Defects and Discontinuities

Tim Turner
Elizabethtown Technical College
 Defect
A flaw or flaws that by nature or
accumulated effect render a part or product
unable to meet minimum applicable
acceptance standards or specifications. The
term designates rejectability.
 Discontinuity
An interruption of the typical structure of a
material, such as a lack of homogeneity in
its mechanical, metallurgical, or physical
characteristics. A discontinuity is not
necessarily a defect.
 Weld Joint Discontinuities
Misalignment (hi-lo) Inclusions Base Metal
Undercut Slag Discontinuities
Wagontracks Lamellar tearing
Underfill
Tungsten Laminations and
Concavity or Convexity Delaminations
Spatter
Excessive reinforcement Laps and Seams
Arc Craters
Improper reinforcement Porosity
Cracks
Overlap Uniformly Scattered
Longitudinal
Burn-through Cluster
Transverse
Incomplete or Insufficient Linear
Crater
Penetration Piping
Throat
Incomplete Fusion Heat-affected zone
Toe
microstructure alteration
Surface irregularity Root
Overlap Base Plate laminations
Underbead and
Arc Strikes Heat-affected zone Size or dimensions
Hot
Cold or delayed
 Misalignment (hi-lo)
Definition: Amount a joint is out of
alignment at the root
Cause: Carelessness. Also due to joining different thicknesses
(transition thickness)
Prevention: Workmanship. Transition angles not to exceed
2.5 to 1.
Repair: Grinding. Careful on surface finish and direction of
grind marks. Inside of Pipe /Tube difficult.
 Undercut
Definition: A groove cut at the
toe of the weld and left unfilled.
Cause: High amperage, electrode
angle, long arc length, rust
Prevention: Set machine on scrap metal. Clean metal before
welding.
Repair: Weld with smaller electrode, sometimes must be low
hydrogen with preheat. Sometimes must gouge first.
 Undercut
(cont......)

Undercut typically has an allowable limit.

Different codes and standards vary greatly
in the allowable amount.
Plate - the lesser of 1/32 or 5% (typ.)
 Insufficient Fill
Definition: The weld surface is below the adjacent surfaces of
the base metal
Cause: Improper welding techniques

Prevention: Apply proper welding techniques for the weld

type and position. Use stripper beads before the cover pass.
Repair: Simply weld to fill. May require preparation by
grinding.
 Insufficient Fill on the Root Side
(suckback)
Definition: The weld surface is below the adjacent surfaces of
the base metal at the weld root.
Cause: Typically improper joint preparation or excessive weld
pool heat.
Prevention: Correct cause. (see next slide)

Repair: Backweld to fill. May requireremoval of weld section

by grinding for access to the joint root.
 Cause for Insufficient Fill at the
Root
Some liquids, like water or molten steel, try to cover as much surface
area of whatever they are in contact with as possible.

Welding a root pass too wide can also cause the bead to sag (overhead
position).
 Removing a root pass by
grinding
1. Recreate the groove geometry as closely as possible.
2. Use a saw or die grinder and 1/16 - 1/8 cut off wheel to recreate root
opening. Remember repairs are sometimes required to be made with a
smaller electrode.
3. Open the groove angle. Be careful to leave the proper root face
dimension.
4. Feather the start and stop to blend smoothly into and out of the
existing weld.
 Excessive Concavity or
Convexity
Definition: Concavity or convexity of a fillet weld which
exceeds the specified allowable limits
Cause: Amperage and travel speed

Prevention: Observe proper parameters and techniques.

Repair: Grind off or weld on. Must blend smoothly into the
base metal.
Concavity
Convexity
 Reinforcement
The amount of a groove weld which extends beyond the surface
of the plate

Excessive
Face Reinforcement
Insufficient
Improper contour

Root Reinforcement
 Excessive Reinforcement
Definition: Specifically defined by the standard. Typically,
Reinforcement should be flush to 1/16(pipe) or flush to
1/8 (plate or structural shapes).
Cause: Travel speed too slow, amperage too low

Prevention: Set amperage and travel speed on scrap plate.

Repair: Remove excessive reinforcement and feather the weld

toes to a smooth transition to the base plate.
 Insufficient Reinforcement
Definition: Specifically defined by the standard. Typically,
Underfill may be up to 5% of metal thickness not to exceed
1/32 as long as the thickness is made up in the opposite
reinforcement. Not applied to fillet welds.
Cause: On root reinforcement - Too little filler metal will cause thinning of the filler metal.
In OH position, too hot or too wide will cause drooping of the open root puddle.

Prevention: Use proper welding technique. Use backing or

consumable inserts. Use back weld or backing.
Repair: Possibly simply increase the face reinforcement. If
backwelding is not possible, must remove and reweld.
 Improper Weld Contour
Definition: When the weld exhibits less than a 135 0 transition
angle at the weld toe. 1350

Cause: Poor welding technique

Prevention: Use proper techniques. A weave or whip motion

can often eliminate the problem.
Repair: The weld face must be feathered into the base plate.
 Overlap
Definition: When the face of the weld extends beyond the toe
of the weld
Cause: Improper welding technique. Typically, electrode
angles and travel speed.
Prevention: Overlap is a contour problem. Proper welding
technique will prevent this problem.
Repair: Overlap must be removed to blend smoothly into the base metal. Be careful of deep
grind marks that run transverse to the load. Also be careful of fusion discontinuities hidden by
grinding. Use NDT to be sure.
 Overlap
Overlap is measured with
a square edge such as a
6 rule. No amount of
overlap is typically
allowed.
 Burn-through (non-standard)
Definition: When an undesirable open hole has been completely
melted through the base metal. The hole may or may not be left open.

Cause: Excessive heat input.

Prevention: Reduce heat input by increasing travel speed, use

of a heat sink, or by reducing welding parameters.
Repair: Will be defined by standards. Filling may suffice.
Otherwise, removal and rewelding may be required. Some
standards may require special filler metal and/or PWHT.
 Incomplete or Insufficient
Penetration
Definition: When the weld metal does not extend to the
required depth into the joint root
Cause: Low amperage, low preheat, tight root opening, fast
travel speed, short arc length.
Prevention: Correct the contributing factor(s).

Repair: Back gouge and back weld or remove and reweld.

 Incomplete Fusion
Definition: Where weld metal does not form a cohesive bond
with the base metal.
Cause: Low amperage, steep electrode angles, fast travel speed, short arc
gap, lack of preheat, electrode too small, unclean base metal, arc off seam.

Prevention: Eliminate the potential causes.

Repair: remove and reweld, being careful to completely remove

the defective area. This is sometimes extremely difficult to find.
 Arc Strike
Definition: A localized coalescence outside the weld zone.

Cause: Carelessness
Prevention: In difficult areas, adjacent areas can be protected
using fire blankets.
Repair: Where applicable, arc strikes must be sanded
smooth and tested for cracks. If found, they must be remove
and repaired using a qualified repair procedure and
inspected as any other weld.
 Inclusions
Slag
Wagontracks
Tungsten
 Slag Inclusion
Definition: Slag entrapped within the weld

Cause: Low amperage, improper technique, Trying to weld in

an area that is too tight. Slow travel in Vertical Down
Prevention: Increase amperage or preheat, grind out tight
areas to gain access to bottom of joint.
Repair: Remove by grinding. Reweld.
 Wagon Tracks (non-standard)
Definition: Slang term for a groove left at the toe of a root pass
which becomes filled with slag and is trapped in the weld.

Cause: The contour of the root pass is too high, or the weld
toe is not bonded to the base metal
Prevention: Use proper technique to deposit the weld root.

Repair: Best repaired before applying the hot pass.

Carefully grind the root pass face flat. be careful not to
gouge other areas on the weldment.
 Tungsten Inclusion
Definition: A tungsten particle embedded in a weld. (Typically
GTAW only)
Cause: Tungsten electrode too small, amperage too high, AC balance on +, Upslope too high,
electrode tip not snipped, electrode dipped into the weld pool or touched with the fill rod,
electrode split.

Prevention: Eliminate the cause

Repair: Grind out and reweld

 Inclusions
fix when you see it. otherwise grind out &
fix
 Whiskers
Unsightly
Inhibits material flow in piping
Are inclusions
Can break off in pipes and damage
equipment downline
 Spatter
Definition: Small particles of weld metal expelled from the
welding operation which adhere to the base metal surface.
Cause: Long arc length, severe electrode angles, high
amperages.
Prevention: Correct the cause. Base metal can be protected
with coverings or hi-temp paints.
Repair: Remove by grinding or sanding. Sometimes must be
tested as if it were a weld.
 Arc Craters
Definition: A depression left at the termination of the weld
where the weld pool is left unfilled.
Cause: Improper weld termination techniques

Prevention:

Repair: If no cracks exist, simply fill in the crater. Generally

welding from beyond the crater back into the crater.
 Cracks
Longitudinal
Transverse
Crater
Throat
Toe
Root
Underbead and Heat-affected zone
Hot
Cold or delayed
 Longitudinal Crack
Definition: A crack running in the direction of the weld axis.
May be found in the weld or base metal.
Cause: Preheat or fast cooling problem. Also caused by
shrinkage stresses in high constraint areas.
Prevention: Weld toward areas of less constraint. Also preheat
to even out the cooling rates.
Repair: Remove and reweld
 Transverse Crack
Definition: A crack running into or inside a weld, transverse to
the weld axis direction.
Cause: Weld metal hardness problem

Prevention:

Repair:
 Crater Crack
Definition: A crack, generally in the shape of an X which is
found in a crater. Crater cracks are hot cracks.
Cause: The center of the weld pool becomes solid before the
outside of the weld pool, pulling the center apart during cooling

Prevention: Use crater fill, fill the crater at weld termination

and/or preheat to even out the cooling of the puddle
Repair:
 Throat Crack
Definition: A longitudinal crack located in the weld throat
area.
Cause: Transverse Stresses, probably from shrinkage. Indicates inadequate filler
metal selection or welding procedure. May be due to crater crack propagation.

Prevention: Correct initial cause. Increasing preheat may prevent

it. be sure not to leave a crater. Use a more ductile filler material.

Repair: Remove and reweld using appropriate procedure. Be

sure to correct initial problem first.
 Toe Crack
Definition: A crack in the base metal beginning at the toe of
the weld
Cause: Transverse shrinkage stresses. Indicates a HAZ
brittleness problem.
Prevention: Increase preheat if possible, or use a more ductile
filler material.
Repair:
 Root Crack
Definition: A crack in the weld at the weld root.

Cause: Transverse shrinkage stresses. Same as a throat crack.

Prevention: Same as a throat crack

Repair:
 Underbead Crack
Definition: A crack in the unmelted parent metal of the HAZ.

Cause: Hydrogen embrittlement

Prevention: Use Lo/Hi electrodes and/or preheat

Repair: (only found using NDT). Remove and reweld.

 Hot Crack
Definition: A crack in the weld that occurs during
solidification.
Cause: Micro stresses from weld metal shrinkage pulling apart
weld metal as it cools from liquid to solid temp.
Prevention: Preheat or use a low tensil filler material.

Repair:
 Cold Crack
Definition: A crack that occurs after the metal has completely
solidified
Cause: Shrinkage, Highly restrained welds, Discontinuities

Prevention: Preheat, weld toward areas of less constraint, use

a more ductile weld metal
Repair: Remove and reweld, correct problem first, preheat
may be necessary.
 Repairs to Cracks
Determine the cause
Correct the problem
Take precautions to prevent reoccurrence
Generally required to repair using a smaller
electrode
 Base Metal Discontinuities
Lamellar tearing
Laminations and Delaminations
Laps and Seams
 Laminations
Base Metal Discontinuity
May require repair prior to welding
Formed during the milling process
Lamination effects can be reduced by joint design:
Delaminations
 Laps and Seams
A mill-induced discontinuity in which results from a lump of metal
being squeezed over into the surface of the material.
If beyond acceptable limits, must be removed and repaired or
discarded.
 Porosity
Single Pore
Uniformly Scattered
Cluster
Linear
Piping
 Single Pore
Separated by at least their own diameter
along the axis of the weld
 Uniformly Scattered Porosity
Typically judged by diameter and proximity
to a start or stop
often caused by low amperage or short arc
gap or an unshielded weld start
 Cluster Porosity
Typically viewed as a single large
discontinuity
 Linear Porosity
being linear greatly affects the severity of
this discontinuity
 Piping Porosity
Generally has special allowable limits
 Porosity
preheat will help eliminate
may need an electrode with more
deoxidizers
Use run-on/run-off taps
restart on top of previous weld and grind off
lump
 Heat-affected zone
microstructure alteration
add drawing of HAZ of groove weld with
leaders to:
grain refinement
grain growth
hardened areas
softened areas
precipitate suseptable areas.
 Size or dimension
If it renders the part unusable, it is a defect.
If it is outside the allowable limit, it renders
the part unusable.
Things dont have to be perfect, just within
the acceptable tolerance. Working to
perfection is too time consuming and costly
 Hammer marks
Stress risers
Unsightly
Unnecessary
 REPAIR TECHNIQUES
May involve:
different process
different procedure
different preheat/PWHT
different electrode
smaller electrode
 Only repair defects.
Discontinuities are, by
definition, acceptable.
Repair is therefore
unnecessary and not cost
effective.
Inspection Tools
 Measuring Weld Sizes

Fillet Weld Size - For equal leg fillet welds, the leg lengths of the largest
isosceles right triangle that can be inscribed within the fillet weld cross
section. For unequal leg fillet welds, the leg lengths of the largest right
triangle that can be inscribed within the fillet weld cross section
Fibre Metal Fillet Gage
Fibre Metal Fillet Gage
Fibre Metal Fillet Gage
Fibre Metal Fillet Gage
Fibre Metal Fillet Gage
Fibre Metal Fillet Gage
Fibre Metal Fillet Gage
Fibre Metal Fillet Gage
Undercut Guage

Gal Gage Co.

Palmgrin Guage
 Magnifying Glass

Used to read small scales

 Flashlight
Used to cast shadows to find porosity, undercut and overlap.