Prepared by Vinod Bhagat
Welding defects
Slag inclusion : Inclusions may be in the form of slag or any other foreign material, which
does not get a chance to float on the surface of the solidifying weld metal and thus gets entrapped inside the same. Inclusions lower the strength of the joint and make it weaker. Causes Failure to remove slag Entrapment of refractory oxides Improper joint design Oxide inclusions Slag flooding ahead of welding arc Entrapped pieces of electrode covering remedies Clean surface of any previous weld bead Power wire brush the previous weld bead Increase groove angle of joint Provide proper gas shielding Reposition work to prevent loss of slag control Use undamaged electrodes
Incomplete penetration: Penetration is the distance from base plate top surface to the,
maximum extent of the weld nugget. Causes
Less arc current Faster arc travel speed Longer arc length Electrode diameter is too large Improper electrode position Improper joint design
remedies
Use proper arc current Use less arc travel speed Use shorter arc length Use small electrode Maintain proper electrode position Change or redesign then joint
Spatter: Spatters are the small metal particles which are thrown out of the arc during welding and get
deposited on the base metal around the weld bead along its length.
Causes
Bad electrode Excessively long arc length Excessively high or low welding current Too high or low arc voltage Unstable condition of machine
remedies
Choose proper electrode Reduce arc length Use proper welding current Properly adjust arc voltage Proper maintenance
Prepared by Vinod Bhagat Distortion: - While welding a job, base metal under the arc melts, base metal ahead gets preheated and the base metal portion already welded starts cooling. There is a good amount of temperature difference at various points along the joint and thus at any instant certain areas of base metal expand and others including weld bead contract.This phenomena leads to distortion. Distortion is the change in shape and difference between the positions of the two plates before welding and after welding.
Causes
High cooling rate Small diameter electrode Residual stress Poor clamping and fixtures Slow arc travel speed
remedies
Cooling rate should be reduced Use proper diameter electrode Reduce the residual stress Use proper clamps ,jigs and fixtures Maintain proper arc travel speed
Undercut: In under cutting a groove gets formed in the parent metal along the sides of the weld
bead. Groove reduces the thickness of the plate and thus the area along the bead, which in turn weakens the weld.
Causes
Higher current Too large electrode diameter Excessive weaving Faster arc travel speed Use proper current
remedies
Use proper electrode Weaving should be proper and as per requirement Maintain proper arc travel speed
Overlap: Overlapping is just reverse to undercutting. An overlap occurs when the molten metal from
the electrode flows over the parent metal surface, and remains there without getting properly fused and united with the same.
Causes
Lower arc current Slower arc travel speed Improper joint geometry Longer arc
remedies
Maintain and use proper arc current Maintain proper arc travel speed Use proper joint geometry Use proper arc
Prepared by Vinod Bhagat Cracks: Cracks may be on microscopic scale or macroscopic scale depending upon their size. Cracks may appear in the base metal, base metal-weld metal boundary, or in the weld metal. Cracks may be on the weld surface or under the weld bead. Cracks may appear in the crater or in the root.
Causes
Highly rigid joint
remedies
Use preheat. Relieve residual stress Mechanically. Minimize shrinkage stresses using backstep welding sequence. Change welding current and travel speed. Weld with covered electrode negative; Change to new electrodes. Bake electrodes to remove moisture. Reduce root opening; build up the edges with weld metal. Increase electrode size, raise welding current; reduce travel speed. Use filler metal low in sulfur. Change to balanced welding on both sides of joint. Use low-hydrogen welding process; preheat and hold for 2 hours after welding or postweld heat treat immediately. Use low heat input, deposit thin layers; change base metal. Use preheat; anneal the base metal. Redesign the weldment change the welding sequence; apply intermediate stress-relief heat treatment
Excessive dilution
Defective electrodes Poor fit-up Small weld bead
High-sulfur base metal Angular distortion Hydrogen in welding atmosphere
Hot cracking
Low ductility High residual stress
Prepared by Vinod Bhagat
Poor weld bead appearance: A weld bead appear to be poor if it is not deposited straight
or the weld bead width varies .
Causes
Bad electrode. Improper manipulation. Too high welding current and too large electrode diameter. Base metal is overheated. lack of fusion in the weld bead. Tip is worn.
remedies
Choose proper electrode. Properly choose travel speed and welding sequence. Properly choose welding current and electrode diameter. Reduce welding current. More practice. Replace a new tip.
Blow holes and porosity : Porosity is a group of small voids, whereas blow hole or gas pocket is a
comparatively bigger isolated hole or cavity. They occur mainly due to the entrapped gases. The parent metal melted under the arc tends to absorb gases like hydrogen, carbon monoxide, nitrogen and oxygen if they are present around the molten weld metal pool.
Causes
Wet, unclean or damaged electrode. Base metal surface covered with oil, rust etc. Over travelling speed. Over currents Excessively long or short arc length. Too thick base-metal or too fast cooling rate.
remedies
Properly maintain and store electrode Properly clean base metal prior to welding Reduce travel speed Use proper welding current Maintain proper arc length Proceed proper pre-heating.
Poor fusion: Sometimes the molten metal deposited by the electrodes does not fuse properly with the
cold base metal and the two do not unite properly and completely. The fusion may be lacking at the root, sides, or between two runs in a multirun weld.
Causes
Incorrect speed Current improperly adjusted Faulty preparation Improper electrode size Improper welding technique
remedies
Use proper speed Use proper current to allow deposition and penetration Use proper cleaning,edge preparation and positioning Select proper electrode Weave must be sufficient to melt sides of joint
Prepared by Vinod Bhagat
