Welding Efficiency & Learning Defects (W.E.L.D) Cardshost.msgapp.com/uploads/95843/Attachments for...

Welding Efficiency &

Learning Defects

(W.E.L.D) Cards

1033480-01A

RealCareer® Welding SolutionsguideWELD™ LIVE real welding guidance

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Ideal weld path and look for tee and butt joints

Definition

The proper weld filament, consistent path and fusion.

Tee Joint

V-Groove Joint


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W.E.L.D – Define, then check your welder and technique

Porosity

Causes

Improper shielding

Contaminated metal

Check Your Welder

Adjust shielding gas flow

Clean nozzle from spatter

Clean diffuser from spatter

Check Your Technique

Keep Contact-To-Work distance ¼” to ½”

Keep nozzle out of the weld puddle

Clean base metal

Definition

The presence of inclusions or gas pockets in a weld.


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Undercut

Causes

Improper settings

Improper work angle

Fast travel speed

Rust

Check Your Welder

Decrease voltage or increase wire feed speed


Keep work angle around 45* for a fillet weld and 90* for a groove weld

Slow down travel speed

Clean base metal

Definition

A groove melted into the base metal adjacent to the toe or root of a weld and left unfilled by weld metal.


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OverlapCauses

Improper settings

Improper work angle

Fast travel speed

Rust

Check Your Welder

Decrease voltage or increase wire feed speed




Clean base metal

Definition

The overhang of weld metal beyond the bond at the toe of a weld.


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Incomplete Joint Penetration

Causes

Improper settings

Fast travel speed

Improper work angle

Too long wire stick out

Improper (too steep) travel angle

Improper joint penetration

Check Your Welder

Adjust settings for the thickness of the base metal

Increase voltage if paired with overlap

Increase wire feed speed if paired with undercut


Increase root opening

Align metal in joint to be even and square

Assure proper bevel angle, if necessary


Keep travel angle at 0* - 15*

Keep contact-to-work distance ¼” to ½”

Slow down travel

Definition

When during/after a weld, the filler metal fails to penetrate and fuse with an area of the weld joint.


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Incomplete Fusion

Causes

Improper settings

Travel speed to fast

Improper work angle

Contamination base metal

Improper (too steep travel angle)

To long wire stick out

Check Your Welder

Adjust setting for the thickness of the base metal

Increase voltage if bead is large and ropey

Increase wire feed speed if bead is small and using proper travel speed



Keep travel angle at 0* -15*

Keep contact-to-work distance ¼” – ½”


Clean base metal

Definition

When during a weld, the failure of a welding process to fuse, or join together, layers of weld metal or weld metal and base metal.


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SpatterCauses

Improper settings

Too long wire stick out

Improper work angle

Contaminated base metal

Improper travel angle

Check Your Welder

Adjust settings for the thickness of the base metal

Decrease voltage if paired with undercut



Keep travel angle at 0*-15*

Keep contact –to work distance ¼” – ½”

Clean base metal

Definition

The metal particles expelled during arc and gas welding which do not form a part of the weld.


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CracksCauses

Stress in the weld and HAZ

Improper bead contour

Fast cooling

Improper travel speed

Improper filler

Improper weld termination

Check Your Welder

Use filler metal with a matching tensile strength and similar composition as base metal


Allow metal to cool on its own

Preheat metal

Adjust travel speed so that contour of weld is proper

Pause at end of weld to fill crater

Definition

A narrow break in the weld metal, base metal, or the crater formed at the end of a weld bead.


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Excessive Concavity or Insufficient Reinforcement

Causes

Improper settings

Fast travel speed

Check Your Welder

Increase wire feed speed


Slow down travel

If multi-pass weld, weld more passes to fill

Definition

When the distance from the weld face perpendicular to a line joining the weld toes curves inward toward the weld joint.


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Excessive Convexity or Reinforcement

Causes

Improper settings

Slow travel speed

Improper travel (too steep) angle

Check Your Welder

Decrease wire feed speed


Speed up travel

If multi-pass weld, weld less passes

Grind to proper size

Keep travel angle at 0*-15*

Definition

When the distance from the weld face perpendicular to a line joining the weld toes curves outward and away from the weld joint.


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