Welding Inspection

Defects/Repairs
Course Reference WIS 5
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M.S.Rogers

Weld Defects
Defects which may be detected by visual inspection can be grouped under five headings

Cracks Surface irregularities

Contour defects
Root defects Miscellaneous
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Weld Defects
Other associated defects

Cavities
Solid inclusions Set up irregularities

Parent material defects

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Cracks
The four essential crack mechanisms

Hydrogen (HICC)
Solidification (Hot tears) Reheat cracks

Lamellar tearing
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Cracks

Longitudinal parent metal crack

Transverse weld metal crack

Longitudinal weld metal crack

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Lamellar tearing
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Transverse crack

Center line crack

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Surface Irregularities

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Undercut
An irregular groove at the toe of a weld run in the parent metal Excessive amps/volts Excessive travel speed

Incorrect electrode angle

Excessive weaving

Incorrect welding technique

Electrode too large
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Cap Undercut

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Root undercut

Cap undercut

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Overlap
An imperfection at the toe or root of a weld caused by metal flowing on to the surface of the parent metal without fusing to it

Contamination
Slow travel speed

Incorrect welding
technique

Current too low

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Overlap

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Crater Pipe
Crater pipe is a shrinkage defect and not a gas defect, it has the appearance of a gas pore in the weld crater

Too fast a cooling rate Deoxidization reactions and liquid to solid volume change
Crater crack (Star crack)

Contamination

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Crater Pipe
Weld crater

Crater pipe

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Contour Defects

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Contour Defects

Incomplete filled groove

Poor cap profile

Incomplete filled groove + Lack of sidewall fusion

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Excessive cap height

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Excess cap reinforcement

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Incomplete filled groove

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Root Defects

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Root Defects
Low Amps/volts

Large Root face

Incomplete root fusion

Small Root Gap Fast Travel Speed Incorrect Electrode Angle

Incomplete root penetration

Contamination
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19 Sep 02

Root Defects

Lack of root fusion

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Lack of root Penetration

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Lack of root penetration

19 Sep 02

Lack of root fusion

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Root Defects
A shallow groove, which may occur in the root of a butt weld

Root faces too large

Root gap too large Excessive back purge pressure during TIG welding
Concave root

Excessive root bead grinding before the application of the second pass
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19 Sep 02

Concave Root

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Root Defects
Root penetration bead in excess in accordance with the relevant specification being used

Root faces too small Root gap too large

Excessive amps/volts
Excessive root penetration

Slow travel speed

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Excessive Root Penetration

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Concave root
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Excessive root penetration

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Root Defects
A shallow groove caused by contraction in the weld metal along each side of the penetration bead

Insufficient weld metal deposited in the root pass Too fast a cooling rate during the application of the root bead pass Poor welding technique
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Shrinkage groove

Root Defects
A localized collapse of the weld pool due to excessive penetration resulting in a hole in the root run

High Amps/volts

Small Root face

Large Root Gap

Slow Travel Speed

Burn through

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Burn Through

19 Sep 02

Burn through

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Root Coking/Oxidized Root

Loss or insufficient back purging gas Most commonly occurs when welding stainless steels

Purging gases include argon, helium and occasionally nitrogen

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Miscellaneous Defects

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Miscellaneous Defects
Accidental striking of the arc onto the parent material Faulty electrode holder

Poor cable insulation

Poor return lead clamping

Arc strike
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Miscellaneous Defects
Excessive current
Damp electrodes

Contamination
Incorrect wire feed speed when welding with the MAG welding process
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Spatter
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Inclusions

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Gas Cavities
Gas pore Cluster porosity

Loss of gas shield Damp electrodes Contamination

Blow hole
Herringbone porosity

Arc length too large

Damaged electrode flux Moisture on parent material

Root piping
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Welding current to low

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Gas Cavities

Porosity

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Root piping

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Cluster porosity

Single gas pore

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Solid Inclusions
Slag inclusions are defined as a non-metallic inclusion caused by some welding process Slag originates from welding flux MAG and TIG welding process produce silica inclusions Slag is caused by inadequate cleaning Other inclusions include tungsten and copper inclusions from the TIG and MAG welding process
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Slag inclusions

Lack of sidewall fusion with associated slag

Parallel slag lines

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Interpass slag inclusions

19 Sep 02

Elongated slag lines

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Set-up Irregularities

Plate/pipe Linear Misalignment (Hi-Lo)

Poor fit-up

Angular Misalignment
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Linear Misalignment

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Parent Material Defects

A welding inspector should also inspect the parent material for any visible defects

Mechanical damage

Lap

Lamination

Segregation line

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Plate Lamination

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Weld Repairs

19 Sep 02

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Weld Repairs
A weld repair may be used to improve weld profiles or extensive metal removal Repairs to fabrication defects are generally easier than repairs to service failures because the repair procedure may be followed The main problem with repairing a weld is the maintenance of mechanical properties During the inspection of the removed area prior to welding the inspector must ensure that the defects have been totally removed and the original joint profile has been maintained as close as possible
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The specification or procedure will govern how the defective areas are to be removed. The method of removal may be
Grinding Chipping

Weld Repairs

Machining
Filling

Arc air gouging

Oxy-gas gouging
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M.S.Rogers