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Defects in Welds

Defects in Welds -
Introduction
The significance of defects in welds, which can be assumed to occur in normal fabrication, is of importance to Design Engineers.A defective weldment fails under service conditions and causes damage to property and loss of human lives.
This makes it necessary to study defects in welded joints and analyses their causes.Improper welding parameters and base metal and wrong welding procedures introduce defects or faults in the weld metal and around (i.e., in the heat-affected zone).
The tolerance of welded joints to defects ranges from acceptance of gross defects (lack of penetration, gross slag inclusions, lack of fusion) under static loading at low stress levels, to sensitivity to extremely small defects, such as cracks, which are almost impossible to detect by non destructive testing.

The significance of individual defects depends on
(i) The microstructure in which the defect occurs.
(ii) The mechanical properties of the material with particular reference to notch toughness.
(iii) The type of general loading (static, cyclical or shock).
(iv) The environment (corrosive or non-corrosive).
(v) Section thickness.
(vi) Type and size of defect, and
(vii) The stress pattern local to the defect.
Some of the common weld defects along with their causes will be discussed below.

1. Cracks.
2. Distortion.
3. Incomplete penetration.
4. Inclusions.
5. Porosity and blow holes.
6. Poor fusion.
7. Poor weld bead appearance.
8. Spatter.
9. Undercutting.
10. Overlapping.

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