SAW DEFECTS

1. Effect of Varying the Welding
Current
• Arc Blow Porosity or
Ropey Bead
• Burn-Through
• Metal Spillage On
Rounds Fusion Zone
• Pear Shaped
• Penetration too deep or
too shallow
• Reinforcement
Overlapped
• Reinforcement too high
or too low
LOW CORRECT HIGH

2. Effect of High Welding Voltage
• Arc Blow Porosity or
Ropey Bead
• Undercutting
• Penetration too deep
or too shallow
• Reinforcement too
high or too low
• Slag Sticking in
Deep Groove
LOW CORRECT

3. Effect of Low Welding Voltage
• Pear Shaped
• Reinforcement Narrow
& Steep-Sided
• Reinforcement
Overlapped
• Reinforcement Ropey
CORRECT HIGH

4. Effect of Varying the Welding
Speed
• Low Speed
• Arc Blow Porosity or
Ropey Bead
• Reinforcement
Overlapped
• High Speed
• Reinforcement too high or
too low
• Transverse Cracking in
Multi-pass Weld
• Undercutting
• Voids and Cracks
LOW CORRECT HIGH

5. Effect of Beveling
• Burn-Through
• Reinforcement Narrow
& Steep-Sided
• Reinforcement too
high or too low

6. Effect of Root Face
Dimension
• Burn-Through

7. Effect of Plate Cleanliness on
Finished Welds
• Porosity and Gas
Pockets
• Rust Porosity
• Transverse Cracking
in Multi-pass Weld
CROSS SECTION
TOP
CLEANED CONTAMINATED

8. Effect of Improper Fit-up in
Welds Having Manual Weld
Backing
• Porosity and Gas
Pockets
• Undercutting
CORRECT
INSUFFICIENT
SPACING

9. Effect of Wire Position and
Reinforcement Shape in Fillet
Welds
• Porosity and Gas
Pockets
• Transverse Cracking
in Multi-pass Weld
• Undercutting
• Voids and Cracks CORRECT
CONCAVE
REINFORCEMENT
IMPROPER WELD POSITION

10. Effect of Improper Fit-up in
Double Welds
• Burn-Through
• Porosity and Gas
Pockets
• Undercutting
• Voids and Cracks
SQUARE GROOVE BUTT
JOINT 3/8-in. Plate
900 DOUBLE- VEE GROOVE
BUTT JOINT 5/8-in. Plate
CORRECT
SPACING
EXCESSIVE
SPACING

11. Effect of Improper Fit-up in
Square Butt Weld
• Reinforcement too
high or too low

12. Effect of Improper Fit-Up in
Steel-Backed Welds
• Penetration too deep
or too shallow
• Reinforcement too
high or too low
• Undercutting
CORRECT
SPACING
INSUFFICIENT
SPACING
EXCESSIVE
SPACING
GAP BETWEEN
PLATES AND
BACKING

13. Effect of Proper and Improper
Depth of Granular Material
• Porosity and Gas
Pockets
• Reinforcement Narrow
& Steep-Sided
• Reinforcement Ropey CORRECT
SHALLOW

14. Effect of Welding Wire
Offset in Circumferential
Seam Welding
• Metal Spillage On
Rounds Fusion Zone
SMALL OFFSET MEDIUM OFFSET LARGE OFFSET