Professional Documents
Culture Documents
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As per ISO 6520-1987 Welding discontinuities
are divided in following six groups
Group Designated Defect
1 Cracks
2 Cavities
3 Solid Inclusions
4 Lack of Fusion &
penetration
5 Imperfect Shape
6 1 Miscellaneous defects
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Weld Discontinuities
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CRACKS
• Crack is a tight linear separation of metal that
can be very short to very long indications
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Solidification Crack
W
W
That is W/P
P
W = Bead Width P
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Transverse Crack
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Crater Crack
Crater crack is generally in the shape of a star in the
center of the terminated weld bead.It is a hot crack
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Causes & Remedies- Weld Cracking
Causes Remedies
Highly restrained joint Preheat, Stress relief, welding sequence change
Excessive dilution Change welding current & speed, use DC-, buttering
Porosity appears often as dark round irregular spots in clusters or
rows. Sometimes it is elongated and may have an appearance of a
tail. This is the result of gas attempting to escape while the metal is
still in a liquid state & is called wormhole porosity. All porosity is
indeed a void will have a darker density than the surrounding.
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Cavities
•Gas pore _ singular.
•Blowhole _ singular.
•Scattered Porosity.
Fine Severe
•Cluster Porosity.
•Linear Porosity.
•Piping.
• Worm holes.
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Cavities
Cluster porosity is caused when electrodes are contaminated with
moisture or hydrocarbon. It appears like regular porosity in a film
but the indications will be grouped close together.
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Cavities
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Causes & Remedies of Porosity
Causes Remedies
Excessive H2,N2,O2 in Use low-H2 electrodes, high deoxider fillers,
welding atmosphere increase shielding gas flow
High solidification rate Use preheat or increase heat input
weld or between the weld and base metal. In a radiograph, dark,
jagged asymmetrical shapes within the weld or along the weld joint
areas are indicative of slag inclusions.
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Solid Inclusions
Tungsten inclusions. Tungsten is a brittle and dense material
used as an electrode in tungsten inert gas welding. If an incorrect
welding procedures & skill is performed, then only the tungsten gets
trapped. Radiographically, tungsten is more dense than aluminum
or steel; therefore, it shows as a lighter area with a distinct outline
on
the radiograph
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Solid Inclusions
Oxide inclusions are usually visible on the surface of a weld mtal
(especially aluminum). Oxide inclusions are less dense than the surr
-ounding metals and, thus it appears as dark irregular shaped discon
-tinuity in radiograph. This is also referred as puckering in ISO.
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Lack of Fusion and Penetration
Lack of side wall fusion is a condition where the weld metal does
not fuse with the base metal. Appearance on radiograph is usually a
darker line or lines oriented in the direction of the weld seam along
the weld joining area.
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Lack of Fusion and Penetration
Lack of interrun fusion is a condition where the weld metal does
not fuse with the base metal or the previous weld bead (interpass
cold lap). The arc does not melt the base metal and causes the
molten puddle to flow into the base metal without the proper
bonding.
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Imperfect Shape
Undercut is an erosion of the base metal next to the toe of the weld
face. It appears in radiograph as a dark irregular line on outer edge
of the weld.
Imperfect
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Imperfect Shape
Root undercut is an erosion of the base metal next to the root of the
weld. It appears in radiographic images as a dark irregular line offset
from the centerline of the weldment. Undercutting is not as straight
edged as LOP because it does not follow the straight edge
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Imperfect Shape
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Imperfect Shape
Root concavity or suck back is a condition where the weld metal
has contracted as it cools down & has been drawn up into the root of
the weld. On a film it appears similar to the lack of root penetration
but the line has irregular wide edges and placed in the middle.
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Imperfect Shape
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Imperfect Shape
the image density in the area of inadequacy will be darker than the
surrounding image density.
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Imperfect Shape
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Imperfect Shape
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Imperfect Shape
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Imperfect Shape
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Imperfect Shape
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Imperfect Shape
Misalignment: The radiographic image is a noticeable difference in
density between the two mismatched pieces. The difference in
density is caused by the difference in material thickness. The dark,
straight line is caused by failure of the weld metal to fuse with the
land area.
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Imperfect Shape
Distortion:
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Whiskers are the short lengths of electrode wire, visible on
the top or bottom surfaces of the weld or contained within the
weld. On radiograph they appear as light, "wire like" indications.
Burn through (icicles) results when too much heat causes weld to
pierce through. Lumps of weld metal sag through the seam creating
a thick globular condition on the root face. On a radiograph, burn
through appears as dark spots surrounded by light globular areas.
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Miscellaneous discontinuities
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Lamellar Tearing:
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Miscellaneous discontinuities
Arc Strike
Spatters
Torn Surface
Grinding Marks
Chipping Marks
Underflushing
Poor Start
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