Welding Defect TWI CSWIP PDF

CSWIP Welder Training
Defects/Repairs
Copyright 2003 TWI Ltd M.S.Rogers

Weld Defects
Defects which may be detected by visual inspection can
be grouped under five headings
Cracks Lack of fusion
Solid inclusions Mechanical damage
Surface and profiles Parent material damage
Misalignment (set-up Miscellaneous

irregularities)
Gas pores and porosity

Cracks

Cracks
Cracks that may occur in welded materials are caused
generally by by many factors and may be classified by
shape and position, cracks are classed as planar.
Classified by Shape Classified by Position

Longitudinal HAZ
Transverse Centreline
Branched Crater
Chevron Fusion zone

Parent metal

Process Cracks
Hydrogen induced cold cracking

(HICC)
Solidification cracking (Hot Tearing)
Lamellar tearing
Re heat cracking

Cracks
Longitudinal parent metal crack Transverse weld metal crack
Longitudinal weld metal crack Lamellar tearing

Transverse crack Longitudinal crack
Inclusions

Gas Cavities
Gas pore <1.5mm Blow hole.1.5mm
Gas pore Cluster porosity
Loss of gas shield
Damp electrodes
Contamination
Blow hole
Herringbone porosity Arc length too large
Damaged electrode flux
Moisture on parent material
Welding current too low

Root piping
Gas Cavities
Porosity
Root piping
Cluster porosity Herring bone porosity
Solid Inclusions
Slag inclusions are defined as a non-metallic inclusion
caused by some welding process
Slag originates from welding
flux
MAG and TIG welding
process produce silica
Slag inclusions Lack of sidewall inclusions
fusion with
associated slag
Slag is caused by
inadequate cleaning
Other inclusions include
tungsten and copper
inclusions from the TIG and
Parallel slag lines Lack of interun
fusion + slag MAG welding process
Interpass slag inclusions Elongated slag lines
Lack of Fusion

Surface and profile Defects
Poor welder skill

Incorrect electrode
manipulation
Incomplete filled groove
+ Lack of sidewall fusion Arc blow
Incorrect welding
1 current/voltage
2
Incorrect travel speed
1. Lack of sidewall fusion Incorrect inter-run cleaning
2. Lack of inter-run fusion

Overlap
An imperfection at the toe or root of a weld caused by
metal flowing on to the surface of the parent metal
without fusing to it
Contamination
Slow travel speed
Incorrect welding technique
Current too low

Overlap
Toe Overlap

Root Defects
Low Amps/volts
Large Root face
Incomplete root fusion Small Root Gap
Fast Travel Speed
Incorrect Electrode Angle
Incomplete root penetration Contamination

Arc blow

Root Defects
Lack of root fusion Lack of root Penetration

Lack of root penetration Lack of root fusion
Surface and Profile

Profile Defects
Incomplete filled groove Poor cap profile
Poor cap profiles and excessive

cap reinforcements may lead to
stress concentration points at
the weld toes and will also
contribute to overall poor toe
blend Excessive cap height

Excess cap reinforcement Incomplete filled groove
Profile Defects
Poor stop/starts

Miscellaneous Defects
Excessive current
Damp electrodes
Contamination
Incorrect wire feed speed

when welding with the MAG
welding process
Spatter

Miscellaneous Defects
Accidental striking of the arc

onto the parent material
Faulty electrode holder
Poor cable insulation
Poor return lead clamping
Arc strike

Undercut
An irregular groove at the toe of a weld run in the
parent metal
Excessive amps/volts
Excessive travel speed
Incorrect electrode angle
Excessive weaving
Incorrect welding technique
Electrode too large

Cap Undercut
Measured in both Length & Depth

Root undercut Cap undercut
Shrinkage Groove
A shallow groove caused by contraction in the weld
metal along each side of the penetration bead
Insufficient weld metal

deposited in the root pass
Too fast a cooling rate during

the application of the root
bead pass
Shrinkage groove
Poor welding technique

Concave Root
A shallow groove, which may occur in the root of a butt weld
Root faces too large
Root gap too large
Excessive back purge pressure

during TIG welding
Concave root Excessive root bead grinding
before the application of the
second pass

Concave Root

Excessive Root Penetration
Root penetration bead in excess in accordance with the
relevant specification being used
Root faces too small
Root gap too large
Excessive amps/volts
Excessive root penetration Slow travel speed

Excessive Root Penetration

Concave root Excessive root penetration
Burn Through
A localized collapse of the weld pool due to excessive
penetration resulting in a hole in the root run
High Amps/volts
Small Root face
Large Root Gap
Slow Travel Speed

Burn through

Root Defects
Burn
Through
Copyright 2003 TWI Ltd

Burn through M.S.Rogers
Root Coking/Oxidized Root
Loss or insufficient back

purging gas
Most commonly occurs

when welding stainless
steels
Purging gases include

argon, helium and
occasionally nitrogen

Crater Pipe
Crater pipe is a shrinkage defect and not a gas defect, it

has the appearance of a gas pore in the weld crater
Too fast a cooling rate
Deoxidization reactions and

liquid to solid volume
change
Crater crack
(Star crack) Contamination

Crater Pipe
Weld crater
Crater pipe

Crater Pipe/Cracks
Crater Cracks
Crater pipe

Mechanical Damage

Mechanical Damage
Mechanical damage can be defined as any surface material
damage cause during the manufacturing process.
This can included damage caused by:
Grinding
Hammering
Chiselling
Chipping
Breaking off welded attachments (torn surfaces)
Using needle guns to compress weld capping runs

Set-up Irregularities

Set-up Irregularities
Linear misalignment is measured

from the lowest plate to the
highest point of the cap
Plate/pipe Linear Misalignment

(Hi-Lo)
Angular misalignment is
measured in degreeso
Angular Misalignment

Linear Misalignment
Highest point
of the cap
mm
Lowest plate

Parent Material Defects
A welding inspector should also inspect the parent
material for any visible defects
Mechanical damage Lap
Lamination
Segregation line

Plate Lamination

Any
Any Questions?
Questions?

Questions
QU 1. Give two main causes for the occurrence of a burn through
QU 2. Give two main causes for the occurrence of excessive root

penetration on a single-V butt weld
QU 3. Give five defects, which may occur when welding carbon

steel using the MMA welding process with the current
setting to low
QU 4. Give three possible causes for the occurrence of lack of

side wall fusion
QU 5. Sketch the following defects

a. Lack of root wall fusion b. Lack of root penetration
c. Incomplete filled groove d. Concave root

Weld Repairs

Welding Repairs
In the event of repair
Authorization for repair
Removal and preparation for repair
Testing of repair - visual and NDT

Weld Repairs
A weld repair may be used to improve weld profiles or
extensive metal removal
Repairs to fabrication defects are generally easier than
repairs to service failures because the repair procedure
may be followed
The main problem with repairing a weld is the
maintenance of mechanical properties
During the inspection of the removed area prior to welding
the inspector must ensure that the defects have been
totally removed and the original joint profile has been
maintained as close as possible
Weld Repairs
The specification or procedure will govern how the defective
areas are to be removed. The method of removal may be
Grinding
Chipping
Machining
Filing
Oxy-Gas gouging
Arc air gouging
Arc air gouging

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CSWIP Welder Training

Copyright 2003 TWI Ltd M.S.Rogers

Solid inclusions Mechanical damage

Surface and profiles Parent material damage

Misalignment (set-up Miscellaneous

Gas pores and porosity

Copyright 2003 TWI Ltd M.S.Rogers

Copyright 2003 TWI Ltd M.S.Rogers

Classified by Shape Classified by Position

Chevron Fusion zone

Copyright 2003 TWI Ltd M.S.Rogers

Hydrogen induced cold cracking

Solidification cracking (Hot Tearing)

Copyright 2003 TWI Ltd M.S.Rogers

Longitudinal parent metal crack Transverse weld metal crack

Longitudinal weld metal crack Lamellar tearing

Copyright 2003 TWI Ltd M.S.Rogers

Copyright 2003 TWI Ltd M.S.Rogers

Damaged electrode flux

Moisture on parent material

Welding current too low

Copyright 2003 TWI Ltd M.S.Rogers

Poor welder skill

Copyright 2003 TWI Ltd M.S.Rogers

Slow travel speed

Incorrect welding technique

Current too low

Copyright 2003 TWI Ltd M.S.Rogers

Copyright 2003 TWI Ltd M.S.Rogers

Large Root face

Incomplete root fusion Small Root Gap

Fast Travel Speed

Incorrect Electrode Angle

Incomplete root penetration Contamination

Copyright 2003 TWI Ltd M.S.Rogers

Lack of root fusion Lack of root Penetration

Copyright 2003 TWI Ltd M.S.Rogers

Copyright 2003 TWI Ltd M.S.Rogers

Incomplete filled groove Poor cap profile

Poor cap profiles and excessive

Copyright 2003 TWI Ltd M.S.Rogers

Copyright 2003 TWI Ltd M.S.Rogers

Incorrect wire feed speed

Copyright 2003 TWI Ltd M.S.Rogers

Accidental striking of the arc

Faulty electrode holder

Poor cable insulation

Poor return lead clamping

Copyright 2003 TWI Ltd M.S.Rogers

Excessive travel speed

Incorrect electrode angle

Incorrect welding technique

Electrode too large

Copyright 2003 TWI Ltd M.S.Rogers

Measured in both Length & Depth

Copyright 2003 TWI Ltd M.S.Rogers

Insufficient weld metal

Too fast a cooling rate during

Copyright 2003 TWI Ltd M.S.Rogers