WELD I N G
DEFECTS
WELDING
Welding is a materials joining process which produces
coalescence of materials by heating them to suitable
temperatures with or without the application of
pressure or by the application of pressure alone, and
with or without the use of filler material.
Welding is used for making permanent joints.
It is used in the manufacture of automobile bodies,
aircraft frames, railway wagons, machine frames,
structural works, tanks, boilers, general repair work
and ship building.
CLASSIFICATION OF WELDING
PROCESSES:
(i). Arc w e l d i n g (iv) Thermit Welding
• Carbon arc
• Metal arc
• Metal inert gas (v) Solid State Welding
• Tungsten inert gas • Friction
• Plasma arc • Ult r a son ic
• Submerged arc • Diffusion
• Electro-slag • Explosive
(ii). Gas Welding
• Oxy-a ce tylene (vi) Newer Welding
• Air-acetylene • E lect r on-bea m
• Oxy- • Laser
h ydr ogen
(iii). R e s i s t a n c e Welding
• Butt (vii) Related Process
• Spot • Oxy-acetylene cutting
• Seam • Arc cutting
• Projection •
Har d facing
• P ercussion •
Brazing
•
Soldering
Equipments:
A welding generator (D.C.) or Transformer (A.C.)
Two cables one for work and one for electrode
Electrode holder
Electrode
Protective shield
Gloves
Wire brush
Chipping ha m m e r
Goggles
ARC WELDING EQUIPMENTS
ARC WELDING
Uses an electric arc to
coalesce metals
Arc welding is the most
common method of
welding metals
Electricity travels from
electrode to base metal to
ground
WELD TERMINOLOGY
7
Heat Affected Zone
Joint and Weld
TYPES OF JOINTS
There are 5 types of
joints …
8
FILLET AND GROOVE WELDS
Groove and fillet welds can be made on many
types of joints
TYPES OF DEFECTS
Slag Inclusion
Undercut
Porosity
Incomplete fusion
Overlap
Underfill
Spatter
Excessive Convexity
Excessive Weld Reinforcement
Incomplete Penetration
Excessive Penetration
SLAG INCLUSION
Cause:- Low amperage, improper techniques, slow travel rate
Prevention:- Increase amperage, increase travel rate
Repair:- Remove by grinding or other mechanical process
U N DERCUT
Cause:- High amperage, wrong electrode angle, long arc length, rust
Prevention:- Set machine on scrap metal to correct parameters, clean metal
before welding
Repair:- Weld with smaller electrode, sometimes must be low hydrogen with
preheat.
POROSITY
INCOMPLETE FUSION
Cause:- Low amperage, steep electrode angle, fast travel speed, short arc
gap, lack of preheat, electrode too small, unclean base metal, arc off seam
Prevention:- Eliminate the potential causes
Repair:- Remove & reweld, being careful to completely remove the defective
area.
OVERLAP
Cause:- Improper welding technique, steep electrode angle, fast travel speed
Prevention:- Overlap is a contour problem. Proper welding technique will
prevent this problem
U N D ERF ILL
Cause:- Improper welding techniques
Prevention:- Apply proper welding techniques for the weld type & position.
Use stripper beads before the cover pass.
Repair:- Simply weld to fill. May require preparation by grinding.
S P ATTER
Cause:- High arc power, magnetic arc blow, Damp electrodes
Prevention:- Reduce arc power, reduce arc length, use dry electrodes
Repair:- Remove by mechanical process
EXCESSIVE CONVEXITY
Cause:- Amperage & travel speed
Prevention:- Observe proper parameters & techniques
Repair:- Must blend smoothly into the base metal
EXCESSIVE CONCAVITY
Cause:- Amperage & travel speed
Prevention:- Observe proper parameters & techniques
Repair:- Must blend smoothly into the base metal
EXCESSIVE WELD REINFORCEMENT
Cause:- Travel speed too slow, amperage too low
Prevention:- Set travel speed & amperage on scrap plate
Repair:- Remove excessive reinforcement and feather the weld toes to a
smooth transition to the base plate.
INCOMPLETE PENETRATION
Cause:- Low amperage, low preheat, tight root opening, fast travel speed,
short arc length
Prevention:- Correct the contributing factors.
Repair:- Back gauge and back weld
EXCESSIVE PENETRATION
