Welding Inspection
Practical Plate Exercise
Welding Process MMA (SMAW)
?
Incomplete Filled Groove
?
Porosity
?
Lack of
fusion
Slag Cap Undercut Cap Undercut
?
Inclusion ?
Intermittent ?
Intermittent
?
Cap Undercut
?
Intermittent
?
Arc Strike
Arc Strike
Note: spatter and surface slag requires removal, arc strikes
require blending and crack detection
Welding Process MMA (SMAW)
Excess
?
Penetration ?
Excess
Penetration
?
Gas Pore
?
Linear Misalignment
? ?
Surface Slag Lack of Root ?
Root Undercut
Fusion
Note: Spatter and surface slag require removal
Welding Process MMA (SMAW)
?
Incomplete Filled Groove
?Porosity
?
Lack of Sidewall Fusion Fusion?
Lack of Sidewall
?
Surface Slag
Overlap and Excess Cap Height Full Weld Length ?
Note: Surface slag requires removal and poor toe blending full
weld length
Welding Process MMA (SMAW)
? ?
Slag Inclusion
Crater Pipe
?
Lack of Root Fusion
?
Lack of Root ?
Lack of Root Fusion
Penetration
Welding Process FCAW
Incomplete
?
Cap Undercut
Filled Groove +
Lack of
?
Sidewall
Surface slag & Spatter ?
Fusion Longitudinal
?
Crack
?
Slag Inclusion
?
Incomplete Filled
Groove + Lack of
Sidewall Fusion + Cap
Undercut Intermittent
Note: Spatter and surface slag requires removal
Welding Process FCAW
Mechanical Damage
? ? Poor Stop/Start + Lack of
Burn Through
?
Root Penetration
?Excess Penetration
?
Lack of Root Fusion
?
Lack of Root Fusion
Welding Process MMA (SMAW)
?
Porosity
Incomplete
?
Filled Groove
Excess Cap Cap
? ?
Lack of Sidewall
?
Cap
Height ?
Undercut Fusion Undercut
?
Overlap between Capping Passes
Note: Excess cap height and poor cap profile throughout.
Welding Process MMA (SMAW)
?
Mechanical Damage
?
Lack of Root Fusion
?
Lack of Root Fusion
Welding Process MMA (SMAW)
Lack of
?
Sidewall
Fusion
?
Cap Undercut Intermittent ?
Cap Undercut Intermittent
?
Incomplete Filled Groove
?
Excess Cap Height
?
Incomplete Filled Groove
Welding Process MMA (SMAW)
?
Poor Stop/Start + Crater Pipe ?
?
Lack of Root Fusion
Lack of Root Fusion
?
Root Undercut
?
Excess Root Penetration
?
Excess Root
Penetration
?
Crater Pipe
?Lack of Root
fusion
Welding Process MMA (SMAW)
Mechanical
Damage
?
?
Lack of Sidewall fusion
?
Crater pipe
?
Poor Toe Blend
?
Lack of Sidewall Fusion + Incomplete Filled Groove
?
Tack Weld ?
Arc
Strikes
Note: Arc strikes require blending and crack detection
Welding Process MMA (SMAW)
Poor Stop/Start + Lack of Root
?
Penetration + Crater Pipe ?
Blow Hole
?
Arc Strikes Lack of Lack of
Mechanical Damage +
?
Lack of Root Fusion
Root
?
Fusion ?
Root
Fusion
?
Lack of Root Fusion
?
Arc Strikes
?
Arc Strikes
Note: Arc strikes require blending and crack detection
Welding Process MMA (SMAW)
?
Parent Material Damage
?
Arc Strikes
?
Arc Strikes
Lack of Sidewall Fusion +
?
Incomplete Filled Groove
?
Poor Toe Blend + Excess Cap Height
?
Porosity
Note: Arc strikes require blending and crack detection, Seek advise
on parent material damage
Welding Process MMA (SMAW)
?
Parent material
gas cavities
?
Plate corrosion
?
Poor Stop/Start
?
Lack of Root Fusion
?
Crater pipe ?
Surface slag
?
Surface Slag
?
Linear Misalignment
Note: Surface slag requires removal, plate corrosion requires
wire brushing
Welding Process MMA (SMAW)
?
Incomplete Filled Groove ? ? ?
?
Arc Strikes
Arc Strikes Slag Inclusion Arc Strikes
Arc Strikes ?
Cap Undercut Intermittent ?
Cap Undercut
?
?
Arc Strikes
Note: Parent plate damage throughout, seek advice. Arc strikes
require blending and crack detection.
Welding Process MMA (SMAW)
?
?
Crater pipe
Excessive root penetration
?
Linear misalignment +
lack of root fusion
?
Lack of root fusion
? ?
Poor stop/start
Lack of root fusion ?
Arc strikes
Arc strikes
Note: Arc strikes require blending and crack detection, Seek advise
on parent material damage
Welding Process MMA (SMAW)
? ?
Spatter
Cap undercut
?
Arc strikes
?
Poor toe blend full weld length
Note: Arc strikes require blending and crack detection. Spatter
requires removal.
Welding Process MMA (SMAW)
Arc strike
?
Lack of root penetration ?
Burn through
?
Poor stop/start ?
?
Linear misalignment
?
Lack of root penetration ?
Lack of root fusion
?
Mechanical damage ?
Lack of root fusion
+ poor stop/start
Note: Arc strikes require blending and crack detection, Seek advise
on parent material damage
Welding Process MMA (SMAW)
Suspect crater cracking
?
Cap undercut ?
Arc strikes
?
Cap undercut
?
Porosity
?
Cap undercut intermittent
?
Cap undercut
Note: Material damage throughout, seek advice. Arc strikes require
blending and crack detection.
Welding Process MMA (SMAW)
?
Mechanical damage
? fusion
Lack of root
Linear misalignment +
?
lack of root fusion
?
Linear misalignment +
lack of root fusion
?
Lack of root penetration
Note: Material damage seek advice on course of action.
Welding Process MMA (SMAW)
Mechanical damage
?
?
Cap undercut ?
Cap undercut
?
Spatter/irregular cap profile
Note: Grinding marks throughout seek advice on course of action.
Excess cap height and poor cap profile throughout.
Welding Process MMA (SMAW)
?
Arc strike
?
Root undercut
intermittent
?
Lack of penetration intermittent
?
Ground flush root
Welding Process MMA (SMAW)
?
Surface slag
?
Arc strikes damage
?
Mechanical
?
Cap undercut intermittent
?
Cap undercut intermittent
?
Mechanical
damage
Note: Mechanical damage seek advice on course of action.
Excess cap height and poor cap profile throughout. Arc
strikes require blending and crack detection.
Welding Process MMA (SMAW)
?
Arc strike ?
Lack of root
fusion
? ?
Spatter
?
Lack of root
fusion
?
Lack of root
fusion
Lack of root
fusion
?
Root undercut intermittent
?
Spatter
Note: Arc strikes require blending and crack detection. Spatter
requires removal
