Welding Defects Causes and Prevention POROSITY (Porosity is defined as cavity-type discontinuities formed by gas entrapment during solidification)

Causes Prevention The cylinder is out of gas. Check the cylinders before Start of Welding An excessive wind in the welding area. This can blow away the gas shield. Protect the area by Proper wind shield preheat the metal to evaporate the moisture. The presence of moisture in materials can lead to problems Weld filler metals contaminated with paint, grease, oil, tape, and glue Ensure Cleanliness of the filler wire before the start of welding The gas flow is too high Maintain the gas flow as per WPS A pinched or smashed gas hose Check the Hoses for damage clean the joint edges immediately before welding Jont edges is contaminated with hydrocarbons such as oil, grease or paint unstable arc, arc gap too short Maintain Stable arc (SMAW) Ensure Electrodes are baked as per the Procedure (SMAW) Improper Baking of Electrodes UNDERCUT (undercutting is a defect that appears as a groove in the parent metal directly along the edges of the weld) Decreasing the arc travel speed will reduce the size of the undercut and eventually eliminate it. Improper welding parameters; particularly the travel speed, When only small or intermittent undercuts are present, raising the arc voltage or High currents,long arc length,incorrect electrode positioning using a leading torch angle are also corrective actions. Base Metal is overheated Use smaller electrode size SLAG INCLUSION (Non-metallic solid material trapped in the weld) Incomplete Slag removal from previous bead Completely remove slag from previous bead Too low welding current use higher welding current Too Slow travel speed use higher travel speed Too large weaving width reduce weaving width INCOMPLETE PENETRATION (weld bead does not penetrate the entire thickness of the base plate) Improper Electrode Select the electrode with beter penetration Too low welding current Use proper welding current Too fast or slow travel speed Properly adjust the travel speed Improper grooving and Fixturing Increase groove angle and root gap INCOMPLETE FUSION (A weld discontinuity in which fusion did not occur between weld metal and joint fusion face or between adjoining weld beads) Too low welding amperage Too fast or slow electrode manipulation Use appropriate welding parameters and groove angles. Too much or too little arc length or arc voltage Too narrow welding groove BURN THROUGH (A hole through the weld metal, usually occurring in the first pass Main Causes) Too large welding current when groove welding Reduce welding current

Too large root gap caused by improper groove shape

Reduce root gap