld Defects Occur?

Porosity
Lack of supervision
Incompetent welder / operator
Poor performance of welding
equipment
In-proper handling / use of
welding
consumables
Poor joints fit-ups
Weather condition
Quality & characteristic of base
metal & etc

Incomplete Penetration
Lack of supervision
Incompetent welder / operator.
Poor joints fit-ups
Welding current too low
Wrongly use of electrode size (too
big)
Arc length too long
Melting filler rod instead of
welding
Insufficient gas shielding (GTAW
SUS)

Slag / Tungsten Inclusions

Lack of supervision
Incompetent welder / operator
Poor performance of welding
equipment
In-proper handling / use of
welding tools
In-proper handling / use of
welding
consumables
Poor joints fit-ups & etc

Cracks
Lack of supervision
Incompetent welder / operator.
In-proper use of welding
consumables.
Weather condition.
Quality & characteristic of base
metal.
In-proper control of preheating &
post heating
process & etc

Incomplete Fusions
Lack of supervision
Incompetent welder / operator
Poor performance of welding
equipment
In-proper handling / use of
welding tools
In-proper handling / use of
welding
consumables
Poor joints fit-ups & etc

Undercut, Excess Penet. Root

Concavity
Lack of supervision
Incompetent welder / operator
Misalignment
Welding current too high
Poor joints fit-ups
Wrong electrode angle

What Are The Possible Root Causes

Lack Of Supervision
Inadequate Knowledge And Awareness In Quality
Control At All Levels
Poor Discipline and Negative Working Attitude
Lack Of Responsibility Toward Quality Control At
Supervisory Level
Inefficient Quality Monitoring & Surveillance Plan
Work Environment Poor Work Site Management &
Control
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Areas Of Concern
Quality Is Client Driven, MSE Has Not Set Clear
Quality Goals & Targets And Communicate To Shop
Floor
Ineffectiveness Of Implementation Of QMS
Expectations And Deliverables Are Not Clearly
Defined At Supervisors, QA Personnel And QC
Personnel Levels
Quality Is A QA/QC Function, Supervisors are more
Concern In Timely Delivery Of Projects
Subcontractors Management Has No Commitment
Toward Quality Goals
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CAUSE EFFECT (FISHBONE) DIAGRAM

WELD DEFECT ROOT CAUSE ANALYSIS
BASE MATERIAL
QUALITY

WELDING
CONSUMABLES

WELDER / OPERATOR
SKILLS

Using of contaminated
electrodes/fluxes

Welding unkilled
steels

Using of cold w elding

consumables

Welding of pitting
corroded plates

Poor house keeping

Welding at dusty
environment

Using of too
narraow groove

Using of unqualified
w elder for tack w elding

Not using w ind

protectors.

Welding on w et
/ oily surfaces

Poor accessibility
for w elding

Not grinding rusted

/mill scales and
gouged surfaces

Not using proper run

and run off plates

Large gps

JOINT FITUPS

Poor control and

guiding w elders

Lack of Quality
aw areness/ targets
Lack of prcess
controlls

SUPERVISOR ROLE

Non uniform
travel speed

POROSITY
Wrong selection of
w elding process
Using of SMAW w here
more appropriate
GTAW process

Lack of responsibility
and commitment
tow ards quality

Poor organizing
of site protection
from w ind

Exocentric or over
loading on rotators.

No calibration of
equipment

Engaging of
unqualified w elders

Lack of job / WPS

know ledge

Poor controls on
electrode baking
and handling

Unstable current

Using of damaged
gas hoses

Using of w rong size

and clod electrodes

Poor in keeping of
w elders records
and repair rates

Using of tack w elds

in the groove for
single side joints

Unstable arc voltage

Non uniform
rotation of
w elding rotators

Poor eye sight,

over fatigue and
personal reasons

Welding on w et
/ oily surfaces

Using of unskilled gas

cutters, gougers and
grinders

Gas cutting notches on

edge preoeration

Not keeping joint for

easy w elding position

WELDING ENVIRONMENT

Using of
contaminated
filler metals

Improper aligning
of rotators

Using of high or
low flow gasses

Using of long arcs

Welding at w indy
environment

Storing of
electrodes and filler
metals together
w ith oils, paints.

Using of w rong
w elding parameters

Using of excessive
electrode stickout

Not using HF units for

GTAW w elding

Frequent
pow er tripping

Lack of commitment
tow ards quality

Lack of w elding/
WPS know ledge

Using of w rong
size electrode

Poor storage and

handling of w elding
consumables

Using of plates oily/

greased

Not using of w eather

protectors

Poor attitude of
w elder/ operator

Using of
unbaked w elding
consumables

Using of poor
quality shielding /
purging gasses

Welding of old and

already used materials
in the process

Lack of skillness

Wrong selection of
type of electrodes
/ fluxes

Using of rusted plates

WELDING
EQIPMENT

Using of GMAW w here

FCAW can be used
Using of SMAW w here
more appropriate SAW
process
Lack of understanding on
application of process

WELDING PROCESS

CAUSE EFFECT (FISHBONE) DIAGRAM

WELD DEFECT ROOT CAUSE ANALYSIS

CAUSE EFFECT (FISHBONE) DIAGRAM

WELD DEFECT ROOT CAUSE ANALYSIS

CAUSE EFFECT (FISHBONE) DIAGRAM

WELD DEFECT ROOT CAUSE ANALYSIS

CAUSE EFFECT (FISHBONE) DIAGRAM

WELD DEFECT ROOT CAUSE ANALYSIS

CAUSE EFFECT (FISHBONE) DIAGRAM

WELD DEFECT ROOT CAUSE ANALYSIS

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