Module 9 - 1
Module 9
Weld and Base Metal
Discontinuities
Am e r i c a n We l d i n g So c i e t y
Module 9 - 2
Discontinuity
“Any interruption in the uniform nature of an
item”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 3
Discontinuities
Seams and laps
Laminations
Weld undercut
Weld cracks
Weld porosity
Many others
Am e r i c a n We l d i n g So c i e t y
Module 9 - 4
Defect
“A non-conforming discontinuity”
All discontinuities are not defects.
All defects are discontinuities.
Am e r i c a n We l d i n g So c i e t y
Module 9 - 5
Discontinuity Criticality
Linear - non-linear
End condition - sharpness
Surface - sub-surface
Loading - uniform, non-uniform
– Fatigue
– Impact
Am e r i c a n We l d i n g So c i e t y
Module 9 - 6
Crack
“A fracture type discontinuity characterized
by a sharp tip and high ratio of length and
width (depth) to opening displacement”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 7
Crack Types
Hot / cold
Delayed / underbead
Longitudinal
Transverse
Throat /toe / root
HAZ / base metal
and many more
Am e r i c a n We l d i n g So c i e t y
Module 9 - 8
Longitudinal Crack
Am e r i c a n We l d i n g So c i e t y
Module 9 - 9
Transverse Crack
Am e r i c a n We l d i n g So c i e t y
Module 9 - 10
Throat Crack
Am e r i c a n We l d i n g So c i e t y
Module 9 - 11
Toe Crack
Am e r i c a n We l d i n g So c i e t y
Module 9 - 12
Crater Cracks in Aluminum Weld
Am e r i c a n We l d i n g So c i e t y
Module 9 - 13
Propagation of Crater Crack in
Aluminum Weld
Am e r i c a n We l d i n g So c i e t y
Module 9 - 14
Underbead
Cracks
Am e r i c a n We l d i n g So c i e t y
Module 9 - 15
Underbead Cracking
Often delayed cracking
Caused by hydrogen
Difficult to detect
Avoid with low H2 process
Am e r i c a n We l d i n g So c i e t y
Module 9 - 16
Incomplete Fusion
“ A weld discontinuity in which fusion did
not occur between weld metal and fusion
faces or adjoining weld beads”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 17
Locations of Incomplete Fusion
Am e r i c a n We l d i n g So c i e t y
Module 9 - 18
Incomplete Fusion at Weld Face
Am e r i c a n We l d i n g So c i e t y
Module 9 - 19
Incomplete Fusion Between
Weld Metal and Base Metal
Am e r i c a n We l d i n g So c i e t y
Module 9 - 20
Radiograph of Side-Wall
Incomplete Fusion
Am e r i c a n We l d i n g So c i e t y
Module 9 - 21
Incomplete Joint Penetration
“Weld metal does not extend entirely through
the joint thickness. The term is used only for
groove welds.”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 22
Examples of Incomplete Joint
Penetration
Am e r i c a n We l d i n g So c i e t y
Module 9 - 23
Incomplete Joint Penetration
Am e r i c a n We l d i n g So c i e t y
Module 9 - 24
Radiograph of Penetration Faults
at Bead Starts and Stops
Am e r i c a n We l d i n g So c i e t y
Module 9 - 25
Partial Joint Penetration
“Penetration not required to be complete by
designer”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 26
Inclusions
“Entrapped foreign solid material such as
slag, flux, tungsten or oxide”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 27
Surface Slag Inclusion
Am e r i c a n We l d i n g So c i e t y
Module 9 - 28
Radiograph of Elongated Slag
Inclusions
Am e r i c a n We l d i n g So c i e t y
Module 9 - 29
Radiograph of Tungsten
Inclusions
Am e r i c a n We l d i n g So c i e t y
Module 9 - 30
Porosity
“Cavity type discontinuities formed by gas
entrapped during weld metal solidification”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 31
Scattered Surface Porosity
Am e r i c a n We l d i n g So c i e t y
Module 9 - 32
Linear Surface Porosity with
Connecting Crack
Am e r i c a n We l d i n g So c i e t y
Module 9 - 33
Isolated Surface Porosity
Am e r i c a n We l d i n g So c i e t y
Module 9 - 34
Elongated Surface Porosity
Am e r i c a n We l d i n g So c i e t y
Module 9 - 35
Radiograph of Scattered Porosity
Am e r i c a n We l d i n g So c i e t y
Module 9 - 36
Radiograph of Cluster Porosity
Am e r i c a n We l d i n g So c i e t y
Module 9 - 37
Radiograph of Linear Porosity
Am e r i c a n We l d i n g So c i e t y
Module 9 - 38
Undercut
“A groove melted into the base metal adjacent
to the weld toe or weld root and left unfilled
by weld metal”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 39
Typical Appearance of Undercut
Am e r i c a n We l d i n g So c i e t y
Module 9 - 40
Undercut Adjacent to Fillet Weld
Am e r i c a n We l d i n g So c i e t y
Module 9 - 41
Radiograph of Surface Undercut
Surface undercut should be found with
VT, NOT RT !
Am e r i c a n We l d i n g So c i e t y
Module 9 - 42
Underfill
“A condition in which the weld face or the
root surface is below the adjacent surface of
the base metal”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 43
Underfill in
Groove Welds
Am e r i c a n We l d i n g So c i e t y
Module 9 - 44
Overlap
“The protrusion of weld metal beyond the
weld toe or weld root”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 45
Overlap in
Fillet and
Groove Welds
Am e r i c a n We l d i n g So c i e t y
Module 9 - 46
Overlap Examples
Overlap
Overlap
Am e r i c a n We l d i n g So c i e t y
Module 9 - 47
Undercut & Overlap in Fillet Weld
Undercut
Overlap
Am e r i c a n We l d i n g So c i e t y
Module 9 - 48
Fillet Weld Convexity
“The maximum distance from the face of a
convex fillet weld perpendicular to a line
joining the weld toes”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 49
Fillet Weld Convexity
Am e r i c a n We l d i n g So c i e t y
Module 9 - 50
Weld Reinforcement
“Weld metal in excess of the quantity
required to fill a joint”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 51
Face and Root Reinforcement
Am e r i c a n We l d i n g So c i e t y
Module 9 - 52
Face Reinforcement on both sides
when welded from both sides
Am e r i c a n We l d i n g So c i e t y
Module 9 - 53
Effect of Weld
Reinforcement
angle on Fatigue
Strength
Am e r i c a n We l d i n g So c i e t y
Module 9 - 54
Improper and Acceptable
Treatment of Weld Reinforcement
Am e r i c a n We l d i n g So c i e t y
Module 9 - 55
Arc Strike
“A discontinuity resulting from an arc,
consisting of any localized remelted metal,
heat-affected metal, or change in the surface
profile of any metal object”
Am e r i c a n We l d i n g So c i e t y
Photomicrograph of Martensitic
Module 9 - 56
Structure Produced by an Arc Strike
Am e r i c a n We l d i n g So c i e t y
Module 9 - 57
Spatter
“Metal particles expelled during fusion
welding that do not form part of the weld”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 58
Crack Formed at Weld Spatter
Am e r i c a n We l d i n g So c i e t y
Module 9 - 59
Lamination
“A discontinuity with separation or weakness
generally aligned parallel to the worked
surface of a metal”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 60
Cracking and
Delamination
Due to
Lamination
Am e r i c a n We l d i n g So c i e t y
Module 9 - 61
Delamination
“Separation of a lamination under stress”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 62
Lamellar Tear
“A subsurface terrace - and step-like
separation in the base metal, parallel to the
surface, caused by tensile stresses in the
through-thickness direction.
Am e r i c a n We l d i n g So c i e t y
Module 9 - 63
Lamellar Tearing
Am e r i c a n We l d i n g So c i e t y
Module 9 - 64
Seams and Laps
“Longitudinal base metal surface
discontinuities found in wrought products”
Am e r i c a n We l d i n g So c i e t y
Module 9 - 65
Deep Seam on Surface of Semi-
Finished Rolled Product
Am e r i c a n We l d i n g So c i e t y
Module 9 - 66
Cluster Seams on Surface of
Semi-Finished Rolled Product
Am e r i c a n We l d i n g So c i e t y
Module 9 - 67
Lap on Surface of Rolled Steel Billet
Am e r i c a n We l d i n g So c i e t y
Module 9 - 68
Dimensional
Size irregularities
Shape imperfections
Distortion
Am e r i c a n We l d i n g So c i e t y
Discontinuities in EBW and Module 9 - 69
LBW
“Unique to the special attributes of the high-
energy beams and narrow weld width”
Beam deflection (missed joint)
Root Porosity
Shrinkage voids
Hot cracks
Lack of fusion (spiking)
Am e r i c a n We l d i n g So c i e t y