I

n the January 2011 AWS publication of Inspection Trends,

Albert J. Moore Jr. states that other than the measuring tape, the
fillet weld gage is the most used measuring device in the welding
inspectors kit. We agree with this statement, but are also
convinced that the fillet weld gage is THE most underused tool by
people responsible for quality and welding operations. In our
experience 98% of fillet gages are owned by CWIs and other
inspectors, yet welders, supervisors and production managers
should all be using them, as they are always conducting welding
inspection. We also know that other than CWIs most people that
owned these gages use them improperly.
There are several kinds of gages used in measuring welds and weld defects such as
porosity, undercut, underfill, concavity, etc. The two most used and certainly our
favorites are the Standard Fillet Weld Gage and the AWS Gage (Automatic Weld
Size Gage). Below are instructions and graphics on how to use both.
Standard Fillet Weld Gage
This Fillet Weld Gage is on of the easiest to use and it is helpful to check for fillet
size and concavity. We always want our welds to be flat to slightly convex. This
gage will let you know if your weld is concave.

A weld fillet gage set will typically include 7 or more pieces similar to this one.

Example of properly sized 1/2 fillet weld

The illustrations above show you how to test a 1/2 fillet. Slide the gage and have
the top end rest against the vertical piece. This end should be exactly at the top
edge of the weld to be a 1/2 fillet. If there is space between the gage and the toe of
the weld then the weld is undersized. The bottom edge of the fillet has more room.
This is to allow for a larger leg size. This is sometimes useful with big fillet welds

were gravity will tend to make the bottom leg larger. The vertical line will show
where the bottom toe should be.

Once we have determined that our weld is properly sized at 1/2 we test for
concavity/convexity. As a general rule of thumb fillet welds should never be
concave. The protrusion in the middle of the gage should make contact with the
weld this verifies that the weld is not concave. If there is daylight between the
face of the weld and this end of the gage then our weld is concave and no longer an
acceptable 1/2 fillet.
Below are examples of welds that were supposed to be 1/2 but ended up being
undersized and convex.

Fillet weld was supposed to be 1/2 but fillet gage shows it is undersized

This weld may have measured at 1/2 but has a concave face making it an unacceptable 1/2 fillet

AWS Gage
This gage is more versatile than the Standard Fillet Gage. Below is all it can
measure:
1. Size of a fillet weld place gage against the toe of the weld and slide the pointer
down towards the bottom piece of the structure being welded. The size of the fillet
weld will be indicated by the gage.

Measuring a fillet weld

2. Permissible tolerance of convexity Using the end of the gage that has the 45degree angle sides bring the gage until it touches both pieces being welded. Once
again, slide the pointer down, this time until it touches the face of the weld. The
gage will indicate if there is too much reinforcement.

Checking for a flat face and/or measuring amount of reinforcement (convexity) on a fillet weld

3. Permissible tolerance of concavity and underfill Doing the same as when

checking for permissible convexity the gage will indicate if there is a concave weld.

Measuring underfill/concavity on a fillet weld

4. Permissible tolerance of reinforcement Butt weld will sometimes have a

specified maximum reinforcement allowed. Placing the gage as shown above you
will be able to measure reinforcement on a butt weld.

Measuring reinforcement on groove butt weld

There are other gages that can also measure undercut, misalignment, amount of
porosity, and angle of preparation.
Do you have a preferred gage? If not, are you considering one of the above or some
other one?