LACK OF FUSION

DEFINITION
Lack of union in a weld between
- deposited metal and parent
metal, or
parent metal and parent metal,
or
deposited metal and deposited
metal

LACK OF FUSION
CAUSES AND REMEDIES
CAUSES
Insufficient welding
current

REMEDIES
Ensure Correct welding
current

Incorrect electrode angle

Correct welding angle

Too high welding speed.

Optimum welding speed

Improper joint preparation

Improper cleaning

Proper joint preparation

Good cleaning

LACK OF FUSION

LACK OF PENETRATION
CAUSES
Incorrect joint design

Improper welding
parameters.
particularly current

REMEDIES
Correct edge preparation is
required. Ensure correct angle
of bevel & required root gap
Correct welding speed, Correct
current setting

Incorrect electrode
size

Use correct size electrode

Incorrect polarity
where DC is used

Ensure correct polarity.

Maintain key-hole throughout
the run

LACK OF PENETRATION

SLAG INCLUSION
DEFINITION

Entrapment of oxides and non

metallic solid material in the weld
deposit or in between the weld
metal.

SLAG INCLUSION
CAUSES
Improper cleaning of
weld metal between
passes

Proper cleaning of the

Stirring action of arc

slag between passes

REMEDIES

Weld metal not hot

enough to flow properly

Rapid solidification of

weld metal

Preheating the base metal

Use of large size electrode

for root pass welding

Excessive Reinforcement
DEFINITION
WELD DEPOSIT OVER AND
ABOVE THE
REQUIORED SIZE OF
THE WELD
SIGNIFICANCE
THE WEIGHT, WIDTH, RADIUS AND
REINFORCEMENT ANGLE IS
MORE IMPORTANT.

Excessive Reinforcement

Excessive Reinforcement
CAUSES
Poor Fit Up
Excessive welding
current
Low welding speed

REMEDIES
Proper fit up
Correct welding
current
Optimum welding
speed

Improper welding
technique

Correct welding
technique

BURN THROUGH (OR)

EXCESSIVE PENETRATION

Definition
Holes burned through the parent
metal in single pass weld or the
root run in multi run welds.
Creates an opening at the root.

BURN THROUGH (OR)

EXCESSIVE PENETRATION

CAUSES

REMEDIES

Excessive root gap

Correct root gap

Insufficient root

Sufficient root face

face
Excessive welding
current
Low welding speed

Correct welding
current
Optimum welding
speed

ARC STRIKES
Definition
Defect caused when the welder accidentally
or in advertently strikes the electrode or the
electrode holder against the work, adjacent
to the weld causing unwanted arc.
Also happened between a faulty ground
clamp and work
EFFECT OF ARC STRIKES
--Create a hard and brittle condition on
materials
--Arc strikes initiate failure in cyclic loading