SHS

TVL-IA (Shielded Metal Arc Welding NC 1)

Activity Sheet Quarter 2 – Competency 3.1
Weld Defects, Causes and Remedies

REGION VI – WESTERN VISAYAS

TVL - IA (SMAW NC 1)
Learning Activity Sheet No. 3
First Edition, 2020

Published in the Philippines

By the Department of Education
Region 6 – Western Visayas

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Introductory Message

Welcome to TVL - IA (SMAW NC 1)

!

The Learning Activity Sheet is a product of the collaborative efforts of the

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 Learning Activity Sheets (LAS) No. 3

Name of Learner: __________________________________________________________

Grade and Section: ________________________ Date: __________________________

TVL - IA (SMAW NC 1) ACTIVITY SHEET

Weld Defects, Causes and Remedies

I. Learning Competency with Code

3.1 Perform finished weldment based on acceptable standards for:

3.1.1 Spatters
3.1.2 Slag
3.1.3 Uniformityofbeads TLE_IAAW9-12FWIIIg-j-3

II. Background Information for Learners

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 Types of Welding Defects:

Welding defects are broadly classified into two categories, and these are:
1. External welding defects (Defects occur on the upper surface of the
welded work).
2. Internal welding defects (Defects occur under the surface of the welded
work).

I. EXTERNAL WELDING DEFECTS

The various types of external defects with their causes and remedies are
listed below:

A. Weld Crack. This is the most unwanted defect of all the other welding defects.
Welding cracks can be present at the surface, inside of the weld material or at the
heat affected zones.

Source:www.theweldingmaster.com

Crack can also appear at different temperatures:

1. Hot Crack – It is more prominent during crystallization of weld joints where

the temperature can rise more than 10,000-degree Celsius.

2. Cold Crack – This type of crack occurs at the end of the welding process
where the temperature is quite low. Sometimes cold crack is visible several
hours after welding or even after few days.

Causes of Weld Crack:

1. Poor ductility of the given base metal.
2. The presence of residual stress can cause a crack on the weld metal.
3. The rigidity of the joint which makes it difficult to expand or contract the metals.
4. If there is high content on Sulphur and carbon then also the cracks may appear.
5. Using hydrogen as a shielding gas while welding ferrous materials.

Remedies for Weld crack:

1. Using appropriate materials may decrease the chances of crack.
2. Preheating the weld and reducing the cooling speed joint helps in reducing crack.
3. Reduce the gap between the weld joints by using reasonable weld joints.

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4. While welding releases the clamping force slowly which increases fill to capacity
of welding material.
B. Undercut. When the base of metal melts away from the weld zone, then a groove
is formed in the shape of a notch, then this type of defect is known as undercut. It
reduces the fatigue strength of the joint.

Source:www.theweldingmaster.com

Causes of Undercut:
1. If the arc voltage is very high then this defect may occur.
2. If we use the wrong electrode or if the angle of the electrode is wrong, then also
the defect may form.
3. Using a large electrode is also not advisable.
4. High electrode speed is also one of the reasons for this defect.

Remedies for Undercut:

1. Reduce the arc length or lower the arc voltage.
2. Keep the electrode angle from 30 to 45 degree with the standing leg.
3. The diameter of the electrode should be small.
4. Reduce the travel speed of the electrode.

C. Spatter. When some metal drops are expelled from the weld and remain stuck to
the surface, then this defect is known as spatter.

Source:www.MillerWelds.com

Causes of Spatter:
1. High welding current can cause this defect.
2. The longer the arc the more chances of getting this defect.
3. Incorrect polarity
4. Improper gas shielded may also cause this defect.

Remedies for Spatter:

1. Reducing the arc length and welding current
2. Using the right polarity and according to the conditions of the welding

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3. Increasing the plate angle and using proper gas shielding

D. Porosity. Porosity refers to small cavities or holes resulting from gas pockets in
weld metal.

Source:www.MillerWelds.com

Causes of Porosity:
1. It occurs when the electrode is not coated properly.
2. Using a longer arc may also increase its chances.
3. Increased welding currents.
4. Rust or oil on the welding surface.

Remedies for Porosity:

1. Proper selection of the electrode
2. Decreasing the welding current
3. Using smaller arc and slowing the process to allow the gases to escape
4. Remove rust or oil from the surface and use a proper technique

E. Overlap. When the weld face extends beyond the weld toe, then this defect
occurs. In this
condition the weld metal rolls and forms an angle less than 90 degrees.

Source:www.theweldingmaster.com

Causes of Overlap:
1. Improper welding technique
2. By using large electrodes this defect may occur.
3. High welding current

Remedies for Overlap:

1. Use a proper technique for welding.
2. Use small electrode.
3. Less welding current.

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F. Distortion. Distortion means contraction of weld metal during welding that forces
base metal to move.

Source:www.MillerWelds.com

Causes of Distortion:
1. A great number of passes with small diameter electrodes
2. Slow arc travel speed
3. High residual stresses in the plate to be welded
4. Using improper welding sequences

Remedies of Distortion:
1. Use the proper amount of weld metal as per the requirement of the joint. It will
reduce the contraction forces.
2. Use an appropriate number of weld passes.
3. Place the weld near the neutral axis.
4. Use proper welding sequences.

G. Burn-Through. Burn-through refers to weld metal melting completely through

base metal resulting in holes where no metal remains.

Source:www.MillerWelds.com

Cause of Burn-Through:
1. Excessive heat input

Remedies of Burn-Through:
1. Select lower amperage. Use smaller electrode.
2. Increase and/or maintain steady travel speed.

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II. INTERNAL WELDING DEFECTS

The various types of internal defects with their causes and remedies are listed
below:

A. Slag Inclusion. If there is any slag in the weld, then it affects the toughness and
metal weldability of the given material. This decreases the structural performance of
the weld material. Slag is formed on the surface of the weld or between the welding
turns.

Source:www.theweldingmaster.com

Causes of Slag:
1. Slag is formed if the welding current density is very small, as it does not provide
the required amount of heat for melting the metal surface.
2. If the welding speed is too fast, then also slag may occur.
3. If the edge of the weld surface is not cleaned properly then also slag may form.
4. Improper welding angle and travel rate of welding rod

Remedies for Slag Inclusion:

1. Increase the current density.
2. Adjust the welding speed so that the slag and weld pool do not mix with each
other.
3. Clean the weld edges and remove the slags of previous weld layers.
4. Have a proper electrode angle and travel rate.

B. Incomplete Fusion. Incomplete fusion occurs when the welder does not
accurately weld the material and the metal pre-solidify which leads to a gap which is
not filled with the molten metal.

Source: www.theweldingmaster.com

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Causes of Incomplete fusion:
1. It occurs because of the low heat input.
2. When the weld pool is very large and runs ahead of the arc.
3. When the angle of the joint is too low.
4. Incorrect electrode and torch angle may also lead to incomplete fusion.
5. Improper bead position

Remedies for Incomplete Fusion:

1. Increasing the welding current and decreasing the travel speed helps in removing
the chances of incomplete fusion.
2. Reducing the deposition rate.
3. Increasing the joint angle.
4. Try to position the electrode and torch angle properly so that the edges of the
plate melt away.
5. Positioning the bead properly so that the sharp edges with other beads can be
avoided.

C. Incompletely Filled Groove or Incomplete Penetration. These defects occur

only in the butt welds where the groove of the metal is not filled completely. It is also
called as incomplete penetration defect.

Source:www.theweldingmaster.com

Causes of an Incomplete Filled Groove:

1. Less deposition of the weld metal
2. Use of improper size of the electrode
3. Improper welding technique

Remedies for Incomplete Filled Groove:

1. More deposition of the weld metal.
2. Use a proper size of the electrode.
3. By using a proper welding technique.

III. Accompanying DepEd Textbook and Educational Sites

SMAW 12 Alternative Delivery Mode by Oculam, King Romy Sean C. et.al pp.26-33
of Upper Balulang Cagayan de Oro City

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IV. Activity Proper

A. Multiple Choice:
Directions: Read and analyze the statement carefully. Choose the correct answer
and write the letter only on your separate answer sheet.

1. ________are generated in a welding job due to the faulty or poor technique

used by the inexperienced or unskilled welder or due to fundamental difficulties in
the welding operation.
a. Spatter b. Porosity
c. Penetration d. Welding Defects

2. ________occurs when the depth of the welded joint is insufficient.

a. Incomplete Penetration b. Porosity
c. Penetration d. Welding Defects

3. ________is defined as the distance from the base plate top surface to the
maximum extent of the weld nugget.
a. Spatter b. Porosity
c. Penetration d. Welding Defects

4. ________is a group of small voids and blowholes are comparatively bigger

isolated holes or cavities.
a. Spatter b. Porosity
c. Penetration d. Welding Defects

5. ________ is the small metal particles that are thrown out of the arc during
welding and get deposited on the base metal around the weld bead along its
length.
a. Spatter b. Porosity
c. Penetration d. Welding defects

6. ________ is the change in the shape and difference between the position of
two plates before and after welding due to the temperature gradient present at
various points along the joints.
a. Groove b. Hot Tear
c. Distortion d. Undercut

7. ________ is a kind of weld defect which forms a groove in the parent metal
along with the sides of the weld bead.
a. Groove b. Hot tear
c. Distortion d. Undercut

8. ________reduces the thickness of the plate and also reduces the strength of
the weld.
a. Groove b. Hot tear
c. Distortion d. Undercut

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 9. ________ is also known as solidification cracking state.
a. Groove b. Hot tear
c. Distortion d. Undercut
10. ___________________ cracking is due to tearing of the grain boundaries of
weld metal before complete solidification has taken place and metal is still in the
plastic states.
a. Groove b. solidification
c. Distortion d. Undercut

Guide Questions

1. What are Welding Defects?

2. What are the causes and remedies of welding defects?

3. As welders, why is it we need to find the remedies of the welding defects in a

particular weld?

V. Reflection

1. What have you learned from this topic?

2. Did you enjoy while learning? Why?

3. If you are going to rate your learnings from 0-5, what should it be? Why?

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VI. Answer Key

Multiple Choice
1. D
2. A
3. C
4. B
5. A
6. C
7. D
8. A
9. B
10. B

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