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Welding Inspection
Defects/Repairs
Course Reference WIS 5
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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
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Cracks
The four essential crack mechanisms
Hydrogen (HICC)
Reheat cracks
Lamellar tearing
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Cracks
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Undercut
An irregular groove at the toe of a weld run in
the parent metal
Excessive amps/volts
Excessive weaving
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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
Incorrect welding
technique
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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
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
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Root Defects
Low Amps/volts
Large Root face
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Root Defects
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Lack of root penetration
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Lack of root fusion
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Root Defects
A shallow groove, which may occur in the root of a butt weld
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Root Defects
Root penetration bead in excess in accordance with the
relevant specification being used
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Excessive Root Penetration
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Concave root 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
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Root Defects
A localized collapse of the weld pool due to excessive
penetration resulting in a hole in the root run
High Amps/volts
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Burn
Through
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
Damp electrodes
Contamination
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Inclusions
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Gas Cavities
Gas pore Cluster porosity Loss of gas shield
Damp electrodes
Contamination
Blow hole Arc length too large
Herringbone porosity
Damaged electrode flux
Moisture on parent
material
Welding current to low
Root piping
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Gas Cavities
Porosity
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
Lamination
Segregation line
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Plate Lamination
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Weld Repairs
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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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Weld Repairs
The specification or procedure will govern how
the defective areas are to be removed. The
method of removal may be
Grinding
Chipping
Machining
Filling
Oxy-gas gouging
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