Defects/imperfections in welds - slag inclusions

Job Knowledge

Prevention of slag inclusions by grinding between runs

The characteristic features and principal causes of slag imperfections are described.

Identification

Fig. 1. Radiograph of a butt weld showing two slag lines in the weld root

Slag is normally seen as elongated lines either continuous or discontinuous along the length of
the weld. This is readily identified in a radiograph, Fig 1. Slag inclusions are usually associated
with the flux processes, ie MMA, FCA and submerged arc, but they can also occur in MIG
welding.

Causes
As slag is the residue of the flux coating in MMA welding, it is principally a deoxidation product
from the reaction between the flux, air and surface oxide. The slag becomes trapped in the weld
when two adjacent weld beads are deposited with inadequate overlap and a void is formed. When
the next layer is deposited, the entrapped slag is not melted out. Slag may also become entrapped
in cavities in multi-pass welds through excessive undercut in the weld toe or the uneven surface
profile of the preceding weld runs, Fig 2.
As they both have an effect on the ease of slag removal, the risk of slag imperfections is
influenced by


Type of flux coating

Welder technique
The type and configuration of the joint, welding position and access restrictions all have an
influence on the risk of slag imperfections.

Fig. 2. The influence of welder technique on the risk of slag inclusions when welding with a basic MMA
(E7018) electrode a) Poor (convex) weld bead profile resulted in pockets of slag being trapped between
the weld runs

b) Smooth weld bead profile allows the slag to be readily removed between runs

Type of flux coating

One of the main functions of the flux coating in welding is to produce a slag which will flow freely over the surface of the weld pool to protect it from
oxidation. As the slag affects the handling characteristics of the MMA electrode, its surface tension and freezing rate can be equally important properties.
For welding in the flat and horizontal/vertical positions, a relatively viscous slag is preferred as it will produce a smooth weld bead profile, is less likely to
be trapped and, on solidifying, is normally more easily removed. For vertical welding, the slag must be more fluid to flow out to the weld pool surface but
have a higher surface tension to provide support to the weldpool and be fast freezing.
The composition of the flux coating also plays an important role in the risk of slag inclusions through its effect on the weld bead shape and the ease with
which the slag can be removed. A weld pool with low oxygen content will have a high surface tension producing a convex weld bead with poor parent
metal wetting. Thus, an oxidising flux, containing for example iron oxide, produces a low surface tension weld pool with a more concave weld bead
profile, and promotes wetting into the parent metal. High silicate flux produces a glass-like slag, often self detaching. Fluxes with a lime content produce
an adherent slag which is difficult to remove.
The ease of slag removal for the principal flux types are:

Rutile or acid fluxes - large amounts of titanium oxide (rutile) with some silicates. The oxygen level of the weld pool is high enough to give flat
or slightly convex weld bead. The fluidity of the slag is determined by the calcium fluoride content. Fluoride-free coatings designed for welding in
the flat position produce smooth bead profiles and an easily removed slag. The more fluid fluoride slag designed for positional welding is less easily
removed.
Basic fluxes - the high proportion of calcium carbonate (limestone) and calcium fluoride (fluospar) in the flux reduces the oxygen content of
the weld pool and therefore its surface tension. The slag is more fluid than that produced with the rutile coating. Fast freezing also assists welding
in the vertical and overhead positions but the slag coating is more difficult to remove.

Consequently, the risk of slag inclusions is significantly greater with basic fluxes due to the inherent convex weld bead profile and the difficulty in
removing the slag from the weld toes especially in multi-pass welds.

Welder technique
Welding technique has an important role to play in preventing slag inclusions. Electrode manipulation should ensure adequate shape and degree of
overlap of the weld beads to avoid forming pockets which can trap the slag. Thus, the correct size of electrode for the joint preparation, the correct angle
to the workpiece for good penetration and a smooth weld bead profile are all essential to prevent slag entrainment.
In multi-pass vertical welding, especially with basic electrodes, care must be taken to fuse out any remaining minor slag pockets and minimise undercut.
When using a weave, a slight dwell at the extreme edges of the weave will assist sidewall fusion and produce a flatter weld bead profile.
Too high a current together with a high welding speed will also cause sidewall undercutting which makes slag removal difficult.
It is crucial to remove all slag before depositing the next run. This can be done between runs by grinding, light chipping or wire brushing. Cleaning tools
must be identified for different materials eg steels or stainless steels, and segregated.
When welding with difficult electrodes, in narrow vee butt joints or when the slag is trapped through undercutting, it may be necessary to grind the
surface of the weld between layers to ensure complete slag removal.

Best practice
The following techniques can be used to prevent slag inclusions:

Use welding techniques to produce smooth weld beads and adequate inter-run fusion to avoid forming pockets to trap the slag
Use the correct current and travel speed to avoid undercutting the sidewall which will make the slag difficult to remove
Remove slag between runs paying particular attention to removing any slag trapped in crevices
Use grinding when welding difficult butt joints otherwise wire brushing or light chipping may be sufficient to remove the slag.

Acceptance standards
Slag and flux inclusions are linear defects but because they do not have sharp edges compared with cracks, they may be permitted by specific standards
and codes. The limits in steel are specified in BE EN ISO 5817: 2007 for three quality levels.