1. Welding Standards and Training
For a little under 2 years McClain E-Z Pack hired Jim
Davis, a recently retired welding instructor, to work
with me on a part-time basis to help the welders
improve weld quality. During that time, the question
came up, what was the difference between a good
weld and a bad weld.
It was decided that showing pictures of good and bad
welds was the best way to get the message across.
Mr. Davis and I made our own examples of
acceptable and unacceptable welding practices and
posted the following pictures and comments. The
last picture is of an actual production weld.

2. Problem:
• Excessive undercut
Potential Problems:
• Failure of Weld
Possible Causes:
• Voltage too high
• Welding speed too fast
• Improper manipulation of weld puddle
Remedies:
• Raise voltage
• Lower wire speed
• Spend more time on outside of weave
Notes:
Undercut causes stress risers in a section of the weld zone that may have been hardened
as a result of the heat of the weld.
Painting does not always cover undercut. This causes rust streaks on the product.

3. Problem:
• Acceptable weld
Potential Problems:
• None
Possible Causes:
• Good work
Remedies:
• Keep up the good work
Notes:
Although amount of spatter in the picture is high the weld size and shape is good. Note
also the frequency and shape of the ridges.

4. Problem:
• Acceptable tack
Potential Problems:
• None
Possible Causes:
• Good work
Remedies:
• Keep up the good work
Notes:
Note the size and shape of the middle tack.

5. Problem:
• Oversize tack
Potential Problems:
• Difficult to weld over
• Unneeded expense
• Weld failure
Possible Causes:
• Workmanship
Remedies:
• Make tacks smaller
Notes:
Although a decent looking tack, larger tacks are difficult to weld over and avoid
excessive weld metal or a bead with “humps” in it. Oversized tacks increase the cost of
the production in material, labor and overhead cost. Also see excessive weld metal.

6. Problem:
• Excessive weld metal in weld crater
Potential Problems:
• Extra time for cleaners to remove
• Extra cost in welding wire, shielding gas, man-hours, overhead
• Looks sloppy
• Possible weld failure
Possible Causes:
• Allowing too much for weld termination
Remedies:
• Increase voltage and amps
• Increase speed
• Smaller and more concave tacks
Notes:
Excessive weld metal raises the price of the product, lowers efficiency, lowers
production, and is a sign of poor workmanship. Excessive weld metal also causes stress
risers in the weld which could cause weld failure

7. Problem:
• Poor weld profile, too much on lower leg
Potential Problems:
• Weld failure, on top leg
Possible Causes:
• Wrong torch angle
• Joining parts of different thickness
Remedies:
• More attention to both legs of weld
• Hold torch longer on thicker part
Notes:
Uneven legs mean that there is insufficient weld on one leg and could cause the weld to
fail, because of an uneven distribution of stress in the legs of the weld.

8. Problem:
• Insufficient weld
• Improper weld speed
Potential Problems:
• Weld failure
• Increase cause weld fatigue
Possible Causes:
• Weld speed too fast
• Improper torch angle
Remedies:
• Slower speed
• Increase amperage
• Decrease voltage
Notes:
Note also the tight angles in the ridges on the weld. Besides the obvious problems
associated with an insufficient weld, the pointed ridges are a sign that the grains in the
metal are not properly interlocking. This could result in a centerline crack within the
weld.

9. Problem:
• Good weld crater
Potential Problems:
• None
Possible Causes:
• Good workmanship
Remedies:
• Keep up the good work
Notes:
Excellent, torch angle and direction of travel.

10. Problem:
• Porosity
Potential Problems:
• Weld failure
• Could be a sign of bigger problems under the weld metal
Possible Causes:
• Poor gas flow
• Excessive heat
• Drafts
• Impurities in weld zone (rust, dirt, moisture)
• Improper torch angle or stickout
Remedies:
• Adjust torch angle or stickout
• Increase weld speed
• Correct shielding gas
• Check for drafts in the work area (e.g., open doors, fans, etc…)
Notes:
Porosity on the surface of the weld may also be a sign of porosity hidden in the weld
metal. Porosity is caused by something disrupting the shielding gas over the weld
puddle. It may be caused by excessive as well as insufficient gas flow.
Painting does not always cover porosity. This causes rust streaks on the product.

11. Problem:
• Poor weld profile
• Improper fusion, both legs
• Improper weld contour
• Bead face too high
Potential Problems:
• Weld failure
Possible Causes:
• Poor gas flow
• Excessive heat
• Poor torch angle
Remedies:
• Adjust torch angle
• Increase weld speed
• Correct shielding gas
• Decrease wire stick-out
Notes:
Give more attention to torch angle, speed of travel, wire stickout, and wire length.

12. Problem:
• Excessive spatter
Potential Problems:
• Weld failure
• Poor workmanship
• Unneeded cleaning
Possible Causes:
• Poor gas flow
• Excessive heat
• Poor torch angle
Remedies:
• Adjust torch angle
• Increase weld speed
• Correct shielding gas
• Decrease wire stick-out
• Decrease voltage or increase amperage
Notes:
Spatter just looks bad and cause increased cleaning cost. Spatter may be caused by poor
gas flow. See porosity for more possible remedies.

13. Problem:
• Whisker
Potential Problems:
• Poor workmanship
• Unneeded cleaning
Possible Causes:
• Burning off extra wire
• Amperage too high
Remedies:
• Adjust torch angle
• Increase weld speed
• Decrease wire stick-out
• Decrease voltage or increase amperage
Notes:
Whiskers just looks bad and cause increased cleaning cost. Whiskers are a sign of poor
workmanship and pride.

14. Problem:
• Overlay or Overlap
Potential Problems:
• Could cause failure
• Insufficient penetration
Possible Causes:
• Poor workmanship
• Excessive weld
• Welding too slow
• Amperage and Voltage too high
• Joining parts of different thickness
Remedies:
• Adjust torch angle
• Increase weld speed
• Decrease voltage or increase amperage
Notes:
Could be a sign that weld isn’t penetrating into base metal on the one side. If this occurs
while welding parts of different thickness, hold the torch longer on the thicker part.
Painting does not always cover overlap. This causes rust streaks on the product.

15. Problem:
• Super Vertical-Up Weld
Potential Problems:
• None
Possible Causes:
• Good workmanship
Remedies:
• “Keep up the good work” (says Jim Davis)
Notes:
Excellent, torch angle and direction of travel.