Sr.

No.
Defect Cause Remedy
a) Excessive Hydrogen or Oxygen or
Nitrogen in atmosphere.
a) Use low Hydrogen welding electrode, filler
wires high in deoxidisers, increase shielding
gas flow.
b) High solodification rate. b) Use preheat or increase heat input.
c) Dirty base metal. c) Clean joint faces or adjucent areas.
d) Dirty filler wire. d) Use cleaned filler wires.
e) Improper arc length.
e) Use proper procedures for baking and
storing of electrodes and fluxes.
f) Excessive moisture in electrode
covering or joint surface.
f) Preheat the base metal if not damaged. /
reheat the base metal.
g) high sulfer base metal.
g) Avoid the material or use low sulfer and
high 'Mn' consumable (S:Mn =1:50).
a) High current a) Reduce current.
b) Incorrect electrode angle. b) Correct electrode angle.
a) failure to remove slag.
a) Clean surface area and previous weld
bead.
b) Entrapment of refractory. b) Power wire brush previous weld metal.
c) Tungsten in weld metal.
c) Avoid contact between electrode and base
metal.
d) Improper joint design. d) Increase groove angle of weld joint.
a) High current a) Reduce current
b) Low speed. b) Increase speed.
a) Incorrect joint design a) Change joint design
b) Low currnt / high speed. b) Use correct parameter.
c) large size electrode. c) Use lower size electrode.
d) Incorrect polarity.( In case of D.C. ) d) Use correct polarity.( In case of D.C. )
a) Improper manipulation of electrode. a) Use correct technique.
b) Incorrect position of electrode. b) Correct position of electrode. parameters.
c) Low welding current. c) Increase current.
d) Too rapid arc advance. d) Slow arc advance.
e) Improper edge cleaning after flame
cutting.
e) Clean edges after falme cutting.
f) Improper joint fitup. f) Correct joint fit up.
g) Incorrect joint design ( No approach
to root. )
g) Change design.
a) Hydrogen in welding atmosphere. a) Use low hydrogen process.
Burn through reduction in thickness & uneven contour
Incomplete penetrataion - may lead to failure due to
stress concentration
Incomplete fusion - may lead to failure due to stress
concentration.
7
Base metal cracking - Critical discontinuity propoagates
under loading & leads to failure.
4
5
6
WELD DISCONTINUITIES - EFFECTS, CAUSES & REMEDIES.
Porosity (Ceaters weakening of section if in gross. )
Under cuts sharp notch, leads to stress concentration. 2
1
3
Inclusions - weakening of section. Small
lengths not critical. No sharp
edges
b) high residual stresses.
b) Pre & post heat the joint. Apply
intermediate stress relieving
a) Highly rigid joint.
a) Preheat the joint, Relieve residual
stresses.
b) Excessive dilution b) Change welding current / speed.
c) defective electrode. c) Bake electrode to remove moisture.
d) Poor fit up. d) Reduce root opening.
e) Small weld bead.
e) Increase electrode size.Increase welding
current.Reduce travel speed.
f) Higher sulfer base metal. f) Use filler wire low in sulfer.
g) Angular distortion.
g) Change to balance welding on both the
sides.
h) Crater cracking. h) Filling crater before existingishing arc.
a) coefiicient of thermal expansion -
higher coefficient higher expansion.
1) Avoid over welidng.
b) Thermal conductivity - Lower
conductivity higher distortion.
2) Use intermittent welding.
c) Thickness - lower thickness higher
distortion
3) Use a few weld passes as possible.
5) Place weld near neurtal axis.
6) balance welds around neutral axis.
7) Use backstep welding.
8) Anticipate shrinkage forces.
9) Plan welding sequence.
10) Minimise welding time.
11) Proper clamping.
Distortion -
d) Modules of elasticity high - modules
less distortion
7
8
9
Base metal cracking - Critical discontinuity propoagates
under loading & leads to failure.
Weld metal cracking