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Root penetration
x x x
x x x
Under Fill
Poor Restart
Poor stop/starts
Cap Undercut
Cap undercut
Overlap
Overlap
Overlap
DEFINITION: An imperfection at the toe or root of a weld caused by metal flowing onto the surface of the parent plate without fusing to it. CAUSES: Contamination Slow travel speed High amperage Welding technique
Overlap
Overlap
Lack of Fusion
Causes Insufficient cleaning between passes Contaminated weld preparation Welding over irregular profile Incorrect welding speed Arc length too long
Causes Low welding current Arc length too long Excessive moisture in flux or preparation Contaminated preparation Damaged electrode flux Removal of gas shield
Spatter
Causes Excessive arc energy Excessive arc length Damp electrodes Arc blow
Arc Strikes
Causes Electrode straying onto parent metal Electrode holder with poor insulation Poor contact of earth clamp
Mechanical damage can be defined as any surface material damage cause during the manufacturing process. This can included damage caused by:
Grinding Hammering Chiselling Chipping
Breaking off welded attachments (torn surfaces) Using needle guns to compress weld capping runs
Chisel Marks Chisel Marks Chisel Marks Pitting Corrosion Grinding Marks
Porosity
Cluster porosity
Porosity
Gas pores
Porosity
Cluster Porosity
Cluster porosity
Worm Hole
Herringbone porosity
Lack of Fusion
Causes
Amperage too low Contaminated weld preparation Amperage too high (welder increases speed of travel)
Slag inclusions
Slag Inclusion
Slag Inclusions
Causes Arc length too long Incorrect welding speed Insufficient cleaning between passes Contaminated weld preparation Welding over irregular profile
Wagon Track
Tungsten Inclusions
Causes Contamination of weld Caused by tungsten touching weld metal or parent metal during welding using the TIG welding process
Excess Penetration
Causes Excessive amperage during welding of root Excessive root gap Poor fit up Excessive root grinding Improper welding technique
L.O.P
Causes Too small a root gap Arc too long Wrong polarity Electrode too large for joint preparation Incorrect electrode angle Too fast a speed of travel for current
Root L.O.F
Lack of fusion
Incomplete Penetration
Root L.O.F
Causes
Too small a root gap Arc too long Wrong polarity Electrode too large for joint preparation Incorrect electrode angle Too fast a speed of travel for current
Root Concavity
Root concavity
Root Concavity
Causes Root gap too large Insufficient arc energy Excessive back purge TIG
Burn Through
Causes Excessive root grinding Excessive amperage during welding of root Improper welding technique Slow travel speed Large root gap/small root face (irregular fit up)
Burn Through
A shallow groove caused by contraction in the weld metal along each side of the penetration bead or can occur in the center of the weld bead
Insufficient weld metal deposited in the root pass Too fast a cooling rate during the application of the root bead pass Poor welding technique
Shrinkage groove
Shrinkage groove
Root piping
Root undercut
Causes Root gap too large Excessive arc energy Small or no root face
Root undercut
Alignment Imperfection
Non-alignment of two abutting edges
50mm 3mm
Angular distortion. Measure the distance to the edge of the plate (50mm). Use a straight edge (rule) to find the amount of distortion then measure the space (3mm). This reported as Angular distortion 3mm in 50mm