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Take a look at gas flow, material conditions, and consumables to prevent this defect
By Phil Evans November 1, 2010
Porosity is a weld defect that is fairly common, but also fairly easy to fix. What issues contribute to weld porosity? This checklist gives a welder a good idea of what might be causing the problem.
Figure 1 Round holes in the weld bead are a sign of a defect called weld metal porosity. Photo courtesy of Bernard. Weld metal porosity is not a welcome sight in a weld bead, but it shows up all too often. Porosity is weld metal contamination in the form of a trapped gas. Shielding gases or gases released as a result of the torch being applied to treated metal are absorbed into the molten metal and released as solidification takes place. In other instances, the shielding gas doesnt completely reach the weld pool and the atmospheric air adversely affects the weld bead. Evidence of porosity comes in the shape of rounded holes, called spherical porosity (see Figure 1). If the holes are elongated, the defect might be called wormholes or piping. Because porosity has acceptable levels, it is infrequently considered a serious defect. However, depending on the welding code or standard, porosity might be cause for a weld reject. Luckily, porosity is a defect that has an approximate 90 percent prevention rate. With a few tips for identifying possible causes of the porosity, a welder quickly can turn reject parts into weldments that are acceptable under most welding codes.
10. SMAW electrodes, FCAW electrodes, and submerged arc welding (SAW) flux absorb moisture in an unprotected environment. To address moisture in the welding process, codes are pretty clear about the use of dryers and ovens to store these materials. SAW flux in particular is like a sponge. Once the container is opened, the welder should store the package according to the manufacturers directions. 11. The gas flow is too high. Gas flow of 50 to 60 cubic feet per hour (CFH) at the GMAW nozzle and 20 to 30 CFH at the GTAW torch should be plenty. If not, ask why. Wide-open gas flow at the nozzle actually creates turbulence and can pull outside air into the weld zone. Additionally, its a terrible waste of gas and adds unnecessary cost to the project. The only exception might be if the shielding gas contains more than 50 percent helium. 12. A pinched or smashed gas hose doesnt deliver the shielding gas properly. If the gas hose is more than 20 ft. long, the possibility of it kinking is pretty good. 13. Improper use of antispatter compounds, sprays, or gels can be a major contributor to porosity. When used in excess, the antispatter material becomes a contaminant, boiling into a gas when exposed to the high temperatures of the welding arc. Also, jamming the GMAW gun into a container of antispatter gel can result in the gel dripping back into the weld puddle. An operator should use the anti- spatter material properly or not at all. 14. Weld filler metals contaminated with paint, grease, oil, tape, and glue can release gases when exposed to the very hot welding arc. Even dirty gloves used during GTAW can contaminate the consumables. Cleaning solid wire and flux-cored wire with wire wipes and GTAW fillers with steel wool is a good idea. 15. Contaminated GMAW gun liners can introduce unwanted elements to the weld pool. All the grease, oil, dust, and dirt found in the shop environment collects on the wire and ends up in the guns whip liner. Stainless steel and highnickel-alloy wires are especially susceptible to attracting these contaminants. 16. GMAW right on the edge of an outside corner joint might create problems given the awkward position of the nozzle. The nozzle often does not cover the joint properly, causes turbulence, and draws in outside air into the weld joint. 17. If the weld joint is open at the root, it will suck in air from the back side. Unprotected liquid metal can absorb air easily. 18. The welding gas itself could be contaminated. If the welding gas is a suspect, the shop needs the gas supplier to certify that the gas has the correct dew point. 19. A contaminated gas hose could be a culprit, in particular, hoses that have been used for other activities prior to being used in a welding application. In one real-world example, a hose was grabbed from a storeroom to repair a cut hose that was attached to the wire feeder. Unfortunately, a bug had built a nest in the hose while it was sitting undisturbed in the storeroom. In another example, an air hose that was previously used as an air line for a tool on a line with an oil lube system on it was quickly connected to welding equipment only to find out later that the hose was full of air tool oil. 20. Damaged O-ring seals on the GMAW gun whip where it plugs into the wire feeder or the GTAW torch cap where it screws into the torch could introduce unwanted air into the welding process. 21. Cut or burnt hose anywhere from the regulator flowmeter to the connection at the feeder could create issues. 22. A defective gas solenoid at the wire feeder or the GTAW machine is a possible contributor to conditions that create porosity.