Weld Defects

Significance of defects

Incomplete fusion can influence brittle fracture in either static or dynamic loads. The effect of lack of fusion is almost same as Lack of penetration Arc strikes consist of un annealed martensite and contains a number of small fissures. These small fissures can lead to brittle fracture when remaining load bearing material has been sufficiently reduced in cross section.

A Defect is Rejactable discontinuity A defect is a discontinuity but a discontinuity need not be a defect. Acceptance of a discontinuity is based on different factors. Few examples are as follows: Stresses to which the parts will be subjected during service Type of Material Used The environment Consequence of failure

Acceptance Standards Dictate the type of Inspection and testing. The weld defects can be broadly classified into two types. Planer defects / two dimensional defects (Crack, Lack of Fusion, Lack of Penetration, Severe Undercut These are not acceptable defects) Volumetric Defects / Three Dimensional defects.(Slag inclusion, cavities, Porosities are acceptable to certain extent)

General Reasons for Defects

Lack of Know-how Welding Process Characteristics Base metal Composition Defective welding filler metal Joint design Welding Environment (Wind, fit-up, Temperature etc.)

Defects involving inadequate bonding Lack of Fusion

Due to improper manipulation of electrode Incorrect position of electrode Low welding current Too rapid arc advance Improper joint fit-up

INCOMPLETE PENETRATION Incorrect Joint design Improper welding parameters specifically current Incorrect electrode size Incorrect polarity where DC is used Un fused root can cause stress concentration that could lead to brittle failure

Inclusions

Slag Inclusion Because of the string action of the arc slag may be forced down to the molten metal and the high viscosity of weld metal, rapid solidification at a low temperature leads to entrapment. Preheating the base metal to control the rate of solidification will ensure release of slag from molten metal

Oxide Films In MIG welding oxides in the form of Globules are found in weld metal. The presence of such films seriously impairs the ductility of weld metal. This defect is rarely detectable except with the aid of a microscope

Tungsten Inclusions These are particles deposition in the weld metal from a tungsten electrode in TIG welding These inclusions are not generally considered harmful unless their size and number become excessive. Superimposed high frequency current for arc starting tends to minimize these inclusions

Geometric Defects Undercuts represents a depression into the base metal adjacent to the toe of the weld and it form a notch. A small amount of undercut under pulsating stress often acts as a starting point for fatigue cracks. Correct choice of current range and good manipulation of electrode during welding will avoid undercut

Burn through or excess penetration Occurs because of very high current and low travel speed. It is also called as icicles and are found at the root of the weld. Consumable inserts may be used to avoid excess penetration

Improper weld profile This occurs more in the case of fillet joints Excessive concave or convex beads are examples of this. These are caused because of improper weld parameters, electrode size & weaving. Visual examination is sufficient to decide these defects.

METALLURGICAL DEFECTS

CRACKS Hot cracking Caused because of restraint on the joint and the presence of higher carbon and sulfur. Segregation of weld metal due to bead shape also is a reason for these defects. MPI or LPI are used to detect surface defects while UT is suitable for internal cracks.

Cold cracking Cold cracking starts in the HAZ of the parent metal It is associated with combined effects of hydrogen, restraint and martensite formation Low hydrogen electrode and preheating minimizes cold cracking.

Crater cracks Cracks formed from a circular surface with a depression either in the weld or at the end of a weld. It is caused by a volume concentration of molten metal during solidification usually the result of abrupt interruption of the welding arc in the root run.

Gas porosity

Porosity is the presence of gas pockets of voids caused by the entrapment of gases evolved during weld metal solidification Porosity is caused due to improper shielding, rust on the weld face, too much generation of gas in the weld pool. Porosity is considered to be the least dangerous defect but is often an indication of damp electrodes having been used.

Arc Strikes

Localized heat affected zone caused by an arc is known as arc strikes Arc strikes produce hardening particularly in high carbon steels and alloy steels.

Embrittlement

The carbon and alloy steels containing 0.18% carbon tends to form brittle martensite structure in HAZ. This is avoided by controlled cooling rate.

Quality Of Welding
Welding Defects (Root Cause Analysis)

Why These 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

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

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

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)

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

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

Areas Of Concern
Quality Is Client Driven, Company 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

CAUSE EFFECT (FISHBONE) DIAGRAM WELD DEFECT ROOT CAUSE ANALYSIS

BASE MATERIAL QUALITY WELDING CONSUMABLES
Wrong selection of type of electrodes / fluxes

WELDER / OPERATOR SKILLS

Lack of skillness Poor attitude of w elder/ operator Lack of w elding/ WPS know ledge Using of excessive electrode stickout Welding on w et / oily surfaces Welding on w et / oily surfaces Using of long arcs Using of tack w elds in the groove for single side joints Poor accessibility for w elding Using of unskilled gas cutters, gougers and grinders Not grinding rusted /mill scales and gouged surfaces Large gps Lack of commitment tow ards quality

WELDING EQIPMENT
Frequent pow er tripping Not using HF units for GTAW w elding

Using of rusted plates Using of contaminated electrodes/fluxes Using of cold w elding consumables

Welding unkilled steels

Using of unbaked w elding consumables Using of w rong size electrode

Using of w rong w elding parameters Using of high or low flow gasses

Improper aligning of rotators

Unstable arc voltage

Welding of pitting corroded plates Welding of old and already used materials in the process

Using of poor quality shielding / purging gasses

Poor storage and handling of w elding consumables

Using of plates oily/ greased

Using of contaminated filler metals

Poor eye sight, over fatigue and personal reasons Not using w ind protectors.

Non uniform rotation of w elding rotators

Unstable current

Using of damaged gas hoses No calibration of equipment

Exocentric or over loading on rotators. Non uniform travel speed

Using of w rong size and clod electrodes

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

Not using of w eather protectors

Welding at w indy environment

Using of too narraow groove

Poor in keeping of w elders records and repair rates Lack of job / WPS know ledge

Engaging of unqualified w elders Poor control and guiding w elders Lack of responsibility and commitment tow ards quality

Poor house keeping

Welding at dusty environment

Using of unqualified w elder for tack w elding Gas cutting notches on edge preoeration

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

Poor organizing of site protection from w ind

Not using proper run and run off plates

Not keeping joint for easy w elding position

Poor controls on electrode baking and handling

Lack of Quality aw areness/ targets Lack of prcess controlls

WELDING ENVIRONMENT

JOINT FITUPS

SUPERVISOR ROLE

WELDING PROCESS

CAUSE EFFECT (FISHBONE) DIAGRAM WELD DEFECT ROOT CAUSE ANALYSIS

WELDING CONSUMABLES WELDER / OPERATOR SKILLS
Poor eye sight, over fatigue and personal reasons Poor quality of electrodes/fluxes Wrong selection of electrodes/fluxes Wrong selection of Tungsten electrode Using of wrong size electrode Using of damaged contaminated electrodes / fluxes / filler metals size electrode Not using any tools Poor attitude of welder/ operator Lack of welding/ WPS knowledge Not using welding tools for inter pass cleaning Using of too low current Using of too low voltage Lack of skill Lack of commitment towards quality Using of wrong welding parameters Not following of foreman instructions Not cleaning interpass Using too low welding speed Prequent power tripping Unstable arc voltage Improper aligning of rotators

WELDING EQIPMENT
Not using HF units for GTAW welding

Unstable current

Non uniform rotation of welding rotators No calibration of equipment

Exocentric or over loading on rotators. Non uniform travel speed

Using of incorrect tools

Using of too narraow groove Using of tack welds in the groove for single side joints

Poor in keeping of welders records and repair rates Lack of job / WPS knowledge Poor organizing of tools Poor monitoring

Engaging of unqualified welders Poor control and guiding welders

SLAG / TUNGSTEN INCLUSIONS

Wrong selection of welding process Using of SMAW where more appropriate GTAW process Using of SMAW where more appropriate SAW process

Using of unqualified welder for tack welding Using defective tools Non availability of proper tools Gas cutting notches on edge preoeration Not using proper run and run off plates

Poor accessibility for welding

Lack of responsibility and commitment towards quality Lack of Quality awareness/ targets

Using of unskilled gas cutters, Gougers and grinders

Not keeping joint for easy welding position

Poor planning and coordination with fitting group

Not keeping job in appropriate position Lack of process controls

WELDING TOOLS

JOINT FITUPS

Lack of understanding on application of process using

SUPERVISOR ROLE

WELDING PROCESS

CAUSE EFFECT (FISHBONE) DIAGRAM WELD DEFECT ROOT CAUSE ANALYSIS

WELDING CONSUMABLES WELDER / OPERATOR SKILLS
Poor attitude of welder/ operator Using of contaminated base metals Using of wrong size electrode Lack of qualification Lack of welding/ WPS knowledge Using of excessive electrode stickout Using of long arcs Using of high welding travel speed Lack of skill Lack of commitment towards quality Using of wrong welding parameters Using of low flow gasses Using of low current Using of improper bead laying sequence Poor eye sight, over fatigue and personal reasons Poor in keeping of welders records and repair rates Lack of job / WPS knowledge Poor organizing of site protection from wind Poor control and guiding welders Lack of prcess controlls Engaging of unqualified welders Poor planning and coordination with fitting group Lack of responsibility and commitment towards quality Lack of Quality awareness/ targets Wrong selection of welding process No calibration of equipment

BASE MATERIAL QUALITY

WELDING EQIPMENT
Frequent power tripping Improper aligning of rotators Not using HF units for GTAW welding

Unstable arc voltage

Using of poor quality shielding / purging gasses Using of damaged contaminated electrodes fluxes / filler metals

Using of plates oily/ greased

Non uniform rotation of welding rotators

Unstable current Exocentric or over loading on rotators. Non uniform welding travel speed

Not using of weather protectors

Welding at dusty environment

Using of too narraow groove

LACK OF FUSION
Using of SMAW where more appropriate GTAW process Using of SMAW where more appropriate SAW process Using of GMAW where FCAW can used Lack of understanding on application of process using

Using of unqualified welder for tack welding Welding at windy environment Inadquate bevel angle

Using of tack welds in the groove for single side joints Poor accessibility for welding

Using of square butt joints. Not using proper run and run off plates

Not grinding rusted /mill scales and gouged surfaces Not keeping joint for easy welding position

WELDING ENVIRONMENT

JOINT FITUPS

SUPERVISOR ROLE

WELDING PROCESS

CAUSE EFFECT (FISHBONE) DIAGRAM WELD DEFECT ROOT CAUSE ANALYSIS

WELDING CONSUMABLES
Using of Ecentric coated cectrodes

WELDER / OPERATOR SKILLS

Poor attitude of welder/ operator Poor eye sight, over fatigue and personal reasons Lack of welding/ WPS knowledge Using of excessive electrode stickout Lack of skill to manipulate beads

WELDING EQIPMENT & ACCESSORIES

Frequent power tripping Not using HF units for GTAW welding

Using of wrong size electrode

Lack of commitment towards quality Using of wrong welding parameters Using of low or high flow gasses

Unstable arc voltage

No calibration of equipment Non uniform welding travel speed

Using of poor quality shielding /purging gasses

Unstable current

Using of damged contaminated electrodes/ fluxes / filler metals

Using of too low currents Using of improper welding manipulation

Using of long arcs Using of too high welding travel speed

Using of tack welds in the groove for single side joints Using of unqualified welder for tack welding Not keeping joint for easy welding position Not using proper run and run off plates Using of too narrow groove

Poor accessibility for welding Inadquate bevel angle

Poor in keeping of welders records and repair rates Lack of job / WPS knowledge

INCOMPLETE PENETRATION
Poor control and guiding welders Using of SMAW where more appropriate GTAW process Lack of understanding on application of process using Using of GMAW where FCAW can used Wrong selection of welding process

Lack of responsibility and commitment towards quality Poor planning and co ordination with fitting group Engaging of unqualified welders

Lack of prcess controlls

Lack of Quality awareness/ targets

Poor organizing of site protection from wind

JOINT FITUPS

SUPERVISOR ROLE

WELDING PROCESS

CAUSE EFFECT (FISHBONE) DIAGRAM WELD DEFECT ROOT CAUSE ANALYSIS

BASE MATERIAL QUALITY WELDING CONSUMABLES
Wrong selection of type of electrodes/ fluxes Using of wrong size electrode Using of contaminated filler metals Selection of non compatible welding consumables

WELDER / OPERATOR SKILLS

Welding on wet / oily surfaces Not using wind protectors. Lack of welding/ WPS knowledge Incorrect welding sequence Using of long arcs Lack of skill

WELDING EQIPMENT
Non uniform travel speed Unstable arc voltage Unstable current No calibration of equipment Using of damaged gas hoses Non uniform rotation of welding rotators

Using of high Sulphur & Phosphorus steels

Using of unbaked welding consumables Using of damaged contaminated electrodes / fluxes

Lack of commitment towards quality Using of wrong welding parameters Using of too high travel speed

Using of quenched & tempered steels

Using of cold welding consumables Using of poor quality shielding / purging gasses

Using of high Ceq. materials Using of unkilled & high impurities content steels

Using of improper bead laying sequence Using of wrong size and cold electrodes

Poor storage and handling of welding consumables

Not using appropriate tempil stiks

Not maintaining preheat, interpass temp. and not covering joints with fire blankets Poor in keeping of welders records and repair rates Lack of job / WPS knowledge Poor organizing of site protection from wind

Poor eye sight, over fatigue and personal reasons Engaging of unqualified welders Poor control and guiding welders

CRACKS
Wrong selection of welding process Using of high hydrogen inducing process ( for Ex. using SMAW instead of GTAW process)

Welding at windy environment

Using of mismatch joints Using of unqualified welder for tack welding

Using toomuch strong backs and making restraint joints.

Poor house keeping Welding at dusty environment Not using of weather protectors Not removing gouged surfaces by grinding Not using proper run and run off plates Large gaps Using of unskilled gas cutters, Gougers and grinders Using of square butt joints for high Sulphour & Phosphorus steels Not keeping joint for easy welding position

Lack of responsibility and commitment towards quality Lack of Quality awareness/ targets Poor planning and coordination with fitting group Using of poor preheating methods and not arranging fire blankets

Poor controls on electrode baking and handling Lack of process controls

Using of high dilution welding process Lack of understanding on application of process

WELDING ENVIRONMENT

JOINT FITUPS

SUPERVISOR ROLE

WELDING PROCESS

CAUSE EFFECT (FISHBONE) DIAGRAM WELD DEFECT ROOT CAUSE ANALYSIS

WELDING CONSUMABLES
Using of wrong size electrode Using of poor quality shielding gasses Using of Ecentric coated cectrodes Using of damaged contaminated electrodes / fluxes, filter metals

WELDER / OPERATOR SKILLS

Poor attitude of welder/ operator Lack of welding/ WPS knowledge Using of excessive electrode stickout Poor eyes sight, over fatigue and personal reasons Using of long arcs Using of too high or low welding travel speed Lack of skill to manipulate beads Lack of commitment towards quality

WELDING EQIPMENT
Frequent power tripping Not using HF units for GTAW welding

Using of wrong welding parameters Using of low or high flow gasses

Improper aligning of rotators Non uniform rotation of welding rotators

Unstable arc voltage

Unstable current

Using of too high or low currents Using of improper welding technic

No calibration of equipment Non uniform welding travel speed

Exocentric or over loading on rotators.

Using of too narrow groove or large groove Using of unqualified welder for tack welding

Using of tack welds in the groove for single side joints

Poor in keeping of welders records and repair rates Lack of job / WPS knowledge

Engaging of unqualified welders Poor control and guiding welders Using of GMAW where FCAW can used

UNDERCUTS, EXCESS PENETRATION, ROOT CONCAVITY

Using of SMAW where more appropriate GTAW process Using of SMAW where more appropriate SAW process

Poor accessibility for welding Inadquate bevel angle Not keeping joint for easy welding position

Poor organizing of site protection from wind

Lack of responsibility and commitment towards quality Lack of Quality awareness/ targets Poor planning and coordination with fitting group

Not using proper run and run off plates

Lack of prcess controlls

Lack of understanding on application of process using Wrong selection of welding process

JOINT FITUPS

SUPERVISOR ROLE

WELDING PROCESS