Weld Discontinuities and defects

Causes & Remedies

Dr.S.Suresh
Sr. Deputy General Manager

Weld Discontinuities and defects

Causes & Remedies

Definition

Influence

Types

Causes

Remedies

Discontinuity & Defect

Discontinuity refers to any interruption or
inin
homogeneity in the material that is otherwise
homogenous
Defect refers to an interruption having dimensions
/features beyond acceptable limits.
Defects are otherwise called as Flaw or
Imperfections that are to be repaired so that the
material is made more homogeneous as assumed in
the design

Weld joint is itself is a Discontinuity

HAZ

WM
PM
The Mi
Th
Microstructure
t
t
iis diff
differentt in
i the
th different
diff
t
regions of weld zones of weld joint.
So the mechanical properties also vary from
zone to
t zone causing
i heterogeneity
h t
it

Discontinuity & Strength

Strength of the weld joint is influenced by
Filler metal strength
Th extent
The
t t off penetration
t ti
Presence of discontinuities in the weld
Presence of stresses in the weld joint

Weld Strength
Lack of penetration

Presence of Fusion related discontinuities

Weld Strength
100% Joint Efficiency
y is obtained when
The weld is carried out on both sides
Back gouging is done after welding the first side
LPI or MPT is carried out after Back gouging
100% RT / UT is carried out after second side
welding

Weld Strength
The Electrode or the filler wire should be selected
such that it
Matches with the strength of the base material
Has fairly low carbon & controlled impurities to
avoid cracking
Moisture level is controlled and is of low H2 type
Is usable in all positions

Influence of discontinuities

They act as stress raisers

They reduce the cross sectional

area and thereby increase the stress
concentration around them

They provide a leak path

They are potential sites of crack

initiation

They act as potential sites of corrosion

and erosion

Types of discontinuities
Metallurgical discontinuity
Fusion type discontinuity
Geometrical discontinuity
Surface discontinuity
Internal
I t
l discontinuity
di
ti it
Voluminar discontinuity
Planar discontinuity

Common surface Discontinuities

Un-equal
Un
equal weld size
Under sized weld
Weld offset ( from seam)
Non-uniform weld size (along the length)
Oversized weld
Excess Penetration
Weld crater
Improper Weld bead Profile
Coarse weld Ripples

Surface Porosity

Excess Convexity

Spatter

Root concavity

Wire sticking

Excess Reinforcement
Overlap
Undercut
Misalignment
Lack of Penetration

C t pin
Crater
i hole
h l
Crater crack
Surface cracks

Common Internal Discontinuities

Porosity
Blow Holes / Aligned / distributed / Cluster /
worm hole Porosities
Lack of fusion/ Lack of Penetration
Lack of side wall fusion / Inter run fusion /
lack of fusion at root
Cracking
Under-bead cracking / delayed cracking /
D l
Delayed
d cracking
ki
/Hydrogen
/H d
induced
i d
d
cracking
Hot cracking, shrinkage cracks, Fatigue
cracking

G
Gouges
& defects
d f t on
Gas cut surfaces

Spatter

Excess Penetration

P
Excess Penetration

Proper Penetration

Excess Penetration

P
Excess Penetration

Proper Penetration

Root Concavity

Undercut & Bead Off-set

Mis-alignment

Mis
Misalignment

Types of Porosity

Distributed Pores

Ali d P
Aligned
Pores

Clustered Pores

Porosity - Cause /Source

Cavities / voids formed due to entrapment of gases when the molten
metal solidifies from liquid state when more gases get dissolved into
molten metal
I d
Inadequate
Gas
G shielding
hi ldi due
d to
Moisture in
Improper setting of gas flow
Plate edges
rates
Non-baked/dried
Improper Torch angles
Electrodes
I
Improper
setting
tti off
Filler wire
welding Parameters
Wet / Non-dried flux
Pneumatic fixture
In the atmosphere

Porosity

Gas
Pores

Slag
inclusion

10 mm

Types of Porosity Distributed and Aligned

Worm hole Porosity

Aligned Porosity

Pin hole Porosity

Pin-hole

Start Stop Porosity

10
mm

Slag Inclusion

Slag Inclusion

Lack of fusion

Lack of Penetration

LOP
1-Lack of penetration
between runs
2-LOP at side wall

Cold Cracking (Under bead cracking)

HAZ

0.5 mm

Cold Cracking (Under bead

cracking)

Lamellar Tearing

Hot Cracking

10 mm

Hot Cracking

Cracking