What are Welding Defects? – Types, Causes, and Remedies
The irregularities formed in the given weld metal due to wrong welding process or incorrect welding patterns, etc. are known as welding defects.
The following table elaborates the different types of welding defects, their causes, and how to prevent these defects −
The irregularities formed in the given weld metal due to wrong welding process or incorrect welding patterns, etc. are known as welding defects.
The following table elaborates the different types of welding defects, their causes, and how to prevent these defects −
Welding Defect | Causes of Welding Defect | Remedies |
---|
Blow hole | Too fast cooling rate. Wet, unclear or damaged electrode. Too thick base metal. Long or short arc length. Rusted wire or flux. Over welding speed. Base metal covered with oil rust etc.
| Proper maintenance Clean properly before welding. Proceed proper pre-heating. Maintain proper arc length. Reduce travelling speed. Store wire and flux properly.
|
Slag Inclusion | | Use higher welding current. Modify groove angle and root gap. Remove the slag from previous bead completely. Use higher travelling speed. Decrease weaving width.
|
Cracks | Electrode is not of good quality or may be damped. Base metal contains over carbon and manganese content. Base metal having higher Sulphur content. Welding is done without pre or post heating. Too large welding current. Thickness of base metal is much more. Too strong restraint for groove.
| |
Undercut | Too high welding current. Improper manipulation. Unclean base metal surface. Excessive arc length. Too high travel speed. Base metal is overheated.
| |
Incomplete Penetration | | Select the electrode with better penetration. Adjust travel speed properly. Increase the groove angle and root gap. Reduce arc voltage. Reduce arc length. Practice more to improve welding skills.
|
Distortion | Excessive weld size. Improper set-up and fixture. Overheating of base plate. Excessive layers. Worn out tip. Wire feeder does work smoothly. Feed roller not fasten properly.
| Make welds of specified size. Clamp the parts securely. Use thicker base plate. Replace the worn out electrode. Grease wire feeder. Adjust feed roller properly.
|
Overlap | Too low welding current. Too slow travel speed.
| |
Pit | | Use good low hydrogen type electrode. Use high basicity electrode. Use dried electrode. Reduce travel speed. Use proper pre and post heating.
|
Bad Appearance | | |
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