HAZ- The black area around weld

Lack of Penetration
Undercut

Multiple forging bursts in a steel blank

Corosion pit that penetrated a pipe wall
Beach Marks in a drill rod fractured by fatigue
Thick lip fracture from creep in a power plant superheater tube.

“Rock Candy” fracture surface of a grade 8 bolt cracked by hydrogen embrittlement.

Brittle fracture surface of fastener. Bright flecks are planara cleavage facets of ferrite in the steel.

Lamination in a plate’s edge.

Forging Lap
Sand and slag inclusions in a casting.

Slag inclusions in weld cross section

Lack of fusion
Seam in bolt

Toe crack in weld.

Surface porosity in weld.

Crack between two welds

Burst in bar

Crack in a bolt

Lack of penetration in an aluminum weld.

Underfill

Undercut

Overlap(or rollover)
Excessive reinforcement.

Concavity

Incomplete Penetration
Indication of a bleedout

Fluorescent penetrant bleedouts.

Initial grinout of an indication

Indication of a quench(Heat Treat) crack in a saw blade(MT)

Lack of fusion(arrow) and undercut (at edge of weld).

Incomplete Penetration(RT)
Icicles and burnthrough.

Slugging (weld rods placed in weld Groove) RT

Tungsten inclusion
Cracks(Longitudinal and at the centerline. It should be Cold Crack)

Gas porosity

Shrinkage(RT)
Black magnetic-powder indications of a cold shut in a casting when seen under black light.

Spindle defects revealed with water base magnetic particle testing.

Compresor vane microcracks revealed with water-base magnetic particle testing.

50 mm diameter gear subjected to water-base magnetic particle testing showing cracks 0.25 mm
long by 0.1 mm wide.

Defects in the leading edge and filet areas of a hydroplane propeller as revealed by water-base.

Casting viewed under black light showing strong magnetic particle indication with minimal backround
fluorescent.(It should be a hot tear because the part is a casting)
Potentially dangerous cracks in a lawn mower blade revealed when fluorescent magnetic particles
are exposed to black light.

Fluorescent magnetic particle indications of quenched-and-drawn drill casing tubing that shows
rejectable, cracked spiral seams in the tubing when exposed to black light.

Black light used to reveal magnetic particle indication of a crack in the centering stud of a ball-yoke-
type universal-joint section of a drive-shaft assembly.
Black light used to reveal magnetic particle indication of a lap that could lead to potential
failure of a forged connecting rod.

Black light used to reveal magnetic particle indication of a dangerous crack near a wheel stud.
The crack was detected during manufacture.

Magnetic particle indications of a seam (at arrow) in the shank of a forged crane hook
Cold shut (at arrow) in the flange of a machined cast drum. Magnetic particle inspection
revealed faint
indications of the cold shut in the rough casting.

Magnetic particle indications of cracks in a large cast splined coupling. Indication (at arrow) in
photo at right is along the fusion zone of a repair weld.

Indications of cracks (at arrows) in the weld between the web and rim of a 1.2 m (4 ft) diam
weldment

Forged crane hook showing stress areas subject to inspection. 50 kN (6 tonf) crane hook
showing magnetic particle indication of a forging lap and section through
hook showing depth of lap
Forged drive-pinion shaft and coupling in which the detection of a crack during preventive
maintenance
magnetic particle inspection prevented a costly breakdown. (a) Drive-pinion shaft and coupler
assembly;
arrows show locations of fillets on wobbler coupling half that were inspected. (b) Fillet
between shaft and
coupling flange showing crack (at arrows) found during inspection

Discontinuities on the surfaces of steel billets that can be detected by magnetic particle
inspection. (a)
Arrowhead cracks. (b) Longitudinal cracks. (c) Normal seams. (d) Brush seams. (e) Laps. (f)
Scabs. See text
for discussion.
A connecting rod processed with magnetic particles and imaged. (a) Before rinsing. (b) After
rinsing.

Indications of discontinuities (arrows) on a magnetic rubber replica removed from a 16 mm (

5/8 in.) diam through hole in 24 mm (15/16 in.) thick D-6ac steel plate

Aircraft longeron (a), of 4.0 mm (5/32 in.) thick D-6ac steel, showing nutplate holes that
were magnetic
rubber inspected. (b) Cured magnetic rubber replica with indications (arrows) of cracks in the
6.4 mm ( ¼ in.)
diam main hole and a 2.4 mm (3/32 in.) diam rivet hole
Blind
Magnetic rubber inspection of spline teeth in a 4330 steel bracket for an aircraft-flap actuator.
(a) View of bracket with rubber replica removed. (b) Macrograph of replica showing crack
indications in roots of teeth
Magnetic rubber replicas used to monitor crack growth in a hole during fatigue testing of a D-
6ac steel aircraft part. Part fractured at 4545 cycles. (a) Initial replica of the hole showing a
tool mark (arrow). (b) Replica made after 3500 fatigue cycles. Intensity of indication
increased at tool mark (lower arrow), and a new indication was formed (upper arrow). (c)
Replica made after 4000 cycles. Indications joined, and growth of crack (arrows) is evident.
(d) Replica made after 4500 cycles. Mature fatigue crack (arrows), extending all along hole, is
very evident.

Wet fluorescent magnetic paint indications of minute grinding cracks in the faces of a small
sprocket

A-scan displays of broadened-echo indications from curved rough or scattering interfaces

showing (a)
indications with back reflection and (b) indications without back reflection. See text for
discussion.
A-scan display showing coarse-grain indications (hash) that interfere with detection of
discontinuities

Angle-beam inspection of a weldment showing effect of search-unit movements on

oscilloscope screen
display patterns from three different types of flaws in welds. (a) Positions of search units on
the testpiece. (b)
Display pattern obtained from a gas hole as the result of traversing the search unit in an arc
about the location
of the flaw. (c) Display pattern obtained from a slag inclusion as the result of swiveling the
search unit on a
fixed point. (d) Display pattern obtained from a crack, using the same swiveling search-unit
movement as in
(c).

Ultrasonic indications from four types of flaws found in castings

Radiographs with poor and improved radiographic definition. (a) Advantage of a higher
radiographic contrast is offset by poor definition. (b) Despite lower contrast, better detail is
obtained with improved definition. Source: Ref 1

Longitudinal sections of two types of ingots showing typical pipe and porosity. When the
ingots are rolled
into bars, these flaws become elongated throughout the center of the bars.
Typical flaws in resistance-welded steel tubing. (a) Contact marks (electrode burns). (b) Hook
cracks (upturned-fiber flaws). (c) Weld-area crack. (d) Pinhole. (e) Stitching. Views (c), (d),
and (e) are mating fracture surfaces of welds.

Typical flaws in double submerged arc welded steel pipe. (a) Incomplete fusion. (b)
Incomplete penetration. (c) Offset of plate edges. (d) Out-of-line weld beads (off seam). (e)
Porosity (gas pocket). (f) Slag inclusions. (g) Weld-area crack
Typical flaws in seamless tubing. (a) Blister. (b) Gouge. (c) Lamination. (d) Lap (arrow). (e)
Pit. (f) Plug scores. (g) Rolled-in slugs. (h) Scab. (j) Seam (arrow)
Type of gas porosity commonly found in weld metal. (a) Uniformly scattered porosity. (b)
Cluster
porosity. (c) Linear porosity. (d) Elongated porosity
Wormhole porosity in a weld bead. Longitudinal cut. 20×

Sections showing locations of slag inclusions in weld metal. (a) Near the surface and in the
root of a single-pass weld. (b) Between weld beads in a multiple-pass weld. (c) At the side of
a weld near the root
Lamellar tear caused by thermal contraction strain

External undercut, which is a gouging out of the piece to be welded, alongside the edge of the
top or
external surface of the weld. Radiographic image: An irregular darker density along the edge
of the weld image.
The density will always be darker than the density of the pieces being welded. Welding
process: SMAW. Source:
E.I. Du Pont de Nemours & Company, Inc.
Internal (root) undercut, which is a gouging out of the parent metal, alongside the edge of the
bottom
or internal surface of the weld. Radiographic image: An irregular darker density near the
center of the width of
the weld image and along the edge of the root pass image. Welding process: SMAW. Source:
E.I. Du Pont de

External concavity or insufficient fill, which is a depression in the top of the weld, or cover
pass,
indicating a thinner-than-normal section thickness. Radiographic image: A weld density
darker than the density
of the pieces being welded and extending across the full width of the weld image. Welding
process: SMAW.
Source: E.I. Du Pont de Nemours & Company, Inc.
Internal concavity (suck back), which is a depression in the center of the surface of the root
pass.
Radiographic image: An elongated irregular darker density with fuzzy edges, in the center of
the width of the
weld image. Welding process: GTAW-SMAW. Source: E.I. Du Pont de Nemours & Company,
Inc.

Excessive penetration (icicles, drop-through), which is extra metal at the bottom (root) of the
weld.
Radiographic image: A lighter density in the center of the width of the weld image, either
extended along the
weld or in isolated circular drops. Welding process: SMAW. Source: E.I. Du Pont de Nemours
& Company, Inc.
Offset or mismatch with LOP, which is a misalignment of the pieces to be welded and
insufficient filling
of the bottom of the weld or root area. Radiographic image: An abrupt density change across
the width of the
weld image with a straight longitudinal darker-density line at the center of the width of the
weld image along
the edge of the density change. Welding process: SMAW. Source: E.I. Du Pont de Nemours &
Company, Inc.

Offset or mismatch (high-low), which is a misalignment of the pieces to be welded.

Radiographic
image: An abrupt change in film density across the width of the weld image. Welding process:
SMAW. Source:
E.I. Du Pont de Nemours & Company, Inc.
Burn-through, which is a severe depression or a crater-type hole at the bottom of the weld
but usually
not elongated. Radiographic image: A localized darker density with fuzzy edges in the center
of the width of the
weld image. It may be wider than the width of the root pass image. Welding process: SMAW.
Source: E.I. Du
Pont de Nemours & Company, Inc.

Root pass aligned porosity, which involves rounded and elongated voids in the bottom tom of
the weld
aligned along the weld centerline. Radiographic image: Rounded and elongated darker-density
spots, which
may be connected, in a straight line in the center of the width of the weld image. Welding
process: GMAW.
Source: E.I. Du Pont de Nemours & Company, Inc.
Cluster porosity, which involves rounded or slightly elongated voids grouped together.
Radiographic
image: Rounded or slightly elongated darker-density spots in clusters with the clusters
randomly spaced.
Welding process: SMAW. Source: E.I. Du Pont de Nemours & Company, Inc.
Fig.

Scattered porosity, which involves rounded voids random in size and location. Radiographic
image:
Rounded spots of darker densities random in size and location. Welding process: SMAW.
Source: E.I. Du Pont
de Nemours & Company, Inc.
Elongated slag lines (wagon tracks), which are impurities that solidify on the surface after
welding and were not removed between passes. Radiographic image: Elongated, parallel, or
single darker-density lines, irregular in width and slightly winding in the lengthwise direction.
Welding process: SMAW. Source: E.I. Du Pont de Nemours & Company, Inc.

Interpass slag inclusions, which are usually nonmetallic impurities that solidified on the weld
surface
and were not removed between weld passes. Radiographic image: An irregularly shaped
darker-density spot,
usually slightly elongated and randomly spaced. Welding process: SMAW. Source: E.I. Du
Pont de Nemours &
Company, Inc.
Transverse crack, which is a fracture in the weld metal running across the weld. Radiographic
image:
Feathery, twisting line of darker density running across the width of the weld image. Welding
process: GMAWGTAW.
Source: E.I. Du Pont de Nemours & Company, Inc.

Longitudinal crack, which is a fracture in the weld metal running lengthwise in the welding
direction.
Radiographic image: Feathery, twisting lines of darker density running lengthwise along the
weld at any
location in the width of the weld image. Welding process: GMAW-SMAW. Source: E.I. Du Pont
de Nemours &
Company, Inc.
Longitudinal root crack, which is a fracture in the weld metal at the edge of the root pass.
Radiographic
image: Feathery, twisting lines of darker density along the edge of the image of the root pass.
The twisting
feature helps to distinguish the root crack from incomplete root penetration. Welding process:
SMAW. Source:
E.I. Du Pont de Nemours & Company, Inc.

Lack of penetration, which occurs when the edges of the pieces have not been welded
together, usually
at the bottom of single-V-groove welds. Radiographic image: A darker-density band, with
very straight parallel
edges, in the center of the width of the weld image. Welding process: SMAW. Source: E.I. Du
Pont de Nemours
& Company, Inc.
Lack of sidewall fusion, which involves elongated voids between the weld beads and the joint
surfaces
to be welded. Radiographic image: Elongated parallel, or single, darker-density lines,
sometimes with darkerdensity
spots dispersed along the LOF lines, which are very straight in the lengthwise direction and
not winding
like elongated slag lines. Although one edge of the LOF lines may be very straight as with
LOP, lack of sidewall
fusion images will not be in the center of the width of the weld image. Welding process:
GMAW. Source: E.I. Du
Pont de Nemours & Company, Inc.

Interpass cold lap, which involves LOF areas along the top surface and edge of lower passes.
Radiographic image: Small spots of darker densities, some with slightly elongated tails,
aligned in the welding
direction and not in the center of the width of the weld image. Welding process: GMAW.
Source: E.I. Du Pont
de Nemours & Company, Inc.
Tungsten inclusions, which are random bits of tungsten fused into but not melted into the
weld metal. Radiographic image: Irregularly shaped, lower-density spots randomly located in
the weld image. Welding process: GTAW. Source: E.I. Du Pont de Nemours & Company, Inc.

Schematic illustrating setup for the pulse-echo ultrasonic inspection of resistance-welded spot
welds.
(a) Wave paths in satisfactory weld. (b) Resulting echoes. (c) Wave paths in an unsatisfactory
weld. (d)
Resulting echoes. Source: Ref 1
In
Ultrasonic thickness measurements of resistance spot weld nuggets. (a) Satisfactory weld. (b)
Resulting attenuation of the ultrasonic wave. (c) Unsatisfactory weld. (d) Resulting wave
attenuation. Source:

Typical CRT C-scan displays obtained for both bonded and unbonded structures using three
pulsed
ultrasound techniques. (a) Pulse echo. (b) Through transmission. (c) Reflector plate
Bonded

Replicas of creep damage in pressure vessel components. (a) Random and linked microvoids
in a 1.25Cr-
0.5Mo main steam line weld. 425×. Courtesy of H.I. Newton, Babcock & Wilcox. (b) and (c) A
comparison of
scanning electron micrographs of a replica from 1.25Cr-0.5Mo material with aligned creep
cavities. (b) Normal
contrast. (c) Reversed image contrast. Etched with 4% picral. Courtesy of E.V. Sullivan,
Aptech Engineering
Services, Inc.

Reformer-furnace cell from which cast tubes of ASTM A 297, HK-40, heat-resistant alloy were
radiographically inspected for the detection of creep fissuring. (a) Schematic of furnace cell
showing positions of
radiographic sources and films. Dimensions given in inches. (b) Radiograph of a section
removed from a failed
tube that contained no catalyst showing fissures near the ruptured area. (c) Same section as
(b) but containing
a catalyst. Fissures are visible but less apparent. (d) Macrograph showing fissures in a tube
that were detected
by radiography. 6×. (e) Macrograph showing fine fissuring that was not indicated by
radiography. 6×
The
Creep fissures in a centrifugally cast HK-40 reformer-furnace tube that are detectable by
ultrasonic inspection and by radiography with nickel catalyst in tube. (a) Tube cross section.
0.45×. (b)Tube wall. 2.5×. (c) Enlargement of inside diameter portion of wall shown at
bottom in (b). 7.5×

Longitudinal Crack
Transverse Crack

Throat Crack
Toe Crack

Crater Crack
Propagation of crater crack in an Aluminum weld

Underbead Cracks
Locations of incomplete fusion

İncomplete Fusion at Weld Face

Incomplete Fusion between weld metal and base metal

Side-wall Incomplete Fusion

Examples of Incomplete Joint Penetration

Penetration Faults at bead starts and stops

Incomplete Joint Penetration

Surface Slag Inclusions

Elongated Slag Inclusions

Tungstene Inclusions

Scattered Surface Porosity

Linear Surface Porosity with connecting Crack

Isolated Surface Porosity

Elongated Surface Porosity

Scattered Porosity

Clustered Porosity
Linear Porosity

Typical Appearance of Undercut

Undercut adjacent to a fillet weld

Surface Undercut(It should be found with VT not RT)

Underfill in a Groove weld

Overlap

Overlap a filet and Groove weld

Undercut and Overlap in a fillet weld

Convexity
Face and Root Reinforcement

Face Reinforcement on both side when welded from both sides

Effect of Weld Reinforcement Angle on Fatigue Strength
Improper and Acceptable Treatment of Excessive Weld Reinforcement

Arc Strike
Crack formed at Weld Spatter

Cracking and Delamination due to Lamination

“Lamination : A discontinuity with separation or weakness generally aligned parallel to the
worked surface of a metal”

“Delamination : Separation of a lamination under stress”

Lamellar Tearing

“A subsurface terrace- and step-like separation in the base metal, parallel to the surface, caused by
tensile stresses in the through-thickness direction.
Deep Seam on the surface of Semi-finished rolled product

“Seams and Laps : Longitudinal base metal surface discontinuities found in wrought products”

Cluster Seams on Surface of Semi-Finished Rolled Product

Lap on Surface of Rolled Steel Billet

Crane Hook with service induced crack

Gear with service induced crack

Drive Shaft with heat treatment induced crack

Splined shaftwith service induced crack

Threaded Shaft with service induced crack

Large Bolt with service induced crack

Crank Shaft with service induced crack near lube hole
Lack of fusion- Visible dry powder method

Toe crack – Visible dry powder method

 Throat and toe cracks in partially ground weld

These cracks formed on the inside surface of a tank near a weld.

View from the edge of a sample cut from a tank showing the depth of one crack made visible with
magnetic particle inspection.
Scab

Scab
Scab

Intergranular cracking in the HAZ of weld (pipe A, 12Cr5Ni2Mo), environment

A "blowhole" casting defect in a commercial steel lathe face plate. A bubble of air became mixed into
the molten iron, then froze with the metal into the plate, and was only exposed while machining the
bolt slots. This part is still usable, although overtightening a bolt over the hole could crush part of the
plate.

Cold Shut
An example of a cold shut defect brake caliper casting produced during trials with the CSIR-RCS-HPDC
cell.

Cold shut in a cast aluminum lower control arm

Misrun
Misrun

Corrosion

Solidification Crack
Porosity
Cold Shuts in castings

Core shift in an engine

Core shift
Core chift, Deliklerin contaya göre pozisyonunu kontrol ettiğinizde özellikle 5 ve 6 ncı deliklerde ciddi
bir kayma olduğu görülür.

Forging lap
Forging Lap

Longitudinal weld metal section showing 45° transverse or 'chevron' cracking

Typical example of root HAZ hydrogen crack extending into the weld metal

Weld metal cracking from a root intrusion initiating feature

Chevron Cracking(Burst)
Figure 15.16 (a) Chevron cracking (central burst) in extruded round steel bars. Unless the
products are inspected, such internal defects may remain undetected, and later cause failure
of the part in service. This defect can also develop in the drawing of rod, of wire, and of
tubes. (b) Schematic illustration of rigid and plastic zones in extrusion. The tendency toward
chevron cracking increases if the two plastic zones do not meet. Note that the plastic zone
can be made larger either by decreasing the die angle or by increasing the reduction in cross
section (or both). Source: B. Avitzur.

Cross Section of a forged bar showing a forging burst. The burst is located approximately at the
centerline of the workpiece. Arrow indicates the direction of working. Internal Bursts are also called
as Chevron Cracks. It is associted most commonly with extrusion and drawing operations although it
can be generated by forging.
Schematic illustration of hydrogen blistering: (a) atomic hydrogen trapping in steel discontinuities;
(b) formation of molecular hydrogen and blistering

Magnetic Particle Indication of Flash Line Tear in a Partially Machined Automotive Spindle Forging.
Cold Shut

Coarse Dentritic Segregation

Average grain size 0.045mm, reduced dendrite arm, increase uniformity of grain .

Average grain size 0.125mm, reduced dendrite arm, increase uniformity of grain .

Dendrites, tree-like advance patterns of crystal growth, in stead of actual trees, are the view out my
window this morning.
This micrograph (right), taken with a reflected light microscope, shows the appearance of dendrites
of a copper-tin alloy when observed as a 2D section through the 3D structure.

Deeply etched Co-dendrites

Polymer Dentrites
Cross-Section of Ingot Showing Shrink Cavity

Magnetic Particle Indication of a Sub-Surface Stringer of Non-Metallic Inclusions

Openned Blister
Blister

Blister

Blister
Typical Magnetic Particle Indications of Cracks

Particle Indication at the Weld Between a Soft and a Hard Steel Rod
Magnetic Particle Indications of Segregations

Cross-Section of Ingot Showing Shrink Cavity

Magnetic Particle Indication of a Subsurface Stringer of Nonmetallic Inclusions

Scabs on the Surface of a Rolled Bloom

How Laps and Seams Are Produced from Overfills and Under-Fills
Magnetic Particle Indication of a Seam on a Bar

Section Through Severe Cupping in a 1 3/8-Inch Bar

Magnetic Particle Indications of Forging Cracks or Bursts in an Upset Section, Severe Case

Surface of a Steel Billet Showing a Lap

Magnetic Particle Indication of Flash Line Tear in a Partially Machined Automotive Spindle
Forging

Fluorescent Magnetic Particle Indications of Typical Grinding Cracks

Magnetic Particle Indications of Grinding Cracks in a Stress-Sensitive, Hardened Surface

Magnetic Particle Indications of Plating Cracks

Magnetic Particle Indication of a Typical Fatigue Crack

Fluorescent Magnetic Particle Indications of Cracks in Crankshaft of Small Aircraft Engine

Damaged in Plane Accident
Black magnetic-powder indications of a cold shut in a casting when seen under black light.
Courtesy of
Magnaflux Corporation

Casting viewed under black light showing strong magnetic particle indication with minimal
background
fluorescence. Courtesy of Magnaflux Corporation

Fluorescent magnetic particle indications of quenched-and-drawn drill casing tubing that

shows
rejectable, cracked spiral seams in the tubing when exposed to black light. Courtesy of
Magnaflux Corporation
Black light used to reveal magnetic particle indication of a crack in the centering stud of a
ball-yoketype
universal-joint section of a drive-shaft assembly. Courtesy of Magnaflux Corporation

Black light used to reveal magnetic particle indication of a lap that could lead to potential
failure of a
forged connecting rod. Courtesy of Magnaflux Corporation
Black light used to reveal magnetic particle indication of a dangerous crack near a wheel stud.
The
crack was detected during manufacture. Courtesy of Magnaflux Corporation

Discontinuities on the surfaces of steel billets that can be detected by magnetic particle
inspection. (a)
Arrowhead cracks. (b) Longitudinal cracks. (c) Normal seams. (d) Brush seams. (e) Laps. (f)
Scabs. See text
for discussion.

A cross section through a billet showing pipe from solidification shrinkage.

(Courtesy of C. Hellier.)
Cold Shut
Images of common defects found on hot rolled bars: (a) inclusion, (b) roll marks, (c) seam, and (d) spall or pit.
Source: Courtesy OG Technologies.

Polished transverse section showing a number of quench cracks through the striking end of the pin punch.
A brass component (a) that was being mass produced. A back end defect was present in the bar feedstock, the extent of

which can be seen on the angled section (b).

Marine engine spring washer for 30 mm diameter engine bolts.

Closer view of the zinc electroplated surface and crack.

Fatigue crack path in CT specimens (a) as-welded and (b) post-weld heat treated.
Stress fracture in a cog made brittle by overtreatment. Crack is at 1 o'clock.

Heavy handler, showing the location of boom arm hinge pin in question. The manufacturers name has been deliberately
removed.
Closer view of broken hinge pin at its junction with the boom arm of a heavy handler.

Darker fracture surface around weld is indicative of older part of crack (a); lighter and most recent part of fracture surface
on web, with fatigue striations clearly visible – arrowed on (b).

Crack running around under-cut weld root, arrowed on (a); additional fatigue crack growing towards outer edge of boom

arm, arrowed on (b).

Micrograph of the new bolt thread showing a rolling seam. 2% nital 200X