WELDING PROBLEMS

AND DEFECTS – CAUSES

AND SOLUTIONS

SPATTER DEFORMATION ARC BLOW

CAUSES SOLUTIONS CAUSES SOLUTIONS CAUSES SOLUTIONS

n  elding current too high
W n  educe welding current
R n  nsuitable welding sequence
U n Weld from both sides of n  rc deflection as a result of
A n Use an AC electrode where
n Arc too long n Reduce arc length n Too many and too thin beads, the joint magnetic effects into the possible
usually because the electrode n Weld from the center out, opposite direction of the earth n Try welding away from the
n Incorrect polarity – arc blow n Check use of correct polarity
is too small in opposite directions lead clamp earth clamp connection
n Insufficient gas shielding for the consumable in
n Arc deflection as a result of
question n Poor plate fit-up before n Use a larger, higher recovery n Try splitting the earth clamp
welding type electrode if possible magnetic effects in the and connect to both sides
n Check shielding gas type
direction of heavy parts of the of the joint
and flow rate n Plates clamped insufficiently n Compensate for shrinkage by
work piece (with magnetic
n Clean gas nozzle fixing the work piece with a n Position earth lead clamp
materials) – especially at
counter-angle clamp such that it counteracts the
n Increase torch to plate angle corners and edges
influence of heavy work
piece parts
n Keep arc as short as possible

LONGITUDINAL CRACKS IN THE ARC STRIKING DIFFICULTIES SOLIDIFICATION CRACKS

HEAT AFFECTED ZONE
CAUSES SOLUTIONS CAUSES SOLUTIONS CAUSES SOLUTIONS
n The base material is prone to n If possible, choose a material n  elding current too low
W n Increase welding current n Formation of phases with a n S elect cleaner parent material
hardening (because of a high with a better weldability or n Arc voltage too low n Use power source with a low melting point in the weld, or buffer plate edges
C content or other alloying apply and maintain preheat higher open circuit voltage due to P, S, Cu – mostly from n Increase joint angle, use lower
n Earth lead is not connected
elements) and interpass temperature the parent metal welding current
properly n Ensure proper earth lead
n Weld cools down too rapidly and delayed cooling n Unfavorable joint geometry –
n Low mains voltage connection nU  se smaller electrode, use
n Hydrogen in the weld, eg/ n Apply a higher preheat width/depth ratio <1
n Uncover striking end and lower welding current
because of wet weld edges, temperature n Weld pool too large
touch-strike nA  pply stringer bead technique
wrong or damp electrodes or n Remove moisture from n Travel speed too high (weld nL  ower the travel speed until
shielding gases welding zone solidifies in an arrow shape) weld solidifies in an elliptical
n Use low-hydrogen n Tack welds or root passes not form
consumables from moisture sufficiently strong for shrinkage nA  pply stronger tacks and
protective packaging, or forces, in the case of restrained bottom passes
rebake welding consumables joints

LACK OF FUSION CRATER CRACKS UNDERCUT

CAUSES SOLUTIONS CAUSES SOLUTIONS CAUSES SOLUTIONS

n  eat input too low
H n Increase welding current and n  he welding ended too
T n  hen finishing, move the
W n  rc voltage too high
A n  ower arc voltage
L
nW  eld pool too large and lower travel speed abruptly electrode back to fill-up n Arc too long n Reduce arc length
running ahead of the arc n Reduce deposition rate and/ n The crack begins at a void in the crater
n Incorrect electrode use or n Apply electrode angle of 30°
n Joint included angle too small or increase travel speed the welding crater, caused by n With root pass welding,
electrode angle to 45° with the standing leg
n Increase joint included angle the solidification shrinkage quickly move the arc from the
n Electrode or torch angle is n The electrode is too large n Weld lightly trailing
weld pool to the plate edge
incorrect n Position electrode or torch in for the plate thickness n Use a smaller diameter
n Increase crater fill time on
n Unfavorable bead positioning such a way that the plate n Travel speed too high electrode
edges are melted power source
n Reduce travel speed
n Position beads in such a way n Use run off plate

that sharp angles with other

beads or plate edges are
avoided

POROSITY SLAG INCLUSIONS LACK OF ROOT PENETRATION

CAUSES SOLUTIONS CAUSES SOLUTIONS CAUSES SOLUTIONS

n  oisture, for example from
M n  ebake or use fresh welding
R n  lag runs ahead of the weld
S n Increase the travel speed or n Root gap too small nU
 se wider root gap
incorrectly stored electrodes consumables, connect new n Insufficient de-slagging electrode angle n Electrode size too big nU
 se electrodes with a
or fluxes, humid shielding gas gas bottle, check welding between passes n Remove slag carefully, grind if diameter approximately the
n Travel speed too high
or leaks in water-cooled torch for leaks necessary size of the gap width
n Convex passes which n Incorrect use of electrode
welding torches n Dry or clean plate edges
produce slag pockets n Avoid sharp angles or grooves nA
 pply lower travel speed
n Moisture, rust, grease or paint n Poor set up
n Check shielding gas type and n Unfavorable bead sequence between beads and layers nW
 eave between plate edges
on the plate edges flow-rate n Increase arc voltage nW
n Insufficient gas shielding
 eld on ceramic backing at
n Clean gas nozzle n Plan bead sequence such that high currents
n Welding onto small gaps filled n Ensure torch to plate angle is sharp corners are avoided
with air not too small n Apply stringer bead technique
n Increase welding gap
n When possible, apply butt
joints instead of fillet or
overlap welds

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