Defects AND Discontinuities

DEFECTS
AND
DISCONTINUITIES
DEFECT
• A flaw or flaws that by nature or accumulated effect render
a part or product unable to meet minimum applicable
acceptance standards or specifications. The term designates
rejectability.
WELD JOINT DISCONTINUITIES
• Misalignment (hi-lo) • Inclusions
• Undercut Slag
• Underfill • Spatter
• Concavity or Convexity
• Excessive reinforcement
• Cracks
• Improper reinforcement
• Longitudinal
• Overlap
• • Transverse
Burn-through
• Incomplete or
Insufficient Penetration
• Incomplete Fusion
• Surface irregularity
– Overlap
• Arc Strikes
MISALIGNMENT (HI-LO)
• Definition: Amount a joint is out
of alignment at the root
• Cause: Carelessness. Also due to joining different
thicknesses (transition thickness)
• Prevention: Workmanship. Transition angles not to exceed
2.5 to 1.
• Repair: Grinding. Careful on surface finish and direction of
grind marks. Inside of Pipe /Tube difficult.
Linear Misalignment
UNDERCUT
• Definition: A groove cut at the
toe of the weld and left unfilled.
• Cause: High amperage, electrode
angle, long arc length, rust
• Prevention: Set machine on scrap metal. Clean metal
before welding.
• Repair: Weld with smaller electrode, sometimes must be
low hydrogen with preheat.
UNDERCUT
INSUFFICIENT FILL
• Definition: The weld surface is below the adjacent surfaces
of the base metal
• Cause: Improper welding techniques
• Prevention: Apply proper welding techniques for the weld

type and position.
• Repair: Simply weld to fill. May require preparation by
grinding.
UNDERFILL
CONCAVE AND CONVEX
WELD PROFILES
The concave defect cause the
weld to be weak across the
throat of the weld
(Middle).
The cause of this are:

• Travel speed is to quick
• Amps are to high
• Poor electrode
Manipulation
CONCAVE AND CONVEX
WELD PROFILES
• The convex defect cause the

weld to become weak at the
toes of the weld (outer edges).
• This is caused by :
• Travel speed being to slow
• Amps to low
• Poor electrode manipulation.
EXCESSIVE CONCAVITY OR
CONVEXITY
• Definition: Concavity or convexity of a fillet weld which
exceeds the specified allowable limits
• Cause: Amperage and travel speed
• Prevention: Observe proper parameters and techniques.
• Repair: Grind off or weld on. Must blend smoothly into the
base metal.
Concavity
EXCESSIVE CONCAVITY
Convexity
EXCESSIVE CONVEXITY
REINFORCEMENT
The amount of a groove weld which extends beyond the surface
of the plate
• Excessive Face Reinforcement

• Insufficient
• Improper contour
Root Reinforcement
EXCESSIVE
REINFORCEMENT
• Cause: Travel speed too slow, amperage too low
• Prevention: Set amperage and travel speed on scrap plate.
• Repair: Remove excessive reinforcement and feather the

weld toes to a smooth transition to the base plate.
EXCESSIVE WELD REINFORCEMENT
UNACCEPTABLE
WELD PROFILES
OVERLAP
• Definition: When the face of the weld extends beyond the
toe of the weld
• Cause: Improper welding technique. Typically, electrode
angles and travel speed.
• Prevention: Overlap is a contour problem. Proper welding
technique will prevent this problem.
• Repair: Overlap must be removed to blend smoothly into
the base metal. Be careful of deep grind marks that run
transverse to the load. Also be careful of fusion
discontinuities hidden by grinding.
Overlap
OVERLAP
BURN-THROUGH
• Definition: When an undesirable open hole has been
completely melted through the base metal. The hole may or
may not be left open.
• Cause: Excessive heat input.
• Prevention: Reduce heat input by increasing travel speed,

use of a heat sink, or by reducing welding parameters.
INCOMPLETE OR INSUFFICIENT
PENETRATION
• Definition: When the weld metal does not extend to the

required depth into the joint root
• Cause: Low amperage, low preheat, tight root opening, fast
travel speed, short arc length.
• Prevention: Correct the contributing factor(s).
• Repair: Back gouge and back weld or remove and reweld.

Incomplete Root Penetration
INCOMPLETE FUSION
• Definition: Where weld metal does not form a cohesive
bond with the base metal.
• Cause: Low amperage, electrode angles, fast travel speed,
short arc gap, lack of preheat, electrode too small, unclean
base metal.
• Prevention: Eliminate the potential causes.
• Repair: remove and reweld, being careful to completely

remove the defective area. This is sometimes extremely
difficult to find.
Incomplete Fusion
INCOMPLETE FUSION
ARC STRIKE
• Definition: A localized coalescence outside the weld zone.
• Cause: Carelessness
• Prevention: In difficult areas, adjacent areas can be
protected using fire blankets.
• Repair: Where applicable, arc strikes must be sanded
smooth and tested for cracks. If found, they must be remove
and repaired using a qualified repair procedure and
inspected as any other weld.
Arc Strike
INCLUSIONS
• Slag
• Tungsten
Slag Inclusion
• Definition: Slag entrapped within the weld
• Cause: Low amperage, improper technique, Trying to weld

in an area that is too tight. Slow travel in Vertical Down
• Prevention: Increase amperage or preheat, grind out tight
areas to gain access to bottom of joint.
• Repair: Remove by grinding. Reweld.
Tungsten Inclusion
• Definition: A tungsten particle embedded in a weld.
(Typically GTAW only)
• Cause: Tungsten electrode too small, amperage too high,
AC balance on +, Upslope too high, electrode tip not
snipped, electrode dipped into the weld pool or touched
with the fill rod, electrode split.
• Prevention: Eliminate the cause
• Repair: Grind out and reweld

SPATTER
• Definition: Small particles of weld metal expelled from the

welding operation which adhere to the base metal surface.
• Cause: Long arc length, severe electrode angles, high
amperages.
• Prevention: Correct the cause. Base metal can be protected
with coverings or hi-temp paints.
• Repair: Remove by grinding
SPATTER
Spatter

Defects AND Discontinuities

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Defects AND Discontinuities

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DEFECTS

• Prevention: Apply proper welding techniques for the weld

The cause of this are:

• The convex defect cause the

• Prevention: Observe proper parameters and techniques.

• Excessive Face Reinforcement

• Cause: Travel speed too slow, amperage too low

• Prevention: Set amperage and travel speed on scrap plate.

• Repair: Remove excessive reinforcement and feather the

• Cause: Excessive heat input.

• Prevention: Reduce heat input by increasing travel speed,

• Definition: When the weld metal does not extend to the

• Repair: Back gouge and back weld or remove and reweld.

• Repair: remove and reweld, being careful to completely

• Cause: Low amperage, improper technique, Trying to weld

• Repair: Grind out and reweld

• Definition: Small particles of weld metal expelled from the

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