Weld Discontinuities and defects Causes & Remedies

    

Definition Influence Types Causes Remedies

Discontinuity & Defect Discontinuity refers to any interruption or in-homogeneity in the material that is otherwise homogenous Defect refers to an interruption having dimensions/features beyond acceptable limits. Defects are otherwise called as Flaw or Imperfections that are to be repaired so that the material is made more homogeneous as assumed in the design

Weld joint is itself is a Discontinuity

HAZ

WM PM The Microstructure is different in the different regions of weld zones of weld joint. So the mechanical properties also vary from zone to zone causing heterogeneity

Common Surface Discontinuities

Surface Porosity Spatter Wire sticking Crater pin hole Crater crack Surface cracks

Common surface Discontinuities Un-equal weld size Under sized weld Weld offset ( from seam) Non-uniform weld size (along the length) Oversized weld Excess Penetration Weld crater

Common surface Discontinuities

Improper Weld bead Profile Coarse weld Ripples Excess Convexity Root concavity Excess Reinforcement Overlap Undercut Misalignment Lack of Penetration

Common Internal Discontinuities

Porosity Blow Holes / Aligned / distributed / Cluster / worm hole Porosities Lack of fusion/ Lack of Penetration Lack of side wall fusion / Inter run fusion / lack of fusion at root Cracking Under-bead cracking / delayed cracking / Delayed cracking /Hydrogen induced cracking Hot cracking, shrinkage cracks, Fatigue cracking

Porosity

Incomplete joint penetration

Lack of

tration

Arc Strike
Definition: A localized coalescence outside the weld zone. Cause: Carelessness Prevention: In difficult areas, adjacent areas can be protected using fire blankets. Repair: Where applicable, arc strikes must be sanded smooth and tested for cracks. If found, they must be remove and repaired using a qualified repair procedure and inspected as any other weld.

Spatter
e inition: Small particles o eld metal expelled rom the elding operation hich adhere to the base metal sur ace. ause: Long arc length, severe electrode angles, high amperages. revention: orrect the cause. Base metal can be protected ith coverings or hi-temp paints. epair: emove by grinding or sanding. Sometimes must be tested as i it ere a eld.

Arc trikes

atter

Excess Penetration

P Excess Penetration

Proper Penetration

Excess Penetration

Misalignment (hi-lo)
Definition: mount a oint is out o alignment at the root Cause: arelessness. lso due to oining di erent thicknesses (transition thickness) Prevention: Workmanship. Transition angles not to exceed 2.5 to 1. Repair: Grinding. are ul on sur ace inish and direction o grind marks. Inside o ipe /Tube di icult.

Mis-alignment

Porosity -

Cause /Source

Cavities / voids formed due to entrapment of gases when the molten metal solidifies from liquid state when more gases get dissolved into molten metal

Moisture in Plate edges

Inadequate Gas shielding due to Improper setting of gas flow rates Improper Torch angles Improper setting of welding Parameters

Non-baked/dried Electrodes Filler wire Wet / Non-dried flux Pneumatic fixture In the atmosphere

Surface Porosity

Internal Porosity

10 mm

Hot rack
e inition: crack in the eld that occurs during solidi ication. ause: Micro stresses rom eld metal shrinkage pulling apart eld metal as it cools rom liquid to solid temp. revention: reheat or use a lo tensil iller material. epair:

Hot Cracking

10 mm

Types of defects

Types of Cracking

Undercut
Definition: groove cut at the toe o the eld and le t un illed. Cause: High amperage, electrode angle, long arc length, rust Prevention: Set machine on scrap metal. lean metal be ore elding. Repair: Weld ith smaller electrode, sometimes must be lo hydrogen ith preheat. Sometimes must gouge irst.

Undercut - Causes

Undercut
(cont......)

Undercut typically has an allo able limit. i erent codes and standards vary greatly in the allo able amount. late - the lesser o 1/32 or 5% (typ.)

Excessive oncavity or onvexity

Definition: oncavity or convexity o a illet eld hich exceeds the speci ied allo able limits Cause: mperage and travel speed Prevention: Observe proper parameters and techniques. Repair: Grind o or eld on. Must blend smoothly into the base metal.

Concavity

Convexity

Weld bead Profile

Fillet Weld with straight bead Fillet Weld with Convex bead Fillet Weld with Concave bead

Excess Penetration

P Excess Penetration

Proper Penetration

Excess Penetration

1-Excessive Penetration 2-slag Inclusion

Gas Pores

Incomplete fusion -Causes

Improper manipulation of electrodes Incorrect position of electrodes Impurities on the weld surface

Weld Strength
100% Joint Efficiency is obtained when The weld is carried out on both sides Back gouging is done after welding the first side LPI or MPT is carried out after Back gouging 100% RT / UT is carried out after second side welding

Weld Strength
The Electrode or the filler wire should be selected such that it Matches with the strength of the base material Has fairly low carbon & controlled impurities to avoid cracking Moisture level is controlled and is of low H2 type Is usable in all positions