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Porosity

When gas becomes trapped along the surface or inside of the weld metal, porosity occurs. Like
other weld flaws, porosity results in a weak weld that must be ground out and reworked.
Causes: Typically, inadequate or contaminated shielding gas is the culprit of porosity. Using a
nozzle that is too small for the application, or a nozzle full of weld spatter, can also cause this weld
flaw. Having a dirty base metal and/or extending the welding wire too far beyond the nozzle is an
additional cause. On warm days, air currents from cooling fans can disrupt the shielding gas
envelope around the weld puddle creating this problem. Another common cause is a poor seal or a
loose fitting in the shielding gas channel through the welding gun. Any gas leaks have the potential
to aspirate air into the gas flow.
Cures: To correct porosity, ensure that that there is adequate gas flow (increasing it as needed),
and replace any damaged gas hoses or GMAW gun components that may be causing leaks. Also,
place a welding screen around the work area if welding outside or in an area inside that is
particularly drafty. Check that the nozzle being used is large enough for the application and replace
with a larger one if it is not. Remove any spatter build up in the nozzle. Extend the welding wire no
more than 1/2 inch beyond the nozzle and make certain that the base metal is clean prior to welding.
Slowing travel speed to gain greater shielding gas coverage can also combat porosity, as can
keeping the nozzle within 1/4- to 1/2-inch of the base metal during welding.

Burn Through
Just as its name implies, burn through results when the weld metal penetrates fully through the base
metal, essentially burning through it. It is most common on thin materials, particular those that are
1/4 inch or less. Another weld flaw, excessive penetration (too much penetration into the weld joint),
can very often lead to burn through.
Causes: Excessive heat is the primary cause of burn through. Having too large of a root opening on
the weld joint can also result in burn through.
Cures: If burn through occurs, lowering the voltage or wire feed speed can help rectify the problem.
Increasing travel speed helps, too, especially when welding on aluminum, which is prone to heat
build-up. If a wide root opening is the suspected cause of burn-through, increasing the wire
extension and/or using a weaving technique during welding can help minimize heat input and the
potential for burn through.
Incomplete Joint Penetration (Lack of Penetration)
Incomplete joint penetration or lack of penetration results when there is shallow fusion between the
weld metal and the base metal, rather than full penetration of the joint. It can often lead to weld
cracking and joint failure.

Causes: Insufficient heat input and improper joint


preparation are the main causes of incomplete joint
penetration. The shielding gas mixture and wire
diameter can also be a factor.
Cures: There are several cures for incomplete joint
penetration, including using higher wire feed speed
and/or voltages. Reducing travel speed also allows
Porosity, as shown here, most often results from more weld metal to penetrate the joint, as does
inadequate shielding gas. Increasing gas flow preparing and designing the joint properly. The joint
and/or ensuring gas hoses or the GMAW gun should allow the welding operator to maintain the
are free of leaks can help solve the problem. proper welding wire extension (no more than 1/2
inch beyond the nozzle) and still access the bottom
of the weld joint. Make sure that the shielding gas or gas mixture, wire type and diameters are
recommended for the application.

Undercutting
Undercutting is a groove or crater that occurs near the toe of the weld. When this weld flaw occurs,
the weld metal fails to fill in that grooved area, resulting in a weak weld that is prone to cracking
along the toes.
Causes: Excessive heat, as well as poor welding techniques, can both lead to undercutting on a
weld joint.
Cures: Reducing the welding current and voltage is the first step to rectifying undercutting. Using a
weaving technique in which the welding operator pauses slightly at each side of the weld bead can
also help prevent this weld flaw. Additional cures include reducing travel speed to a rate that allows
the weld metal to fill out the joint completely and adjusting the angle of the GMAW gun to point more
directly toward the weld joint.
Hot Cracking
Hot cracking typically appears along the length of a
weld or directly next to it almost immediately after
the weld puddle solidifies. This weld flaw occurs at
temperatures greater than 1,000 degrees
Fahrenheit (538 Celsius). There are multiple
variations of hot cracking including centerline, bead
shape and crater cracks.
Causes: Hot cracking can result from several
factors. These include poor fit-up or joint design,
creating too thin of welds and welding at too high of Incomplete joint penetration, or lack of penetration, as shown in this
voltages. High levels of base metal impurities can microscopic image is commonly the result of insufficient heat input.
also cause this weld flaw. In some cases, high Increasing wire feed speed and/or voltages, and reducing travel
levels of specific alloys (boron, for example) in filler speed can all help to rectify the problem. (Image courtesy of Hobart
metals can cause the problem. Brothers)
Cures: Having the proper joint design and good
part fit up is one way to help prevent hot cracking, as it keeps the weld puddle the appropriate size
and minimizes the chance of the throat of the weld being too thin. In the case of crater cracking, in
particular, using a backfill technique (backing up to fill in the joint fully) can minimize cracking by
adding throat thickness to the crater weldment. Careful filler metal selection and shielding gas
selection is also imperative.

Incomplete Fusion
When the weld metal fails to completely fuse with the base metal or with the preceding weld bead in
multi-pass applications, incomplete fusion can occur. Some people also refer to this weld flaw as
cold lap or lack of fusion.
Causes: Most often the cause of incomplete fusion is an incorrect gun angle, although contaminants
on the base metal can also cause this weld flaw. In some instances, insufficient heat can be the
culprit.
This microscopic image shows incomplete fusion on either side of the
weld. Commonly caused by an incorrect gun angle, this weld flaw can be Cures: First, clean the base metal properly
corrected, in part, by maintaining a gun angle of zero to 15 degrees and prior to welding, making sure it is free of dirt,
keeping the arc on the leading edge of the weld puddle. (Image courtesy oil, grease or other debris. Next, welding
of Hobart Brothers) operators should place their GMAW gun at an
angle of zero to 15 degrees in order to access
the groove of the weld joint fully and keep the arc on the leading edge of the weldpuddle. Increase
travel speed as necessary to keep the arc from getting too far ahead of the weld puddle. For joints
requiring a weaving technique, holding the arc on the sidewall for a moment can help prevent
incomplete fusion. Make certain, too, that there is enough heat input to fuse the weld metal and base
metal fully. Increase the voltage range and adjust the wire feed speed as necessary to complete the
weldment.
Remember, even the most skilled welding operators can experience weld flaws. The key to keeping
them from affecting productivity and increasing costs in the welding operation is to identify and
rectify the problems as quickly as possible. Proper maintenance of the welding equipment is also
imperative. Repair or replace any worn or defective items.

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