Top 10 Welding Defects and What Causes Them

 


Welding is a process that may seem easy from a distance. Sparks fly off as metal is melted, and two parts are brought together. However, as a welder gets into a workshop, things are not as smooth as they seem. Small mistakes can quickly lead to welding defects. These defects may cause a weld to become weaker or cause more problems when it is put to use again. Welders are taught not only to weld but also to identify defects that may occur during a weld. In a busy place like Engineering Toowoomba, where machines and parts are manufactured for use under pressure, weld quality is very important.

Here are ten common defects that may occur during a weld and why they may happen.

1. Porosity
Porosity is a weld that has holes inside it. This occurs when there is a buildup of gas inside a weld. The buildup occurs when metal surfaces are dirty, or there is moisture or rust on the metal.

2. Lack of Fusion
This is a weld that has developed a defect as a result of a lack of fusion between the weld metal and the base metal. Lack of fusion occurs when there is insufficient heat or when the welding speed is too fast.

3. Cracking
Cracking occurs as a result of a weld being exposed to too much heat or when it is cooled down quickly. The wrong filler metal is also a cause of cracking.

4. Undercut
Undercut is a weld that has developed a groove along its edge as a result of melting of the base metal. Excessive welding current or moving the welding torch too quickly is a cause of undercut.

5. Slag Inclusions
Slag is a weld that has developed non-metallic particles inside it. The non-metallic particles are a result of slag from previous welds that was not removed properly.

6. Overlap
Overlap is a weld that has developed a defect as a result of weld metal spreading over the base metal but failing to fuse into it. The welder moving too slowly or using a lot of filler metal is a cause of overlap.

7. Burn-Through
Burn-through occurs when too much heat is applied to the metal, which causes it to melt completely. A hole is therefore created. This mostly occurs while welding thin materials using high currents.

8. Incomplete Penetration
This occurs when the weld does not penetrate to the bottom of the joint. This mostly occurs due to poor joint preparation and insufficient heat input.

9. Spatter
Spatter occurs when small droplets of metal are scattered around the weld area. This mostly occurs due to incorrect voltage settings.

10. Distortion
Distortion occurs when the metal changes its original shape due to the application of too much heat while welding. This occurs due to uneven heating and cooling of the metal.

Final Thoughts

As mentioned earlier, defects in the weld will always occur. What is important is the ability to identify them and the reasons behind them. With the right preparations and settings, most of the defects mentioned above can be avoided.


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