Welding Inspection

Practical Plate Exercise

Welding Process MMA (SMAW)

?
Incomplete Filled Groove
?
Porosity
?
Lack of
fusion
Slag Cap Undercut Cap Undercut
?
Inclusion ?
Intermittent ?
Intermittent

?
Cap Undercut
?
Intermittent
?
Arc Strike
Arc Strike

Note: spatter and surface slag requires removal, arc strikes

require blending and crack detection
Welding Process MMA (SMAW)

Excess
?
Penetration ?
Excess
Penetration
?
Gas Pore

?
Linear Misalignment

? ?
Surface Slag Lack of Root ?
Root Undercut

Fusion

Note: Spatter and surface slag require removal

Welding Process MMA (SMAW)

?
Incomplete Filled Groove
?Porosity
?
Lack of Sidewall Fusion Fusion?
Lack of Sidewall

?
Surface Slag

Overlap and Excess Cap Height Full Weld Length ?

Note: Surface slag requires removal and poor toe blending full
weld length
Welding Process MMA (SMAW)

? ?
Slag Inclusion
Crater Pipe

?
Lack of Root Fusion
?
Lack of Root ?
Lack of Root Fusion
Penetration
Welding Process FCAW

Incomplete
?
Cap Undercut
Filled Groove +
Lack of

?
Sidewall
Surface slag & Spatter ?
Fusion Longitudinal
?
Crack

?
Slag Inclusion
?
Incomplete Filled
Groove + Lack of
Sidewall Fusion + Cap
Undercut Intermittent

Note: Spatter and surface slag requires removal

Welding Process FCAW

Mechanical Damage
? ? Poor Stop/Start + Lack of
Burn Through
?
Root Penetration
?Excess Penetration

?
Lack of Root Fusion

?
Lack of Root Fusion
Welding Process MMA (SMAW)

?
Porosity
Incomplete
?
Filled Groove
Excess Cap Cap
? ?
Lack of Sidewall
?
Cap
Height ?
Undercut Fusion Undercut

?
Overlap between Capping Passes

Note: Excess cap height and poor cap profile throughout.

Welding Process MMA (SMAW)

?
Mechanical Damage

?
Lack of Root Fusion

?
Lack of Root Fusion
Welding Process MMA (SMAW)

Lack of
?
Sidewall
Fusion
?
Cap Undercut Intermittent ?
Cap Undercut Intermittent

?
Incomplete Filled Groove

?
Excess Cap Height

?
Incomplete Filled Groove
Welding Process MMA (SMAW)

?
Poor Stop/Start + Crater Pipe ?
?
Lack of Root Fusion
Lack of Root Fusion
?
Root Undercut

?
Excess Root Penetration
?
Excess Root
Penetration

?
Crater Pipe
?Lack of Root
fusion
Welding Process MMA (SMAW)

Mechanical
Damage
?

?
Lack of Sidewall fusion
?
Crater pipe

?
Poor Toe Blend
?
Lack of Sidewall Fusion + Incomplete Filled Groove

?
Tack Weld ?
Arc
Strikes

Note: Arc strikes require blending and crack detection

Welding Process MMA (SMAW)

Poor Stop/Start + Lack of Root

?
Penetration + Crater Pipe ?
Blow Hole
?
Arc Strikes Lack of Lack of
Mechanical Damage +
?
Lack of Root Fusion
Root
?
Fusion ?
Root
Fusion

?
Lack of Root Fusion
?
Arc Strikes

?
Arc Strikes

Note: Arc strikes require blending and crack detection

Welding Process MMA (SMAW)

?
Parent Material Damage
?
Arc Strikes
?
Arc Strikes
Lack of Sidewall Fusion +
?
Incomplete Filled Groove

?
Poor Toe Blend + Excess Cap Height

?
Porosity

Note: Arc strikes require blending and crack detection, Seek advise
on parent material damage
Welding Process MMA (SMAW)

?
Parent material
gas cavities

?
Plate corrosion
?
Poor Stop/Start

?
Lack of Root Fusion

?
Crater pipe ?
Surface slag
?
Surface Slag

?
Linear Misalignment

Note: Surface slag requires removal, plate corrosion requires

wire brushing
Welding Process MMA (SMAW)

?
Incomplete Filled Groove ? ? ?
?
Arc Strikes
Arc Strikes Slag Inclusion Arc Strikes

Arc Strikes ?
Cap Undercut Intermittent ?
Cap Undercut
?
?
Arc Strikes

Note: Parent plate damage throughout, seek advice. Arc strikes

require blending and crack detection.
Welding Process MMA (SMAW)

?
?
Crater pipe
Excessive root penetration

?
Linear misalignment +
lack of root fusion

?
Lack of root fusion

? ?
Poor stop/start
Lack of root fusion ?
Arc strikes

Arc strikes

Note: Arc strikes require blending and crack detection, Seek advise
on parent material damage
Welding Process MMA (SMAW)

? ?
Spatter
Cap undercut
?
Arc strikes

?
Poor toe blend full weld length

Note: Arc strikes require blending and crack detection. Spatter

requires removal.
Welding Process MMA (SMAW)

Arc strike

?
Lack of root penetration ?
Burn through
?
Poor stop/start ?

?
Linear misalignment

?
Lack of root penetration ?
Lack of root fusion

?
Mechanical damage ?
Lack of root fusion
+ poor stop/start

Note: Arc strikes require blending and crack detection, Seek advise
on parent material damage
Welding Process MMA (SMAW)

Suspect crater cracking

?
Cap undercut ?
Arc strikes
?
Cap undercut
?
Porosity

?
Cap undercut intermittent

?
Cap undercut

Note: Material damage throughout, seek advice. Arc strikes require

blending and crack detection.
Welding Process MMA (SMAW)

?
Mechanical damage
? fusion
Lack of root
Linear misalignment +
?
lack of root fusion

?
Linear misalignment +
lack of root fusion
?
Lack of root penetration

Note: Material damage seek advice on course of action.

Welding Process MMA (SMAW)

Mechanical damage
?
?
Cap undercut ?
Cap undercut

?
Spatter/irregular cap profile

Note: Grinding marks throughout seek advice on course of action.

Excess cap height and poor cap profile throughout.
Welding Process MMA (SMAW)

?
Arc strike
?
Root undercut
intermittent

?
Lack of penetration intermittent

?
Ground flush root
Welding Process MMA (SMAW)

?
Surface slag
?
Arc strikes damage
?
Mechanical
?
Cap undercut intermittent

?
Cap undercut intermittent

?
Mechanical
damage

Note: Mechanical damage seek advice on course of action.

Excess cap height and poor cap profile throughout. Arc
strikes require blending and crack detection.
Welding Process MMA (SMAW)

?
Arc strike ?
Lack of root
fusion

? ?
Spatter
?
Lack of root
fusion
?
Lack of root
fusion
Lack of root
fusion

?
Root undercut intermittent
?
Spatter

Note: Arc strikes require blending and crack detection. Spatter

requires removal