Welding Standards and Training

For a little under 2 years McClain E-Z Pack hired Jim

Davis, a recently retired welding instructor, to work
with me on a part-time basis to help the welders
improve weld quality. During that time, the question
came up, what was the difference between a good
weld and a bad weld.
It was decided that showing pictures of good and bad
welds was the best way to get the message across.
Mr. Davis and I made our own examples of
acceptable and unacceptable welding practices and
posted the following pictures and comments. The
last picture is of an actual production weld.

Problem:

Excessive undercut

Potential Problems:

Failure of Weld

Possible Causes:

Voltage too high

Welding speed too fast
Improper manipulation of weld puddle

Remedies:

Raise voltage
Lower wire speed
Spend more time on outside of weave

Notes:
Undercut causes stress risers in a section of the weld zone that may have been hardened
as a result of the heat of the weld.
Painting does not always cover undercut. This causes rust streaks on the product.

Problem:

Acceptable weld

Potential Problems:

None

Possible Causes:

Good work

Remedies:

Keep up the good work

Notes:
Although amount of spatter in the picture is high the weld size and shape is good. Note
also the frequency and shape of the ridges.

Problem:

Acceptable tack

Potential Problems:

None

Possible Causes:

Good work

Remedies:

Keep up the good work

Notes:
Note the size and shape of the middle tack.

Problem:

Oversize tack

Potential Problems:

Difficult to weld over

Unneeded expense
Weld failure

Possible Causes:

Workmanship

Remedies:

Make tacks smaller

Notes:
Although a decent looking tack, larger tacks are difficult to weld over and avoid
excessive weld metal or a bead with humps in it. Oversized tacks increase the cost of
the production in material, labor and overhead cost. Also see excessive weld metal.

Problem:

Excessive weld metal in weld crater

Potential Problems:

Extra time for cleaners to remove

Extra cost in welding wire, shielding gas, man-hours, overhead
Looks sloppy
Possible weld failure

Possible Causes:

Allowing too much for weld termination

Remedies:

Increase voltage and amps

Increase speed
Smaller and more concave tacks

Notes:
Excessive weld metal raises the price of the product, lowers efficiency, lowers
production, and is a sign of poor workmanship. Excessive weld metal also causes stress
risers in the weld which could cause weld failure

Problem:

Poor weld profile, too much on lower leg

Potential Problems:

Weld failure, on top leg

Possible Causes:

Wrong torch angle

Joining parts of different thickness

Remedies:

More attention to both legs of weld

Hold torch longer on thicker part

Notes:
Uneven legs mean that there is insufficient weld on one leg and could cause the weld to
fail, because of an uneven distribution of stress in the legs of the weld.

Problem:

Insufficient weld
Improper weld speed

Potential Problems:

Weld failure
Increase cause weld fatigue

Possible Causes:

Weld speed too fast

Improper torch angle

Remedies:

Slower speed
Increase amperage
Decrease voltage

Notes:
Note also the tight angles in the ridges on the weld. Besides the obvious problems
associated with an insufficient weld, the pointed ridges are a sign that the grains in the

metal are not properly interlocking. This could result in a centerline crack within the
weld.

Problem:

Good weld crater

Potential Problems:

None

Possible Causes:

Good workmanship

Remedies:

Keep up the good work

Notes:
Excellent, torch angle and direction of travel.

Problem:

Porosity

Potential Problems:

Weld failure
Could be a sign of bigger problems under the weld metal

Possible Causes:

Poor gas flow

Excessive heat
Drafts
Impurities in weld zone (rust, dirt, moisture)
Improper torch angle or stickout

Remedies:

Adjust torch angle or stickout

Increase weld speed
Correct shielding gas
Check for drafts in the work area (e.g., open doors, fans, etc)

Notes:
Porosity on the surface of the weld may also be a sign of porosity hidden in the weld
metal. Porosity is caused by something disrupting the shielding gas over the weld
puddle. It may be caused by excessive as well as insufficient gas flow.

Painting does not always cover porosity. This causes rust streaks on the product.

Problem:

Poor weld profile

Improper fusion, both legs
Improper weld contour
Bead face too high

Potential Problems:

Weld failure

Possible Causes:

Poor gas flow

Excessive heat
Poor torch angle

Remedies:

Adjust torch angle

Increase weld speed
Correct shielding gas
Decrease wire stick-out

Notes:
Give more attention to torch angle, speed of travel, wire stickout, and wire length.

Problem:

Excessive spatter

Potential Problems:

Weld failure
Poor workmanship
Unneeded cleaning

Possible Causes:

Poor gas flow

Excessive heat
Poor torch angle

Remedies:

Adjust torch angle

Increase weld speed
Correct shielding gas
Decrease wire stick-out
Decrease voltage or increase amperage

Notes:
Spatter just looks bad and cause increased cleaning cost. Spatter may be caused by poor
gas flow. See porosity for more possible remedies.

Problem:

Whisker

Potential Problems:

Poor workmanship
Unneeded cleaning

Possible Causes:

Burning off extra wire

Amperage too high

Remedies:

Adjust torch angle

Increase weld speed
Decrease wire stick-out
Decrease voltage or increase amperage

Notes:
Whiskers just looks bad and cause increased cleaning cost. Whiskers are a sign of poor
workmanship and pride.

Problem:

Overlay or Overlap

Potential Problems:

Could cause failure

Insufficient penetration

Possible Causes:

Poor workmanship
Excessive weld
Welding too slow
Amperage and Voltage too high
Joining parts of different thickness

Remedies:

Adjust torch angle

Increase weld speed
Decrease voltage or increase amperage

Notes:
Could be a sign that weld isnt penetrating into base metal on the one side. If this occurs
while welding parts of different thickness, hold the torch longer on the thicker part.
Painting does not always cover overlap. This causes rust streaks on the product.

Problem:

Super Vertical-Up Weld

Potential Problems:

None

Possible Causes:

Good workmanship

Remedies:

Keep up the good work (says Jim Davis)

Notes:
Excellent, torch angle and direction of travel.