Weld defects

Question 1

Defect definition

Answer 1

An amount of weld irregularities which exceed the limit of quality control

Question 2

Discontinuity definition

Answer 2

An acceptable amount of weld irregularities within limits of quality control

Question 3

Inadequate penetration definition

Answer 3

The weld metal fails to extend completely through the joint thickness

Question 4

Inadequate penetration cause

Answer 4

Incorrect rod angle, inadequate amperage, inadequate gap or land

Question 5

Excessive penetration definition

Answer 5

Weld metal exceeds allowable limit of penetration by quality control usually over 1/8

Question 6

Excessive penetration cause

Answer 6

Excessive amperage, incorrect rod angle, excessive gap or land, feeding to much wire

Question 7

Insufficient fill definition

Answer 7

Fill places in a v groove which is more than 1/16 below flush

Question 8

Insufficient fill cause

Answer 8

Incorrect: bead placement, size, travel speed

Question 9

Internal undercut definition

Answer 9

Gouging or cutting away of the base metal on the root side of metal

Question 10

Internal undercut cause

Answer 10

Insufficient metal prep, excessive amperage, rod angle, long arching

Question 11

Wagon tracks definition

Answer 11

Two black parallel lines of slag trapped on each side of root next to bevel 6010 root

Question 12

Wagon tracks cause

Answer 12

Incorrect method of grinding

Question 13

Unbroken land definition

Answer 13

Weld metal fails to extend completely through the land thickness, lack of melt through on root pass

Question 14

Unbroken land cause

Answer 14

Usage of incorrect, rod angle, amperage, gap and or land

Question 15

Off set and or high-low definition

Answer 15

Incorrect internal alignment of pipe or uneven plates

Question 16

Off set and or high-low cause

Answer 16

Incorrect alignment while tacking, pipe with two different ID inside diameter

Question 17

Incomplete fusion definition

Answer 17

Lack of fusion between filler metal and the base metal, inadequate coalescence of molecules

Question 18

Incomplete fusion cause

Answer 18

Amperage too low, travel speed too fast, improper joint design

Question 19

Tungsten inclusion definition

Answer 19

Random pieces of unmelted tungsten electrode that are trapped in the weld

Question 20

Tungsten inclusion cause

Answer 20

Placing the tungsten electrode into the molten weld metal. Generally happens with inexperience

Question 21

Slag inclusion definition

Answer 21

A non metal substance of irregular shape that is trapped in weld area

Question 22

Slag inclusion cause

Answer 22

Improper bead placement, insufficient cleaning, improper joint design

Question 23

Porosity definition

Answer 23

Gas pockets trapped in weld area

Question 24

Porosity cause

Answer 24

Cracked or missing flux, wind, improper rod angle, moisture, lack of shielding gas

Question 25

Burn thru definition

Answer 25

Melting or burning through hot pass

Question 26

Burn they cause

Answer 26

Grinding root to thing, long arching, excessive amperage