WELDING DEFECTS AND REMEDIES

In the process of welding various

materials precautions must be taken to prevent
the development of certain defects in the weld
metal otherwise these defects that are significant
in any welding process.
Welding Defects
and Remedies Blowholes
Blowholes are cavities cause by gas entrapment during
the solidification of the weld metal.
 CAUSES
They usually develop because of improper manipulation of the
electrode and failure to maintain the molten pool long enough
to float out the entrapped gas, slag, & other foreign matter.

REMEDIES
Blowholes can be avoided by keeping the molten pool at
uniform temperature throughout the welding operation.
This can be done by using a constant welding speed so
the metal solidifies evenly.
CAUSES
When gas and other matter become trapped
in the grains of the solid metal, small holes
are left in the weld after the metal cools.

REMEDIES
 Welding Defects
and Remedies INCLUSION
Inclusions are impurities or foreign substances which are
forced in a molten puddle during the welding process.

Any inclusion tends to weaken a weld because it has the

same effects as a crack. A typically example of an
inclusion is slag which normally forms over a deposited
weld.
CAUSES
If the electrode is not manipulated correctly, the
force of the arc causes some of the slag particles
to be blown into the molten pool.

Dirt from the base metal

REMEDIES
 CAUSES
When the molten metals freeze before these inclusions.
before the solidification of metals. Another caused of this
defect is the dirty work.

Unclean
Slag

REMEDIES
However if the parent metal is properly clean and electrode
is manipulated correctly with the proper setting of current,
inclusion can be avoided, or at least kept to a minimum.
 Welding Defects
and Remedies CRACKS
Cracks which occur in the weld and heat affected zone are
the major threat to the survival of the weldment. Cracks
form stress concentration areas at their extremities causing
them to propagate.
 CAUSES
Cracks are the result of stresses usually generated by
shrinkage forces concentrated in localized areas where
brittleness.

All rights reserved or where

low strength grain boundary
precipitants exist and the
material responds to the
stress by cracking rather
than yielding or elongating.

REMEDIES

Use the best electrode for the job, do not deep the
Work in the water to cool down immediately. Let them
Cool in normal way to ensure the quality of weld.
 Welding Defects
and Remedies POROSITIES
Porosity Is refers to the formation tiny pinholes generated
by atmospheric contamination. Some metals have a high affinity for
oxygen & nitrogen when in a molten state unless

an adequate protective shield is protective shield is provided over

the molten metal, gas will enter the metal and weaken it.
 CAUSES

Most of the time the causes of this particular defect is the

too long arc length and not properly storage of electrode.

Incorrect arc length Proper arc length

REMEDIES
To minimize the problem in porosities proper arc length
should always be considered before and during the
welding process. Proper temperature also in storing the electrode to
avoids the moisture to penetrate in the flux
coating.
 Welding Defects
and Remedies UNDERCUT
Undercut is the small groove along the entire length of
weld. It is formed because of excessive heat produced during the
welding process.
 CAUSES

Most of the time the one main causes in this type of

welding defect is that the amperage setting. Specifically
is the to high of amperage used in the parent metal.

REMEDIES
Always observe the proper amperage during welding; proper
current should be base on the thickness of the parent metal.
As a general rule when the thickness of the metal become
increases it goes also the welding current.
Welding Defects
and Remedies INCOMPLETE PENETRATION

It is sometimes called lack of fusion. This the lack to

penetrate the molten pool in the parent metal during
the welding process.
 CAUSES
A number of causes of this defect is the incorrect or very
low amperage or current setting, welding speed is too
fast, incorrect electrode angle and edge preparation.

REMEDIES

Increase the current setting and adjust as much as

possible your travel and speed.
 Welding Defects
and Remedies METAL DISTORTION
Distortion results from the expansion and contraction of the
Weld details during heating and cooling. During the
Solidification of the weld melt it shrinks transversely and

longitudinally and as a result tends to draw the details

together resulting in buckling or other visual evidence of
distortion.
 Welding Defects
and Remedies

TYPES OF DISTORTIONS

When two plates are welded at the

Angular
right angles, with the weld on one
side only, the plates will not remain at
right angles when the joint has cooled.

When a weld is deposited on one side

Transverse Of a flat narrow strip of sheet which is
Not clamp or held down, the strip will
Bend upward or downward.

When two plates are being butt welded

Together and are free too move, they
Longitudinal Will be drawn closer together by
Contraction across the weld metal.
REMEDIES

DISTRIBUTION OF STRESS
BACK STEP WELDING
RESTRAINING THE PARTS
PRESETTING THE PARTS
 WELDING DEFECTS AND REMEDIES

a. Correct bead
Unfilled Crater
b. Speed too slow
c. Speed too fast and Arc length too high
d. Amperage too low
e. Amperage too high
f. Amperage too high and speed too slow
g. Amperage too low and speed too fast
During welding process