Weld Defects

Study common weld defects and how to avoid them.

Sample Cards

Cracking

A defect characterized by a crack that forms in the weld metal or heat-affected zone during or af...

Lack of Fusion

A defect that occurs when the weld metal does not fuse properly with the base metal, creating a gap.

Porosity

A defect characterized by the presence of gas bubbles trapped in the weld metal, often caused by ...

Burn-Through

A defect where excessive penetration causes the weld to burn through the base material.

Distortion

A defect resulting from uneven heating and cooling, leading to warping or distortion of the welde...

Incomplete Joint Penetration

A defect where the weld filler does not extend through the joint thickness.

Undercutting

A defect where an unintended groove is cut into the base metal.

Overlapping

A defect where the weld metal rolls over the top of the weld, not blending smoothly into the base...

Weld Defects Flashcards

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Cracking

A defect characterized by a crack that forms in the weld metal or heat-affected zone during or after welding.

A defect characterized by a crack that forms in the weld metal or heat-affected zone during or after welding.

Cracking

Lack of Fusion

A defect that occurs when the weld metal does not fuse properly with the base metal, creating a gap.

A defect that occurs when the weld metal does not fuse properly with the base metal, creating a gap.

Lack of Fusion

Porosity

A defect characterized by the presence of gas bubbles trapped in the weld metal, often caused by moisture or contamination.

A defect characterized by the presence of gas bubbles trapped in the weld metal, often caused by moisture or contamination.

Porosity

Burn-Through

A defect where excessive penetration causes the weld to burn through the base material.

A defect where excessive penetration causes the weld to burn through the base material.

Burn-Through

Distortion

A defect resulting from uneven heating and cooling, leading to warping or distortion of the welded parts.

A defect resulting from uneven heating and cooling, leading to warping or distortion of the welded parts.

Distortion

Incomplete Joint Penetration

A defect where the weld filler does not extend through the joint thickness.

A defect where the weld filler does not extend through the joint thickness.

Incomplete Joint Penetration

Undercutting

A defect where an unintended groove is cut into the base metal.

A defect where an unintended groove is cut into the base metal.

Undercutting

Overlapping

A defect where the weld metal rolls over the top of the weld, not blending smoothly into the base metal.

A defect where the weld metal rolls over the top of the weld, not blending smoothly into the base metal.

Overlapping

Excessively convex

A defect where the face of the weld extends above the weld joint in a convex shape.

A defect where the face of the weld extends above the weld joint in a convex shape.

Excessively convex

Slag Inclusion

A defect characterized by the presence of slag in the weld metal, usually caused by failure to remove slag between weld passes.

A defect characterized by the presence of slag in the weld metal, usually caused by failure to remove slag between weld passes.

Slag Inclusion

Incomplete Filling

A defect where the weld metal does not fully fill the joint.

A defect where the weld metal does not fully fill the joint.

Incomplete Filling

Gas Inclusion

A defect caused by the trapping of shielding gas in the weld metal.

A defect caused by the trapping of shielding gas in the weld metal.

Gas Inclusion

Tungsten Inclusion

A defect caused by the accidental inclusion of tungsten electrode material in the weld.

A defect caused by the accidental inclusion of tungsten electrode material in the weld.

Tungsten Inclusion

Crater Cracks

A defect caused by high thermal stresses near the end of the weld.

A defect caused by high thermal stresses near the end of the weld.

Crater Cracks

Cold Lap

A defect where the weld metal forms a shallow angle to the base metal, often due to low welding currents.

A defect where the weld metal forms a shallow angle to the base metal, often due to low welding currents.

Cold Lap

Overwelding

A defect where the weld size significantly exceeds that required for joint strength.

A defect where the weld size significantly exceeds that required for joint strength.

Overwelding

Repairing Weld Defects

A practice of rectifying welding defects in a manner that is compliant with quality assurance standards.

A practice of rectifying welding defects in a manner that is compliant with quality assurance standards.

Repairing Weld Defects

Welding Procedure Specifications (WPS)

A document describing the specific welding method to be used for a specific task.

A document describing the specific welding method to be used for a specific task.

Welding Procedure Specifications (WPS)

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