Welding Defects & Tests

INTRODUCTION:
As we all know that welding is one of the most important fabrication

process .if welding of joints is not done by specified process than certain
defects will occur which can cause severe damages .in correct sense of the
word, a defects is rejectable discontinuity or a flaw of rejectable nature.
Certain flaws may be acceptable in one type of product need not be
acceptable in another product
There are certain factors on which acceptance and
rejection of defects depends these are.
 Stress to which the part will be subjected during service.

 Types of material used
 The temperature and pressure to which the parts will be stressed
 It thickness
 The environment (corrosive and non-corrosive)
 Cost and accessibility of repair.
GENERAL REASONS FOR DEFECTS
 lack of know-how and experience.

 Welding process and characterstics
 Base metal composition
 Defective welding filler metals
 Joint design
 Welding environment (wind, fit-up,
temperature)
TYPES OF DEFECTS
 Defects can be classified as:
 defects involving inadequate bonding
 lack of fusion
 Incomplete penetration.
 foreign inclusion
 slag
 oxide films
 tungsten
 geometric defects
 undercut
 excessive reinforcement
 burn through or excessive penetration
 distortion
 improper weld profile
 metallurgical defects
 cracks
 gas porosity
 arc strikes
 structural notches
INADEQUATE BONDING
LACK OF FUSION:
involve incomplete melting and fusion of some portion of weld
metals in joints. it may occur either between parent metal and weld metal
or between two layers of weld metals. These basically occur in fusion and
pressure welding.
REASONS:
 improper manipulation of electrodes
 incorrect position of electrodes
 low welding current
 too rapid arc advance
 poor edge preparation .
DISAVANTAGES
 lower strength of joints
 stress concentration will occur
LACK OF FUSION
INCOMPLETE PENETRATION:
 This is lack of penetration of the welds through the thickness of
the joints. This usually occur at the root of the weld or between deposits
made from both sides.
REASONS:
 incorrect joint design
 improper welding parameters particularly currents.
 Incorrect electrode size.
DISADVANTAGES:
 It adversely affects the joints which are subjected to either tensile or
bending stresses.
 It can initiate brittle fracture under static or dynamic loads.
 Causes stress concentration which leads to deformation.
 Cracks can be initiate.
INCOMPLETE
PENETRATION
FOREIGN INCLUSION
SLAG INCUSION,:
This is formed due to entrapment of oxides and non metallic solids in the
weld deposits or between the weld metals and base metals. Rapid solidification at
lower temperature of weld metals prevent the release of such entrapments.
OXIDES FILMS:
A thin film of oxides forms due to inadequate shielding in case of MIG
welding. It affects the ductility of weld metals
TUNGSTEN INCLUSION:
In case of TIG welding some particle may get deposits from tungsten
electrode.
REASONS:
 Improper preparation of groove
 Preheating the base materials is not done properly
 Improper size of electrode.
 Inadequate shielding in case of oxides films.
SLAG INCLUSIONS
GEOMETRIC DEFECTS:
UNDERCUT:
It represent a depression into the base metal adjacent to the toe of the weld and
if it forms a notch it is danger for the welds.
EXCESS REINFORCEMENT:
Reinforcement represent the metal on the face of the weld in access. Access
reinforcement can cause fatigue failure. Reinforcement should be in between 1.5-2.5mm.
EXCESS PENETRATION:
This generally occur at the root of the weld. sometimes it creates opening at the
root. It is also affect the fatigue strength of the joint
DISTORTION:
It is the deviation from desired form or shape and is due to unequal heating and
cooling which cause unequal expansion and contraction. The effect of distortion is mainly
dimensional..
IMPROPER WELD PROFILE:
This occur more in case of fillet joints. Excessive concave or convex bead are
the example of this. Sharp. This can lead to cracks.
.
REASONS:
 incorrect choice of current range
 Improper travel speed.
 Improper design and poor fit-up.
 Not following the welding procedure.
 Improper electrode size and weaving

UNDER CUT
METALLURGICAL DEFECTS:
CRACKS:
 These are linear ruptures of the metals under stress.
CRATOR CRACKS:
 Cracks formed from a circular surface with depression either in the welds or at the
end of the welds.
POROSITY:
 Porosity is the presence of the gas pockets of voids caused by the entrapment of
the gas evolved during weld metal solidification.
WELD DEPOSITS:
Sometimes in a particular zone excess welds accumulate due to high current which
can cause formation of notches and ultimately affect fatigue strength.
REASONS:
 Uneven heating and cooling rate
 Improper shielding, rust on the weld face, too much generation of gas in weld pool, sudden
cooling of slag
POROSITY
TESTS
In the field pf manufacturing and production there

are lots of area which needs 100% reliability. To
meet this demand non-destructive testing has
originated and got lots of significance. With the help
of ndt method, defect can be located without
destroying the material. Some of ndt methods are:-
Dye penetration test (dpt)
Magnetic particle test (mpt)
Radiography test (rt)
Ultrasonic test (ut)
Dye penetration test
Surface discontinuity, such as cracks or other separation as
well as porosity open to the surface can be detected by
bleeding after the surface has been treated by penetrant .
Steps:
 Surface preparation
 Application of the penetrant, hold it for some time.
 Removal of excess penetration from the surface.
Application of developer and inspection.

DPT
Magnetic particle test
The job is suitably magnetized and magnetic lines of force
of enough density is made available. Discontinuity in the path
of magnetic flux create a disturbance in the uniform magnetic
field causes flux leakage. Due to this it attracts iron powder
Steps:
 Magnetized the job suitably
 Apply the examination medium (iron powder)
 Interpret and evaluate the indication.

MPI
Ultra sonic test
 Ultrasonic inspection is the method by which beams of high frequencies
sound waves are used to detect surface and sub-surface flaws. The sound
waves travel through the material with some loss of energy and reflected
at the interface. The deflected beam is detected and analyze to define the
presence and location of the flaws.
RADIOGRAPHY TEST
radiography is a non-destructive testing tool used in

industry. Its capability to look through opaque material
and helps in detecting the internal defects.
radiography employs the penetrating capacity of
ionising radiation like x or gamma rays to produce the
shadow of the internal condition. The record in the film is
called radiograph. basic requirements are:
 an enclosure or a cordoned area to operate the equipment.
 X-ray source or gamma ray source.
 Recording medium like x-ray films.
 Evaluating equipment like illuminator

Welding Defects & Tests

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What are some common welding defects discussed in the document?

What are some factors that welding defects depend on?

INTRODUCTION:

As we all know that welding is one of the most important fabrication

 Stress to which the part will be subjected during service.

 lack of know-how and experience.

 Improper travel speed.

 Improper design and poor fit-up.

 Not following the welding procedure.

 Improper electrode size and weaving

In the field pf manufacturing and production there

 Application of the penetrant, hold it for some time.

 Removal of excess penetration from the surface.

Application of developer and inspection.

 Apply the examination medium (iron powder)

 Interpret and evaluate the indication.

radiography is a non-destructive testing tool used in

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