Weld Defects 2
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1/29/03 1
WELCOMEWELCOME
ESAB Welding InstituteESAB Welding Institute
ChennaiChennai
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Weld Defects
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Weld Defects
REJECTABILITY
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Weld DefectsFormation of Pores
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Uniformly distributed porosity
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Weld Defects
Surface porosity in a ‘T’ joint on a primed plate
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Porosities in the weld bead
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• Elongated pores or worm holes
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Weld Defects» Principal gases causing porosity and recommended
cleaning methods
• Material Gas Cleaning• C Mn steel Hydrogen, Nitrogen Grind to remove
and Oxygen scale coatings• Stainless steel Hydrogen Degrease + wire
brush • Aluminium and alloys Hydrogen Chemical clean +
wire brush + degrease + scrape
• Copper and alloys Hydrogen, Nitrogen Degrease + wire brush + degrease
• Nickel and alloys Nitrogen Degrease + wire brush + degrease
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Incomplete Fusion of Side Wall
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Incomplete inter-run fusion
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Insufficient Penetration• Root Face too thick
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Insufficient Penetration• Root Face too Narrow
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Insufficient Penetration• Misplaced Welds
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Insufficient Penetration• Power Input too Low
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Insufficient Penetration• Arc (heat) input too low
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Effect of electrode size on root fusion• Too large a diameter
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Effect of electrode size on root fusion
• Too small a diameter
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Weld DefectsPotential and actual Hydrogen levels in Weld
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Weld DefectsHydrogen crack examples
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Weld Defects• Crack in coarse grained HAZ due to
Hydrogen embrittlement
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Weld DefectsPreheating to avoid HIC
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Guide to Preheat Temperature
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• Micrograph of a crack in coarse grained Weld
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Intergranullar morphology of a reheat crack
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Solidification Crack
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Weld bead penetration too small
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• Brittle fracture in CrMoV Steel Pressure Vessel - Combination of Hydrogen Induced Cracking
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Slag inclusion due to a poor bead - Convex
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Smooth Bead profile allows easy slag removal
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Radiograph of Slag Inclusions
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Weld Defects
Grinding out Slag Inclusions
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Thickness measurements
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• Measurement of Combined Thickness
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Lamellar Tearing
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Fracture face of Lamellar Tearing
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Suggested configuration to avoid lamellar Tearing
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Suggested configuration to avoid lamellar Tearing
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• Buttering to avoid Lamellar Tearing
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In-situ buttering to avoid Lamellar Tearing
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• Arc Deflection By Magnetic Forces
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• Bead Deflection in dc SMAW
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