Welding Defects: Causes and Remedies Quiz
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Questions and Answers

Use ______ electrode to increase or maintain steady travel speed

smaller

Distortion is the contraction of ______ metal during welding

weld

In order to prevent incomplete fusion, increase the ______ input

heat

Place ______ bead in proper locations at joint during welding

<p>stringer</p> Signup and view all the answers

Remove all ______, oil, rust, paint, coating, slag & dirt from work surface before welding

<p>grease</p> Signup and view all the answers

Welding defects can be defined as ______ surface irregularities, discontinuities, imperfections, or inconsistencies that occur in welded parts.

<p>weld</p> Signup and view all the answers

Porosity is caused by ______ pocket in weld metal.

<p>gas</p> Signup and view all the answers

One of the possible causes of Excessive Spatter is ______ too high for electrode.

<p>amperage</p> Signup and view all the answers

Lack of Penetration can be corrected by ______ heat input.

<p>increasing</p> Signup and view all the answers

Burn-through can be prevented by selecting ______ amperage.

<p>lower</p> Signup and view all the answers

Study Notes

Welding Defects

  • Welding defects are defined as weld surface irregularities, discontinuities, imperfections, or inconsistencies that occur in welded parts.
  • Defects can result in rejection of parts and assemblies, costly repairs, reduction of performance, and catastrophic failures.

Distortion

  • Distortion is the contraction of weld metal during welding that forces base metal to move.
  • Possible causes: excessive heat input.
  • Corrective actions:
    • Use restraint clamp to hold base metal in position.
    • Make tack weld along joint before starting weld operations.
    • Predict anticipated weld distortion and pre-camber base metal.
    • Select lower amperage for electrode.
    • Increase travel speed.
    • Weld in small segments and allow cooling between welds.

Incomplete Fusion

  • Incomplete fusion is the failure of weld metal to fuse completely with base metal or a preceding weld bead.
  • Possible causes: insufficient heat input, improper welding technique, and work piece dirty.
  • Corrective actions:
    • Increase amperage and select larger electrode.
    • Place stringer bead in proper locations at joint during welding.
    • Adjust work angle or widen groove to access bottom during welding.
    • Momentarily hold arc on groove side walls when using weaving technique.
    • Keep arc on leading edge of weld puddle.
    • Remove all grease, oil, rust, paint, coating, slag, and dirt from work surface before welding.

Porosity

  • Porosity is small cavities or holes resulting from gas pockets in weld metal.
  • Possible causes: arc length too long, work piece dirty, and damp electrode.
  • Corrective actions:
    • Reduce arc length.
    • Remove all grease, oil, rust, paint, coating, slag, and dirt from work surface before welding.
    • Use dry electrode.

Excessive Spatter

  • Excessive spatter is the scattering of molten metal particles that cool to solid form near weld bead.
  • Possible causes: amperage too high for electrode, arc length too long, and voltage too high.
  • Corrective actions:
    • Decrease amperage or select larger electrode.
    • Reduce arc length or voltage.

Lack of Penetration

  • Lack of penetration is shallow fusion between weld metal and base metal.
  • Possible causes: improper joint penetration, material too thick, and improper weld technique.
  • Corrective actions:
    • Improve joint penetration and design to provide access to bottom of groove.
    • Keep arc on leading edge of weld puddle.
    • Reduce travel speed.
    • Increase amperage and select larger electrode.

Burn-Through

  • Burn-through is weld metal melting completely through base metal, resulting in holes where no metal remains.
  • Possible causes: excessive heat input.
  • Corrective actions: select lower amperage.

Mark/Locate Weld Defects

  • Identify/determine location of weld defects in accordance with industry standard.
  • Mark weld defects for repair in accordance with industry standard.
  • Perform procedures in locating weld defects as per approved procedures.

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Description

Test your knowledge on welding defects, causes, and remedies. Learn about common weld surface irregularities, discontinuities, and imperfections that can occur in welded parts, as well as the potential consequences of these defects. Identify and locate weld defects for quality assurance purposes.

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