Study common weld defects and how to avoid them.
A defect characterized by a crack that forms in the weld metal or heat-affected zone during or af...
A defect that occurs when the weld metal does not fuse properly with the base metal, creating a gap.
A defect characterized by the presence of gas bubbles trapped in the weld metal, often caused by ...
A defect where excessive penetration causes the weld to burn through the base material.
A defect resulting from uneven heating and cooling, leading to warping or distortion of the welde...
A defect where the weld filler does not extend through the joint thickness.
A defect where an unintended groove is cut into the base metal.
A defect where the weld metal rolls over the top of the weld, not blending smoothly into the base...
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A defect characterized by a crack that forms in the weld metal or heat-affected zone during or after welding.
Cracking
A defect that occurs when the weld metal does not fuse properly with the base metal, creating a gap.
Lack of Fusion
A defect characterized by the presence of gas bubbles trapped in the weld metal, often caused by moisture or contamination.
Porosity
A defect where excessive penetration causes the weld to burn through the base material.
Burn-Through
A defect resulting from uneven heating and cooling, leading to warping or distortion of the welded parts.
Distortion
A defect where the weld filler does not extend through the joint thickness.
Incomplete Joint Penetration
A defect where an unintended groove is cut into the base metal.
Undercutting
A defect where the weld metal rolls over the top of the weld, not blending smoothly into the base metal.
Overlapping
A defect where the face of the weld extends above the weld joint in a convex shape.
Excessively convex
A defect characterized by the presence of slag in the weld metal, usually caused by failure to remove slag between weld passes.
Slag Inclusion
A defect where the weld metal does not fully fill the joint.
Incomplete Filling
A defect caused by the trapping of shielding gas in the weld metal.
Gas Inclusion
A defect caused by the accidental inclusion of tungsten electrode material in the weld.
Tungsten Inclusion
A defect caused by high thermal stresses near the end of the weld.
Crater Cracks
A defect where the weld metal forms a shallow angle to the base metal, often due to low welding currents.
Cold Lap
A defect where the weld size significantly exceeds that required for joint strength.
Overwelding
A practice of rectifying welding defects in a manner that is compliant with quality assurance standards.
Repairing Weld Defects
A document describing the specific welding method to be used for a specific task.
Welding Procedure Specifications (WPS)
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