


 WELD DEFECTS
1. LACK OF PENETRATION

• 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.
 WELD DEFECTS
2. 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.
 WELD DEFECTS
3. 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.
 WELD DEFECTS
4. POROSITY

• Porosity is gas pores found in the solidified weld bead

• pores may vary in size and are generally distributed in a random
manner.
• Pores can occur either under or on the weld surface.
 WELD DEFECTS
5. CRACKING

• Two Types - Hot crack & Cold crack

• Hot cracks are those that occur while the weld bead is between
the liquidus (melting) and solidus (solidifying) temperatures.
• Those cracks that occur after the weld bead has completely
solidified are called cold cracks.
 WELD DEFECTS
5. OTHERS

• SLAG INCLUSIONS
• TUNGSTEN INCLUSIONS
• EXCESSIVE SPATTER
• BURNTHROUGH
• CONVEX BEAD
• ROOT CONCAVITY
• MISMATCH
……………………etc
 NON DESTRUCTIVE TEST
CONVENTIONAL
• VISUAL INSPECTION
• LIQUID DYE PENETRATION TEST
• MAGNETIC PARTICLE TEST
• RADIOGRAPHIC INSPECTION
• ULTRASONIC FLAW DETECTION

ADVANCED
• ACOUSTIC EMISSION TEST
• EDDY CURRENT TEST
• IN-SITU METALLOGRAPHY
• REAL TIME X-RAY
• RADIOGRAPHIC INSPECTION
• ULTRASONIC FLAW DETECTION
 NON DESTRUCTIVE TEST
VISUAL INSPECTION
• FIRST STEP FOR NON-DESTRUCTIVE INSPECTION

• DETECTS UNDERCUT, FIT-UP MISMATCH, SPATTERING ETC.

• GUIDES METHOD SELECTION OF OTHER NDT

• GIVES IDEA ON SOUNDNESS OF WELD

 NON DESTRUCTIVE TEST
LIQUID DYE PENETRATION TEST

• Test to detect surface discontinuities in non-porous materials.

• In general, a liquid penetrant is applied evenly over the pre-
cleaned surface of the weld being tested and allowed to enter
discontinuities.
 NON DESTRUCTIVE TEST
LIQUID DYE PENETRATION TEST

• After suitable dwelling time, the excess surface penetrant is

removed and the weld dried.
 NON DESTRUCTIVE TEST
LIQUID DYE PENETRATION TEST

• A developer is then applied which draws the entrapped penetrant

out of the discontinuity, staining the developer.
• The weld part is then inspected visually to determine the
presence and absence of indications.
 NON DESTRUCTIVE TEST
LIQUID DYE PENETRATION TEST
ADVANTAGES
• Easy to perform.
• Cheap.
• Not dependent on dimensional intricacy.
• All type of material, which is not porous, can be tested.

DISADVANTAGES
• Detect discontinuities that are exposed to surface only.
• Cannot define the depth of defect.
• Sensitivity highly dependent on extent of surface cleaning.
 NON DESTRUCTIVE TEST
LIQUID DYE PENETRATION TEST
TYPES
Based on Type of Penetrant
• Water Washable.
• Post-emulsifiable.
• Solvent-removable.

Based on Type of Inspection

• Visible.
• Fluorescent.
 NON DESTRUCTIVE TEST
MAGNETIC PARTICLE TEST
• Test to detect surface and subsurface discontinuities in ferro-
magnetic materials.

• It is based on the principle that magnetic lines of force, when

present in a ferro-magnetic material, will be distorted by a
change in material continuity, such as a sharp dimensional
change or a discontinuity.

• If the discontinuity is open to or close to the surface of a

magnetized material, flux lines will be distorted at the surface, a
condition termed “FLUX LEAKAGE”.
 NON DESTRUCTIVE TEST
MAGNETIC PARTICLE TEST
• When fine magnetic particles are distributed over the surface of
the magnetized material while the flux leakage exists, they will be
attracted in the place of flux leakage and the accumulation of the
particles will be visible under the proper lighting condition.
 NON DESTRUCTIVE TEST
MAGNETIC PARTICLE TEST
TYPES

BASED ON TYPE OF MAGNETISATION

• DIRECT – where current is directly applied to the part to be
tested to induce magnetic flux in the part.
• INDIRECT – where magnetic flux is introduced in the part using
another magnet.
BASED ON EXTENT OF MAGNETISATION
• FULL – where entire part is being magnetized at a time.
• PART - where a portion of the part is magnetized at a time.
 NON DESTRUCTIVE TEST
MAGNETIC PARTICLE TEST
TYPES

BASED ON TYPE OF MAGNETISING CURRENT

• AC – where alternating current is used to magetize.
• HWDC – where half wave rectified current is used to magnetize.
• FWDC – where full wave rectified current is used to magnetize.
• PERMANENT – where permanent magnet is used to magnetize.

BASED ON EXTENT OF MAGNETIC PARTICLE

• DRY – where particles are applied in dry form.
• WET - where particles are applied in liquid suspension.
 NON DESTRUCTIVE TEST
MAGNETIC PARTICLE TEST
TYPES

BASED ON TIME OF INSPECTION

• CONTINUOUS – where magnetization, particle application and
inspection are carried out at a time.
• RESIDUAL – where particle application and inspection are
carried out after the magnetization force has been discontinued.

BASED ON TIME OF INSPECTION

• VISIBLE – where inspections are carried out under normal light.
• FLUORESCENT - where inspections are carried out under
fluorescent light.
 NON DESTRUCTIVE TEST
MAGNETIC PARTICLE TEST
ADVANTAGES
• Can detect sub-surface discontinuities also.
• Wide variety, can be stationary and portable also.
• Independent on extent of surface cleaning.

DISADVANTAGES

• Detect discontinuities that are nearer to surface only.

• Cannot define the depth of defect.
• Can not work on dia or para magnetic material.
 NON DESTRUCTIVE TEST
RADIOGRAPHIC INSPECTION

• Test to detect internal discontinuities in non-porous materials.

• In general, radiation (X-ray or Gamma-ray) is penetrated on one
side of the weld and radiographic films are fixed on the opposite
side.
• Sufficient energy and time (based on type of material and
thickness) is given to allow the radiation to penetrate and react
the film placed on opposite side.
• The films are then processed and developed in the dark room to
get planar image of the weld.
 NON DESTRUCTIVE TEST
RADIOGRAPHIC INSPECTION
TYPES

• X-RAY – where X-Radiation is used to penetrate the weld.

• GAMMA RAY – where Gamma Radiation is used to penetrate the

weld. In general, Iridium-192 and Cobalt-60 isotopes are used to
generate Gamma-ray.
 NON DESTRUCTIVE TEST
RADIOGRAPHIC INSPECTION
ADVANTAGES
• Can detect internal discontinuities also.

• Can be stationary and portable also.

• Independent on extent of surface cleaning.

• Permanent radiographs can be stored for future reference.

 NON DESTRUCTIVE TEST
RADIOGRAPHIC INSPECTION
DISADVANTAGES

• Hazardous, harmful to the health.

• Gives only planar image of the discontinuity, cannot define the
depth of that.
• Slow process.
• Poor sensitivity on higher thickness and dimensionally intricate
job.
NON DESTRUCTIVE TEST
RADIOGRAPHIC INSPECTION

A SAMPLE RADIOGRAPH SHOWS LACK OF PENETRATION

 NON DESTRUCTIVE TEST
ULTRASONIC FLAW DETECTION

• Test to detect internal discontinuities in materials.

• Ultrasonic waves are transmitted in a material by a probe
along a pre-defined path.
• Part of the waves are reflected if any discontinuity comes
in its wave path.
• The reflected waves are again received by the probe and
be analyzed.
• The travel time and intensity of the reflected wave defines
the discontinuity.
NON DESTRUCTIVE TEST
ULTRASONIC FLAW DETECTION
NON DESTRUCTIVE TEST
ULTRASONIC FLAW DETECTION
 NON DESTRUCTIVE TEST
ULTRASONIC FLAW DETECTION
TYPES

BASED ON BASIC PRINCIPLE

• RESONANCE METHOD – frequency of the sound pulse
generated is continuously changed to detect the
resonance frequency of the part tested.
• THROUGH TRANSMISSION METHOD – where the intensity
of the ultrasound is measured after it has passed through
the test piece.
• PULSE ECHO METHOD – where a sound pulse is
transmitted in the test piece and the reflected waves are
analyzed.
 NON DESTRUCTIVE TEST
ULTRASONIC FLAW DETECTION
TYPES

BASED ON PROBE USED

• NORMAL PROBE SCANNING – where longitudinal sound
waves are transmitted in the part tested in perpendicular
direction of the surface and the same crystal is used as
transmitter and receiver.
• ANGLE PROBE SCANNING – where shear sound waves
are transmitted in the part tested at a particular angle.
• T-R PROBE SCANNING – same as normal probe scanning
but separate crystals act as transmitter and receiver.
 SUMMARY OF WELD DEFECT CHARACTERIZATION
USING NON-DESTRUCTIVE TEST

Sl. No. Type of Weld Defect LPT MPT RI UFD

01 LACK OF PENETRATION X #  

02 LACK OF FUSION # #  
03 UNDERCUTTING # #  
04 POROSITY # #  
05 CRACKING # #  
06 SLAG INCLUSION X #  
07 TUNGSTEN INCLUSION X X  
08 EXCESSIVE SPATTER X X  
09 BURN THROUGH X X  X
10 ROOT CONCAVITY    
11 MISMATCH    
THANK YOU