WELD DEFECTS

DEFECTS: A flaw or flaws that by nature or accumulated effect render a part or product unable to meet applicable acceptance standard or specifications. The term
designates rejectability. Defects may be repaired.

DISCONTINUITIES: An interruption of the typical structure of a material, such as lack of homogeneity in its mechanical, metallurgical or physical characteristics. A
discontinuity is not necessarily a defect. Discontinuity by definition is acceptable. Repair is therefore unnecessary and not cost effective.

S No Defects Definition Figural representation Causes Code Acceptance- API 1104

1 CRACKS Linear discontinuity produced a. The crack of any size or
by fracture location in the weld, if not
They are classified as a shallow crater crack or
1. Weld metal cracks star crack is not
a. Solidification cracking Discussed elsewhere. acceptable.
b. For shallow crater cracks
or star cracks if length
exceeds 5/32, it is not
acceptable.

b. Hydrogen induced Discussed elsewhere.

cracking (HICC)
i. Macro cracks
ii. Fissures
iii. Micro cracks
iv. Chevron cracks

2. HAZ cracks
a. HICC Discussed elsewhere.
b. Reheat cracks
c. Liquation cracks

3. Parent Material / HAZ Discussed elsewhere.

cracks
a. Lamellar tearing
2 INCOMPLETE The failure of the material a. Excessive root face Inadequate penetration
ROOT to penetrate into the root width without high low:
PENETRATION of the weld joint b. Low current setting If following conditions exists, then it is
They can be c. Root gap too small considered as a defect,
a. Inadequate d. Arc too long a. The length of an individual
penetration without e. Wrong polarity indication of IP exceeds 1
high low f. Travel speed too b. The aggregate length of
high for the current indications of IP in any
continuous 12 length of weld
g. Incorrect electrode exceeds 1
tilt angle
c. The aggregate length of
h. Electrode too large indication of IP exceeds 8%
for joint penetration of the weld length in any weld
less than 12 in length.
b. Inadequate Inadequate penetration due
penetration due to to high low:
high low
If the following conditions exist, it is
considered as a defect.
a. Length of an individual
indication of IPD exceeds 2
b. The aggregate length of
indication of IPD in any
continuous 12 length of the
c. Inadequate inter weld exceeds 3
penetration (double No Reference
sided welds)

d. In adequate cross
penetration (double In adequate cross penetration
sided welds) (double sided welds):

If the following conditions exist, it is

considered as a defect.
i. The length of an individual
indication of ICP exceeds 2
ii. The aggregate length of
indication of ICP in any
continuous 12 length of weld
exceeds 2
3 LACK OF FUSION It is the lack of union in a a. Linear Misalignment Lack of Fusion and lack of
weld b. Incorrect tilt angle aide wall fusion
- Between weld metal c. Differing root face If the following conditions exist, it is
and parent metal width considered as a defect.
- Between parent d. Arc blow effect 1. The length of an individual
metal and parent e. Amperage too low indication of IF exceeds 1
metal f. Amperage too high, 2. The aggregate length of
- Between weld metal may cause welder to indication of IF in any
continuous 12 length of
and weld metal increase the travel weld exceeds 1.
They can be speed resulting in
3. The aggregate length of
a. Lack of root fusion lack of melting on the indications of IF exceeds
under lying material 8% of the weld length in
g. Contaminated weld any weld less than 12 in
penetration, length.
preventing the
melting of the
material beneath
h. Excessive
b. Lack of side wall inductance in MIG or
fusion MAG Dip transfer
welding

c. Lack of inter-run Lack of inter-run fusion

fusion (also known as If the following conditions exist, it is
considered as a defect.
lack of fusion due to
cold lap) a. The length of an individual
indication of IFD exceeds
2
b. The aggregate length of
indication of IFD in any
continuous 12 length of
weld exceeds 2
c. The aggregate length of
indications of IFD exceeds
8% of weld length.
4 ARC STRIKE Damage on the parent a. Electrode straying Measured dimension Acceptance limit
(STRAY FLASH) material / weld metal onto the parent Width Lesser of t or 5/16
resulting from the material.
Length (any direction) Lesser of t or
accidental striking of an b. Electrode holder with
arc from the weld. poor insulation 5/16
touching the work Depth (to bottom of crater) 1/16 max
piece
c. Poor contact of the
earth clamp

5 BURN-THROUGH A localized collapse of the
molten pool of weld metal
due to excessive
penetration resulting in a
hole, usually at the root of
butt welds.
a. Excessive amperage The acceptance criterion for BT defers
during the welding of when
the root / hot pass on OD of the pipe is < 2.375 (60.3 mm)
butt welds OD of the pipe > 2.375 (60.3 mm)
b. Excessive root
Under the following conditions a BT
grinding which may is considered as a defect if the pipe
cause the second OD > 2.375.
pass to burn through a. The maximum dimension exceeds
c. Improper welding (6mm) and the density of the
technique BTs image exceeds that of the
thinnest adjacent parent material.
b. The max dimension exceeds the
thinner of the nominal wall
thickness joined and the density of
the BTs image exceeds that of the
thinnest adjacent parent material.
c. The sum of the max dimensions of
separate BTs whose image density
exceeds that of the thinnest
adjacent parent material and
exceeds in any continuous 12
length of the weld or the total weld
length whichever is less.
Under the following conditions, a
BT is considered as a defect if the
pipe OD< 2.375.
a. The max dimension exceeds
and the density of the BTs image
exceeds that of the thinnest
adjacent parent material.
b. The max dimension exceeds the
thinner of the nominal wall
thickness joined and the density of
the BTs image exceeds that of the
thinnest adjacent parent material.
c. More than one BT of any size is
present and the density of more
than one of the images exceeds
that of the thinnest adjacent parent
material.
6 CRATER PIPE A depression due to shrinkage
at the end of a weld run,
where the source of heat was
removed.
It is often associated with
crater cracks or star cracks.
They are located at the
stopping point of the weld
beads and are the result of
weld metal contractions during
solidifications.
7 SLAG INCLUSION It is an entrapped, fused non-
metallic residue produced
from some welding process.
Linear slag inclusions or slag
lines almost exclusively exist
at the toes of a weld pass.
Equi-axed slag inclusions may
exist any where in the weld.
Tungsten inclusions occurs
from the electrode in TIG
welding.
a. De-oxidation reaction Under the following condition, it is
b. Liquid to solid considered as a defect.
volume change] The crack is a shallow crater or star
c. Faster cooling rate crack with a length that exceeds 5/32
1. Insufficient cleaning For pipe with an OD > 2.375, slag
between the passes inclusions shall be considered a defect
2. Contaminated weld under following conditions.
preparation 1. The length of an ESI indication
3. Incorrect welding speed exceeds 2
4. Welding over an irregular 2. The aggregate length of ESI
indications in any continuous 12
profile length of weld exceeds 2
5. Arc too long
3. The width of an ESI indication
exceeds 1/16.
4. The aggregate length of ISI
indication in any continuous 12
length of weld exceeds .
5. The width of an ISI indication
exceeds 1/8.
6. More than 4 ISI indications with the
max width of 1/8 are present in
any continuous 12 length of the
weld.
For pipe with an OD <2.375. slag
inclusions shall be considered a defect,
once it exceeds the following
conditional limits.
a. The length of an ESI indication
exceeds 3 times the thinner of the
nominal wall thickness joined.
b. The width of an ESI indication
exceeds 1/16.
c. The aggregate length of ISI
indications exceeds 2 times the
thinner of the nominal wall
thickness joined and the width
exceeds one half of the thinner of
the nominal wall thickness joined.
d. The aggregate length of ESI & ISI
indications exceeds 8% of the weld
length.
8 POROSITY It is a cavity generally under 4. Excessive moisture in the Under the following conditions,
1.5mm in dia, formed by flux individual / scattered porosity is
entrapped gas during 5. Excessive moisture in the considered as a defect.
solidification of molten metal. weld preparation a. The size of an individual pore
Other terms which relate to 6. Contaminated weld exceeds 1/8
entrapped gas in welds are, preparation, scales oxides b. The size of an individual pore
exceeds 25% of the thinner of
1. Blow hole - a cavity etc the nominal wall thickness
generally over 1.5 7. Arc length too long joined.
mm (especially with Hydrogen c. The distribution of the scattered
2. Worm hole (piping) controlled electrodes) porosity exceeds the
an elongated or 8. Removal of gas shields concentration permitted by
tubular cavity (e.g., wind on site)
3. Hollow Bead 9. Damaged electrode flux
Elongated porosity in 10. Incorrect weaving
the root bead technique
Insert Fig 19 &
4. Herring Born porosity 11. Current setting too low. 20
worm holes side by
side taking on a
herring born pattern
Porosity can be divided into,
1. Individual /
scattered
porosity.
2. Cluster porosity
3. Hollow bead
porosity.
The acceptance criteria for cluster
porosity (CP) that occurs in any
pass except the finish pass is same
as that of individual / scattered
porosity.
CP which occurs in the finish pass
shall be considered as a defect, should
any of the following conditions exist.
a. The dia of the cluster exceeds

b. The aggregate length of CP in
any continuous 12 length of
weld exceeds
c. An individual pore within a
cluster exceeds 1/16 size.
Under the following conditions HB
is considered as a defect.
1. The length of an individual
indication of HB exceeds
2. The aggregate length of
indications of HB in any
continuous 12 length of weld
exceeds 2
3. I
ndividual indications of HB,
each greater than in
length are separated by less
than 2
4. T
he aggregate length of all
indications of HB exceeds
8% of the weld length.
9 OVERLAP An imperfection at the toe or
root of a weld caused by metal
flowing onto the surface of the
parent metal without fusing to
it.
1. Poor welding technique
2. Amperage too high
3. Contaminated weld
preparation
4. Travel speed too low
The face of the completed weld
should be 1/8 (3mm) wider than the
width of the original groove.

10 UNDER CUT An irregular groove at the toe
of a run in the parent material
or in previously deposited
weld metal
1. Excessive weld Under the following conditions
current undercutting shall be considered as
2. Excessive weaving a defect.
3. Electrode too large 1. The aggregate length of
4. Welding speed too indications of EU and IU in
any combination, in any
high continuous 12 length of
5. Incorrect electrode weld exceeds 2
angle 2. The aggregate length of
indications of EU & IU, in
any combination exceeds
1/6th of the weld length.
(Please note that the acceptance
std is different for undercutting
when visual and mechanical
measurements are involved)

11 SPATTER Small droplets of electrode 1. Arc blow effect No ref in the code
material which have strayed 2. Damp electrodes
away from the arc, which may 3. Excessive arc energy
or may not have fused on to 4. Excessive arc length
the parent metal.

12 ROOT A shallow groove that may 1. Root face too large 1. Any length of internal root
CONCAVITY occur in the root of a butt 2. Insufficient arc concavity is acceptable,
weld. Also called suck back or energy provided the density of the
radiographic image of the
under cutting. 3. Excessive back internal concavity does not
purge pressure with exceed that of the thinnest
TIG welding adjacent parent material.
4. Excessive root 2. For areas that exceed the
grinding (before density of the thinnest
adjacent parent material the
application of the criteria of burn through is
second run) applicable.
13 EXCESS Weld metal protruded out of 1. Travel speed too low 1. Reinforcement should be flush to
REINFORCEMENT the bond line and excessive 2. Amperage too low 1/16 in pipe
surface weld deposition at the 2. Reinforcement should be flush to
toe of the weld. 1/8 in plate and structural
Feather the weld toes to a shapes.
smooth transition to the base
plate.

14 INSUFFIECIENT Weld metal thickness is less 1. Too little filler metal 1. Typically under-fill is
REINFORCEMENT than the parent metal will cause thinning of allowed upto 5% of the
thickness. the filler metal. metal thickness, but not to
exceed 1/32.
Use proper welding technique 2. In OH position, too
to avoid this. hot or too wide weld This criteria is not applicable to
fillet welds.
Also use backing or bead may cause
consumable inserts. drooping of the open
root puddle.
15 IMPROPER WELD When the weld exhibits less 1. Poor welding The weld face must be properly
CONTOUR than a 1350 transition angle at technique. feathered into the base plate.
the weld toe.
Use proper techniques, a
weave or whip motion can
often eliminate this problem.