WELDING DEFECTS

INCOMPLETE PENETRATION:
This type of defect is found in any of three ways:
 When the weld bead does not penetrate the entire thickness of the base plate.
 When two opposing weld beads do not interpenetrate.
 When the weld bead does not penetrate the toe of a fillet weld but only bridges
across it.
Welding current has the greatest effect on penetration. Incomplete penetration is usually
caused by the use of too low welding current and can be eliminated by simply increasing
the amperage. Other causes can be the use of too slow a travel speed and an incorrect
torch angle. Both will allow the molten weld metal to roll in front of the arc, acting as a
cushion to prevent penetration. The arc must be kept on the leading edge of the weld
puddle.
Examples of Lack of Penetration

LACK OF FUSION:
Lack of fusion, also called cold lapping or cold shuts, occurs when there is no
fusion between the weld metal and the surfaces of the base plate. Either the weld puddle
is too large (travel speed too slow) and/or the weld metal has been permitted to roll in
front of the arc. Another cause is the use of a very wide weld joint. If the arc is directed
down the center of the joint, the molten weld metal will only flow and cast against the
side walls of the base plate without melting them. The heat of the arc must be used to
melt the base plate. This is accomplished by making the joint narrower or by directing the
arc towards the side wall of the base plate.
The common cause of this type of defect is the presence of aluminum oxide.
This oxide is a refractory with a melting point of approximately 3500 0F (19270C). It is
also insoluble in molten aluminum. If this oxide is present on the surfaces to be welded,
fusion with the weld metal will be hampered
 UNDERCUTTING:
Undercutting is a defect that appears as a groove in the parent metal directly
along the edges of the weld. It is most common in lap fillet welds, but can also be
encountered in fillet and butt joints. This type of defect is most commonly caused by
improper welding parameters; particularly the travel speed and arc voltage. When the
travel speed is too high, the weld bead will be very peaked because of its extremely fast
solidification. The undercut groove is where melted base material has been drawn into the
weld and not allowed to wet back properly because of the rapid solidification. Decreasing
the arc travel speed will gradually reduce the size of the undercut and eventually
eliminate it. When only small or intermittent undercuts are present, raising the arc voltage
or using a leading torch angle are also corrective actions. In both cases, the weld bead
will become flatter and wetting will improve.

POROSITY:
Porosity is gas pores found in the solidified weld bead. these pores may vary in
size and are generally distributed in a random manner. However, it is possible that
porosity can only be found at the weld center. Pores can occur either under or on the weld
surface. The most common causes of porosity are atmosphere contamination, excessively
oxidized work piece surfaces, inadequate deoxidizing alloys in the wire and the presence
of foreign matter.
Atmospheric contamination can be caused by:
1) Inadequate shielding gas flow.
2) Excessive shielding gas flow. This can cause aspiration of air into the gas stream.
3) Severely clogged gas nozzle or damaged gas supply system.
4) An excessive wind in the welding area. This can blow away the gas shield.
CRACKING:
Longitudinal or centerline cracking, of the weld bead is not
often encountered in MIG (metal inert gas) welding. That which does occur can be one of
two types: hot cracks and cold cracks.
Hot cracking: Hot cracks are those that occur while the weld bead is between the
liquidus (melting) and solidus (solidifying) temperatures. In this temperature range the
weld bead is “mushy” (soft). Hot cracks usually result from the use of an incorrect wire
electrode (particularly in aluminum and stainless steel alloys). The chemistry of the base
plate can also promote this defect (an example would be any high carbon stainless steel
casting). These are small cracks which appear at the end of the weld where the arc has
been broken. Although small, these cracks are troublesome since they can propagate into
the weld bead. The major reason for this defect is the incorrect technique for ending the
weld. The crater should be shielded until it is completely solidified.
Example of Crater Cracking
Those cracks that occur after the weld bead has completely solidified are called cold
cracks. These defects occur only when the weld is too small to withstand the service
stresses involved.