Definition Types Location Example

Cracks  Longitudinal WM  Hot ( solidification

Is an imperfection  Transverse HAZ or liquidation)
cause by rupture in a  Radiating(radiate PM cracks
solid state, arise from from common point) Crater cracks only in  Precipitation
the effect ofWELDING  Crater
cooling orIMPERFECTION WM induced (reheat
stresses.  Branching(group of
Definition (BS EN ISO 6520-1) cracks in creep
Classed as planar
 Imperfection: Any deviation
connected
fromcracks)
the ideal resisting steel)
defect weld  Cold ( HIC)
Large stress
Defect : An unacceptable imperfection  Lamellar tearing
concentration and
more likely to cause
fracture.

Hot Cracks Hydrogen Induced Cracks (HIC)

Solidification Liquidation  Occur in grain coarsened region of HAZ
Occur in WM (along Occur in coarse grain  Cold, delayed, underbead /toe cracking
centerline of weld) HAZ (Near fusion line)  Path is a combination of inter and transgranular
Solidification Cracking – can be wide and open to cracking
the surface like shrinkage voids  Causes HIC in HAZ:
Occur when: Hydrogen level >15ml/100g of WM
 WM has high carbon or impurity (Sulphur, Stress >0.5 of the yield stress
etc.) Temperature <300°
 Depth-to-width of solidifying weld bead is Susceptible micro >400HV hardness
large (deep and narrow0  Prevention:
 Disruption of heat flow, e.g. stop/start -Apply preheat : slow down cooling rate
 Thermal shrinkage of the cooling weld -maintain specific inter-pass temperature
bead cause rupture and form crack. -Postheat after weld to reduce hydrogen
Lamellar Tearing content
 Occurs only in rolled steel product -Apply PWHT: reduce residual stress
 Has terraced appearance -Proper selection of consumables reduce WM
 Occurs in joints where: hydrogen (TIG intead of MMA, basic instead of
-thermal contraction strain occurs in the through cellulose)
thickness direction of plate -Multi run instead of single run: eliminate
-non-metallic inclusion present in thin platelets susceptible microstructure by self-tempering
 Prevention: and hydrogen diffused.
 Use clean steel with guaranteed through -Blend weld profile: reduce stress concentration
thickness properties (Z grade) at toes of weld
Combination of joint design, restraint control and
welding sequence to minimize the risk
 Type of Cavity Forms Causes Prevention
Gas Pore  Isolated Damp fluxes/corroded use dry electrode
 Spherical shape  Uniformly electrode
trapped with distributed Grease/hydrocarbon or clean prepared surface
weld metal porosity water contamination
Cavities
 Clustered Air entrapment in gas shield check hose connection
porosity
 Linear porosity Too great an arc voltage or reduce voltage and arc
 Elongated cavity length length
 Surface pore Too high shielding gas flow Optimize gas flow rate
rate
Worm holes Gross contamination of Preweld cleaning
 Elongated or tubular cavity preparation surface
 Formed by trapped gas during Laminated work surface Replace parent
solidification material with
 Can appear as a herringbone array on unlaminated piece
radiography Crevices in work surface due Eliminate joint shapes
 Some may break the surface of weld to joint geometry which produce crevice
Surface Porosity Damp electrode Clean surface and dry
 Pores that breaks the surface of weld electrode
 Origin is similar to uniform porosity Low fluxing activity Use high fluxing activity
(MIG/MAG)
Excess sulphur Use high manganese
electrodes
Loss of shielding gas Improve screening
(MIG/MAG) against draughts and
reduce arc length
Shielding gas flow rate is to Optimize flow rate
high
Crater Pipe Lack of welder skill with Retain welder
 Shrinkage cavity at end of weld caused by current too high
shrinkage during solidification Inoperative crater filler Use correct filling tech.
 SOLID INCLUSION
Solid foreign substances trapped in the weld metal

Slag Inclusion
 Lack of Fusion and Penetration
LACK OF FUSION
 Lack of union between weld metal and the
parent meatl or between the sucessive
layer of weld metal

1. Lack of sidewall fusion

- Low heat input Lack of root fusion
- Excessive inductance in - Low heat input
MAG dips transfer - Excessive inductance
welding in MAG dips transfer
- Poor welder skill welding -Large
LACK OF PENETRATION - Oxide on weld root face
preparation -Small root gap
- Incorrect angle
2. Lack of inter-run fusion - excessive
- Low arc current misalignment of root
- Low heat input - Too high travel speed
- Excessively thick root - Inaccurate bead
face - Excessive
inductance in MAG placement
- Root gap too small
- Low heat input dips transfer welding
- Excessive inductance in -Large root face
MAG dips transfer -Small root gap
welding - Incorrect angle
- MMA electrode too - excessive
large misalignment of root

Undercut
 Irregular groove at the toe of a run in the Caused by:
parent metal. CAP
 Characterized by depth, length and  Excessive current
sharpness  Welding speed too high
 Excessive weave
 Electrode too large
ROOT
 Root gap too large
 Excessive arc energy
 Small or no root face

Overlap
Caused by:
 Poor electrode manipulation
 High heat input/slow travel speed
 Incorrect positioning of weld
 Wrong electrode coating Type: resultin too high a Linear and Angular Misalignment
fluidity

Burn-through
Caused by:
 Insufficient travel speed
 Excessive weld current
 Lack of welder skill
 Excessive grinding of root face
 Excessive root gap

Root Imperfection Caused by :

 Inaccurate assembly
 Distortion from other weld
 Excessive weld metal

Spatter
Gobule of weld or filler metal expelled during
welding
Caused by:
 High arc current
 Long arc current
 Magnetic arc blow
 Incorrect setting for GMAW
 Damp electrode
Wrong selection of welding gas (100CO2)