Weld Quality & Weld Testing

What is unique about the Eisenhower

Interstate Highway System?

One in every 5 miles is

straight, this can be used as
airstrips in times of war and
other emergencies
Each Weldment Should Be:
Adequately Designed to meet the intended
service for the required life
Fabricated with specified materials and in
accordance with the design concepts
Operated and maintained properly
Welds are examined in regard to:
Size
Shape
Contour
Soundness
Other Features as Specified
 Welding Code
Effect of Discontinuities on
Properties
Discontinuities in a welded
joint can influence
mechanical properties
Codes establish size limits
for acceptable
discontinuities
Discontinuities
unacceptable by a given
code are called defects and
are subject to repair
Classification of Weld Joint Discontinuities

Welding Process or Procedure Related Discontinuities

Metallurgical Discontinuities
Design Related Discontinuities
Classification of Weld Joint Discontinuities
Welding Process or Procedure Related Discontinuities

Geometric Other
Misalignment Arc Strikes
Undercut Slag Inclusions
Concavity or Convexity Tungsten Inclusions
Excessive Reinforcement Oxide Films
Improper Reinforcement Spatter
Overlap Arc Craters
Burn-through
Backing left on
Incomplete Penetration
Lack of Fusion
Shrinkage
Surface Irregularities
Classification of Weld Joint Discontinuities
Metallurgical Discontinuities

Cracks or Fissures Heat-Affected Zone

Hot Microstructural Alterations
Cold or Delayed
Reheat
Stress-Relief
Strain-age Weld Metal & HAZ Segregation
Lamellar Tearing

Porosity Base Plate Laminations

Spherical
Elongated
Worm-hole
Classification of Weld Joint Discontinuities
Design Related Discontinuities

Changes in Section & Other Stress Concentrators

Weld Joint Type

 Open the web page under
Demonstrations and do the
exercise entitled Discontinuities

http://www-iwse.eng.ohio-
state.edu/we300/Discontinuity/discontinuity.aam
Pages 364 through
367 of the Welding
Handbook list table
of Common Causes
and Remedies like the
one on the Right.
Review these tables to
gain insight about
Discontinuities
Turn to the person sitting next to you and discuss (1 min.):
From a general point of view, how would you rank the
following discontinuities in their severity to weld properties:
Hot Cracks, Change in section size, Porosity, ? Why
 Welding Discontinuities

Porosity
Porosity is the entrapment of small volumes
of gas in solidifying weld metal
Prevention
Drying consumables
Cleaning, degreasing material being welded
Electrode or filler metals with higher level of
deoxidants
Sealing air leaks, reducing excess shielding gas
flow 0.1.1.4.2.T7.95.12
 Welding Discontinuities

Slag inclusions
Slag inclusions are irregularly shaped, not
spherical like porosity
Prevention
Position work and/or change electrode/flux to
increase slag control
Better slag removal between passes
Dress weld surface smooth if it is likely to
cause slag traps
Remove heavy mill scale on plate 0.1.1.4.2.T8.95.12
 Welding Discontinuities

Lack of Fusion
Lack of fusion is caused by incorrect
welding conditions
Prevention
Procedure for complete fusion should be
verified by testing
Increased energy input
Correct electrode angle and work position

0.1.1.4.2.T9.95.12
 Welding Discontinuities

Incomplete Root Penetration

Incomplete root penetration can be caused by
Excessively thick root face, insufficient root gap
Incorrect welding conditions
Misalignment of second weld
Prevention
Improved joint preparation
Test weld verifications for correct parameters
Reassessment of back gouging

0.1.1.4.2.T10.95.12
 Welding Discontinuities

Overlap
Overlap is an imperfection at the weld toe
or root caused by metal flowing onto the
surface of the base metal without fusing to
it
Prevention
Adjust electrode manipulation to ensure fusion
of base metal
Limit size of fillet to 9-mm leg length
0.1.1.4.2.T11.95.12
 Welding Discontinuities

Undercut
Undercut is an irregular groove at the weld toe in the
parent metal or previous pass caused by
excessive weaving
melting of top edge of fillet weld with high current
Prevention
Weld in flat position
Change shielding gas to one which produces better wetting
Terminate welds so they dont finish at a free edge

0.1.1.4.2.T12.95.12
 Welding Discontinuities

Excessive Penetration
Excessive penetration is caused by
Incorrect assembly or preparation
Edge preparation too thin to support weld underbead
Excessive root gap
Energy input too high
Lack of operator skill
Prevention
Control of preparation, backing bars
0.1.1.4.2.T13.95.12
 Welding Discontinuities

Root Concavity
Root concavity is caused by
Excessively thick root face
Insufficient arc energy for penetration
Excessive backing gas pressure
Prevention
Reduce root face thickness, control backing gas
pressure
Establish a procedure by test welding
0.1.1.4.2.T14.95.12
 Welding Discontinuities

Spatter
Spatter consists of small droplets of
electrode material that land beside the weld
and may or may not fuse to the base
material
Prevention
Reduce energy input
Shorter arc length
Reposition current return clamp to reduce
magnetic arc blow or switch to AC current 0.1.1.4.2.T15.95.12
Turn to the person sitting next to you and discuss (1 min.):
We have just looked at a list of discontinuities and
preventative measures. How does this information effect the
opinions of people involved in writing codes for proper
welding conditions?
Weld Test Samples Help Reveal
Discontinuities and Defects
 Fatigue Design

Fatigue Appearance
Distinct fracture
surface has a
characteristic
texture
Concentric line
multiple initiation sites
pattern
Smooth portion
referred to as
clamshell texture