M.

Rogers
WI 3.1

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Welding Imperfections
Course notes section reference 3

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WI 3.1
Weld Defect Classification
Defects can be grouped under three main
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classifications
Planar Defects: linear from at least one dimension
• Cracks
• Lack of fusion
Linear Volumetric Defects: Linear in length with volume
• Slag lines
• lack of fusion with associated slag
• Piping.
Non-planar defects: rounded indications without significat length
• Slag inclusions
• Gas pores/blow holes.
• Other matallic and non-matallic inclusions

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WI 3.1
Faults in Fusion Welds
Defects which may be detected by visual inspection
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can be grouped under the following headings

Cracks Lack of fusion

Solid inclusions Mechanical damage

Surface and profiles Parent material damage

Misalignment (set-up Miscellaneous

irregularities)

Gas pores and porosity

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WI 3.1
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Cracks

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WI 3.1
Cracks
Cracks that may occur in welded materials are caused
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generally by many factors and may be classified by
shape and position, cracks are classed as planar.

Classified by Shape Classified by Position

Longitudinal HAZ
Transverse Centreline

Branched Crater

Chevron Fusion zone

Parent metal

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Cracks
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Longitudinal parent metal crack Transverse weld metal crack

Longitudinal weld metal crack Lamellar tearing

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WI 3.1

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Transverse crack Longitudinal crack

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Inclusions

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WI 3.1
Gas Cavities
Gas pore <1.5mm Blow hole.>1.6mm
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Gas pore Cluster porosity

Loss of gas shield

Damp electrodes

Contamination
Blow hole
Herringbone porosity Arc length too large

Damaged electrode flux

Moisture on parent material

Welding current too low

Root piping
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Gas Cavities
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Porosity

Root piping

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Cluster porosity Herringbone porosity

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Solid Inclusions
Slag inclusions are defined as a non-metallic inclusion
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caused by some welding process

Slag originates from welding
flux
MAG and TIG welding
process produce silica
Slag inclusions Lack of sidewall inclusions
fusion with
associated slag
Slag is caused by
inadequate cleaning
Other inclusions include
tungsten and copper
inclusions from the TIG and
Parallel slag lines Lack of interun
fusion + slag MAG welding process
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WI 3.1
Solid Inclusions
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Lack of interun fusion + slag

Lack of sidewall fusion + slag

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Interpass slag inclusions Elongated slag lines

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WI 3.1

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Lack of Fusion

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Lack of Fusion
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Poor welder skill

Incorrect electrode
manipulation
Incomplete filled groove
+ Lack of sidewall fusion Arc blow
Incorrect welding
1 current/voltage
2
Incorrect travel speed
1. Lack of sidewall fusion Incorrect inter-run cleaning
2. Lack of inter-run fusion

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WI 3.1
Lack of Fusion
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Lack of sidewall fusion + incomplete filled groove

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Overlap
An imperfection at the toe or root of a weld caused by
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metal flowing on to the surface of the parent metal

without fusing to it

Contamination

Slow travel speed

Incorrect welding technique

Current too low

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WI 3.1
Overlap
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Toe Overlap
Butt weld

Toe Overlap
Fillet weld

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Weld Root Defects
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Low Amps/volts

Large Root face

Small Root Gap

Lack of root fusion
Fast Travel Speed

Incorrect Electrode Angle

Contamination
Incomplete root penetration
Arc blow

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WI 3.1
Weld Root Defects
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Lack of root fusion Incomplete root

Penetration

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Lack of root penetration Lack of root fusion

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Surface & Profile

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Weld Profile Defects
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Incomplete filled groove Poor cap profile

Poor cap profiles and excessive

cap reinforcements may lead to
stress concentration points at
the weld toes and will also
contribute to overall poor toe
blend Excessive cap height

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WI 3.1
Weld Profile Defects
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Poor Cap Profile & Poor Toe Blend

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Excess cap reinforcement Incomplete filled groove

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Weld Profile Defects
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Poor stop/starts

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Miscellaneous Defects

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Miscellaneous Defects
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Spatter

Excessive current

Damp electrodes

Contamination

Incorrect wire feed speed

when welding with the MAG
welding process

Arc blow

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WI 3.1
Miscellaneous Defects
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Accidental striking of the arc

onto the parent material

Faulty electrode holder

Poor cable insulation

Poor return lead clamping

Arc strike

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WI 3.1
Cap & Root Undercut
An irregular groove at the toe of a weld run in the
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parent metal
Excessive amps/volts

Excessive travel speed

Incorrect electrode angle

Excessive weaving

Incorrect welding technique

Electrode too large

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Cap Undercut
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Intermittent Cap Undercut

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Root undercut Cap undercut

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Weld Root Defect
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A shallow groove caused by contraction in the weld

metal along each side of the penetration bead

Insufficient weld metal

deposited in the root pass

Too fast a cooling rate during

the application of the root
bead pass
Shrinkage groove Poor welding technique

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Weld Root Defect
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A shallow groove, which may occur in the root of a butt weld

Root gap too large

Excessive back purge pressure

during TIG welding

Excessive root bead grinding

before the application of the
Concave root
second pass

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Weld Root Defect
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Concave Root

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Weld Root Defect
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Root penetration bead in excess in accordance with the
relevant specification being used

Root faces too small

Root gap too large

Excessive amps/volts
Excessive root penetration Slow travel speed

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Weld Root Defect
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Excessive root
penetration

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Concave root Excess root penetration

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Weld Root Defect
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A localized collapse of the weld pool due to excessive

penetration resulting in a hole in the root run

High Amps/volts

Small Root face

Large Root Gap

Slow Travel Speed

Burn through

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WI 3.1
Weld Root Defect
Burn Through
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Oxidized Root (Root Coking)
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Loss or insufficient back

purging gas

Most commonly occurs

when welding stainless
steels

Purging gases include

argon, helium and
occasionally nitrogen

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WI 3.1
Crater Pipe
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Weld crater

Crater pipe

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Crater Pipe
Crater pipe is a shrinkage defect and not a gas defect, it
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has the appearance of a gas pore in the weld crater

Crater cracks Too fast a cooling rate

(Star cracks)
Deoxidization
reactions and liquid to
solid volume change

Contamination
Crater pipe

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Mechanical Damage

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Mechanical Damage
Mechanical damage can be defined as any surface material
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damage cause during the manufacturing process.

This can included damage caused by:

Grinding

Hammering

Chiselling

Chipping

Breaking off welded attachments (torn surfaces)

Using needle guns to compress weld capping runs

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Mechanical Damage
Chipping Marks
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Mechanical Damage/Grinding Mark

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Set-up Irregularities

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WI 3.1
Unequal Leg Lengths
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A variation of leg lengths on a fillet weld

Note: Unequal leg lengths on a fillet weld may be specified

as part of the design, in which case it will not be
considered as a defect.

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Set-up Irregularities
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Linear misalignment is
measured from the lowest
plate to the highest point.

Plate/pipe Linear Misalignment

(Hi-Lo)

Angular misalignment is
measured in degrees

Angular Misalignment

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WI 3.1
Set-up Irregularities
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Linear Misalignment
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Set-up Irregularities
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Linear Misalignment

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