In this post, we will briefly see some commonly occuring Welding Defects and their Solutions.
WELDING
DEFECTS
|
CAUSES
|
SOLUTIONS
|
Porosity
|
Wrong current setting
Excessive speed
Dirt or impurities in base
metal
|
Set proper current
Reduce speed of travel
Use shallow penetration
electrode.
|
Spatter
|
Amperage (heat) too high
Excessive arc length
.Arc Blow
Wrong polarity
|
Reduce amperage
Shorten arc
Direct travel to the
direction of blow.
Switch to opposite
|
Arc Hard to Start
|
Current setting too low
Poor or no ground
Work dirty
Low input line voltage
Broken cable
Corroded holder jaws
|
Increase current (Amperage)
Attach ground to clean
area of metal
Remove rust, paint, oxides
Check line voltage
Usually in holder or ground- replace cable
File and clean them up
nicely
|
Slag Inclusions
|
Current setting too low
Too short an arc
Wrong bead forming
procedure
|
Increase amperage
Increase arc length
Correct to proper waving
bead (Welder Skills)
|
Poor Fusion
|
Current setting too low
Wrong manipulation
Too long an arc
Incorrect work preparation
|
Reset current
Correct speed and change weave
Shorten arc length to
frying sound
Clean and prepare weld joint (V Joint)
|
Undercut
|
Current amperage too high
Travel speed too fast
Arc length excessive
Incorrect electrode to
work angle
Wrong diameter electrode
|
Lower amperage
Reduce welding travel speed
Shorten arc length
Use correct electrode angle (Welder Skills)
Increase electrode diameter one size
|
Distortion
|
Improper set-up and
jigging
Excessive heating of weld
area
Wrong welding procedure
|
Correct set-up or jigging
design
Reduce heat in work
Use
correct welding procedure
Use
back step welding
|
Cracking
|
High carbon or poor
quality material
Wrong bead configuration
Improper selection of
electrode type
Too fast cooling
|
Preheat
Avoid excessive heat and
puddle size
Check and use correct type of electrode
Preheat and
post-heat, Cool slowly
|
