WELD DEFECT SMAW

1. WELD
DEFECT
S

2. WELD
DEFECTS

3. `
WELD DEFECTS
A flaw or flaws that by nature or accumulated
effect render a part or product unable to meet
minimum applicable acceptance standards or
specifications. The term designates rejectability
and Discontinuity.

4. DISCONTINUITY
a distinct break
in physical
continuity or
sequence in
time.

5. Types of Weld
Defects

6. MISALIGNMENT
• Definition: Amount of joint that is
out of alignment at the root.
• Cause: Carelessness. Also due to joining different
thicknesses (transition thickness)
• Prevention: Workmanship. Transition angles not to exceed
2.5 to 1.
• Repair: Grinding. Careful on surface finish and direction of
grind marks. Inside of Pipe /Tube difficult.

7. MISALIGNMENT

8. UNDERCUT
• Definition: A groove cut at the toe of the weld and left
unfilled.
• Cause: High amperage, electrode angle, long arc length,
rust
• Prevention: Set machine on scrap metal. Clean metal before
welding.
• Repair: Weld with smaller electrode, sometimes must be low
hydrogen with preheat.

9. UNDERCUT

10. REINFORCEMENT
The amount of a groove weld which extends beyond the surface of the plate
Two Types of Reinforcement
1. Excessive
2. Insufficient
Face Reinforcement
Root Reinforcement

11. Excessive Reinforcement
• Definition: Excess on weld puddle.
• Cause: Travel speed too slow, amperage too low
• Prevention: Set amperage and travel speed right.
• Repair: Remove excessive reinforcement and grind
the weld toes to a smooth transition to the base
plate.

12. Excessive Reinforcement

13. • Definition: Insufficient weld on puddle.
• Prevention: Use proper welding technique.
• Repair: Possibly simply increase the face
reinforcement. If backwelding is not possible, must
remove and reweld.
Insufficient Reinforcement

14. Insufficient Reinforcement
EXCESSIVE
REINFORCEMENT

15. SLAG INCLUSION
■Definition: Slag entrapped within the weld
■Cause: Low amperage, improper
technique, Trying to weld in an area that is
too tight. Slow travel in Vertical Down
■Repair: Remove by grinding. Reweld.

16. SLAG INCLUSION

17. SPATTER
■ Definition: Small particles of weld metal expelled
from the welding operation which adhere to the base
metal surface.
■ Cause: Long arc length, severe electrode angles, high
amperages.
■ Repair: Remove by grinding or sanding. Sometimes
must be tested as if it were a weld.

18. SPATTER

20. 1. A flaw or flaws that by nature or accumulated effect render a part or product
unable to meet minimum applicable acceptance standards or specifications.
The term designates rejectability.
a. Defect
b. Discontinuity
c. Flaw
2. A distinct break in physical continuity or sequence in time.
a. Defect
b. Discontinuity
c. Flaw
3. Amount of joint that is out of alignment at the root.
a. Misalignment
b. Undercut
c. Spatter

21. 4. A groove cut at the toe of the weld and left unfilled.
a. Excessive Reinforcement
b. Undercut
c. Spatter
5. What are the two types of reinforcement?
a. Misalignment and Undercut
b. Excessive and Insufficient
c. Reject and Discontinuity
6. It is the Excess on weld puddle.
a. Insufficient Reinforcement
b. Undercut
c. Excessive Reinforcement

22. 7. What do you call to the defect that has a Slag entrapped within the weld?
a. Slag Inclusion
b. Spatter
c. Reinforcement
8. What do you call to the defect that has an Insufficient weld on puddle?
a, Excessive Reinforcement
b. Insufficient Reinforcement
c. Misalignment
9. What do you call to a defect that has a Small particles of weld metal expelled from the
welding operation which adhere to the base metal surface?
a. Spatter
b. Undercut
c. Misalignment

23. 10. What is the Key Ingredient to prevent
weld defects? Essay (Minimum of 20
words)

24. ASSIGNMENT! On a 1 whole sheet of yellow
paper, answer the following questions.
1. What is Welding Procedure Specifications (WPS)
2. How to use WPS?