SPATTERS

UNDERCUT
POROSITY / BLOW HOLES
LACK OF FUSION
LACK OF PENETRATION
SLAG INCLUSION
EXCESSIVE REINFORCEMENT

COMMON WELDING DEFECTS

-CONTD

END CRATER
ARC STRIKES
BURN THROUGH
CRACKS
DISTORTION

Definition
Small Metal Particles Thrown Out Of The Arc
During Welding

CAUSES
Current too high
Long arc
Wrong polarity
Arc blow
Uneven flux coating

UNDERCUT
DEFINITION
A groove cut into the base metal
along the toe of a weld and left
unfilled by the weld metal.

UNDERCUT
CAUSES

REMEDIES

Current too high

Ensure proper

High Welding speed

current

Faulty electrode

Correct welding

manipulation
Wrong electrode
angle

speed
Correct arc length
Correct manipulation
of electrode

POROSITY/BLOW HOLES
Group of pin holes on the surface of the weld
due to gas entrapment.
CAUSES
Presence of contaminants on job or electrode
Presence of high sulphur in the job or electrode
materials
Trapped moisture
Fast freezing of weld metal
Improper cleaning of the edges

POROSITY/BLOW HOLES
CONTD

REMEDIES

Remove oil, grease, rust, paint, moisture

Use fresh and dried electrodes
Use good flux coated electrodes
Avoid long arcs

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

Proper joint preparation

Improper cleaning

Good cleaning

LACK OF FUSION

LACK OF PENETRATION
CAUSES

REMEDIES

Incorrect joint design

Correct edge preparation is

required. Ensure correct angle
of bevel & required root gap

Improper welding
parameters.
particularly current

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

REMEDIES
Proper cleaning of the
slag between passes

Stirring action of arc

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

Correct welding

current

current

Low welding speed

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

ARC STRIKES

CRACKS
DEFINITION
Cracks are the linear ruptures of the metal
under stress.
Classification : hot, cold, base metal, crater,
micro fissuring

CRACKS
CAUSES
Presence of
localized stress
Fast cooling
Improper welding
techniques
Poor Ductility
Absence of preheating and
post heating on
High Carbon steels

REMEDIES
Pre-heating and
Post heating to
be done on high
carbon
steel
Uniform cooling
Use fewer passes
Adopt proper
welding
technique

DISTORTION

DEFINITION
Deviation from the desired shape due to
residual stresses.
Resistance created by surrounding cold
metal to the cooling weld metal is the
cause for residual stresses and distortion

DISTORTION
CAUSES
REMEDIES
Presence of
residual stresses
Absence of pre &
post heating

Design
Accuracy of
manufacture
Assembly procedure
Counter allowance
Welding sequence