Weld Cracks are not acceptable in the welding industry. However, a crack may occur just about everywhere in a weld; in the weld metal, on the plate next to the weld metal, or anyplace affected by intense heat. The three major types of weld cracks are: Hot cracks, cold cracks, and crater cracks. Causes of weld cracks. The crater is a kind of crack which occurs when the welding arc is broken and molten metal is not available to fill the cavity. Crater occurs due to residual stress imposed by the lack of metal in the cavity.
Crater pipe causes and prevention during welding A crater pipe forms during the final solidified weld pool and is often associated with some gas porosity. This imperfection results from shrinkage on weld pool solidification. Consequently, conditions which exaggerate the. Longitudinal Crack. Definition: A crack running in the direction of the weld axis. May be found in the. Unless welding is performed with a very low current, a concave dip, called a crater occurs at the end of a weldment. This crater results from the force of the arc and the contraction of melted metal when it cools and solidifies. The size of each crater relates directly to the welding current.
Undercutting has always been a serious concern in welding, especially in the steel welding industry.
In recent times, series of efforts have been made to curtail this problem. Undercutting in welding is a weld defect usually characterized by a groove formation at the weld toe, this occurs when the free edges of the weld metal or base metal are overheated.
The major cause of undercuts in welding is when the operator (welder) uses a high welding current or welds with fast travel speed. At the same time, the use of incorrect shielding gas, incorrect welding angle, wrong welding technique, and position are some of the primary causes of this welding flaw.
In this article, we shall be discussing the 7 possible ways to prevent the undercutting welding problem.
What is Undercutting in Welding
Undercutting is a crater or groove that occurs near the toe of the weld. Undercutting in welding occurs when the weld metal failed to fill-in the grooved area.
The result of which is a weak weld that is prone to cracking along the toes. In that case, the edge of the weld assumes a U-shape. Undercutting in welding may occur as a result of high travel speed, poor welding techniques, excessive heat, and too high amperage.
Causes of Undercutting in Welding
Undercutting appears as a groove in the weld metal along the edges of the weld. This kind of welding defect is mostly common in lap fillet welds, and can also be encountered in butt and fillet joints.
It’s mostly caused by using improper welding parameters; usually the arc voltage and travel speed.
Excessive heating as well as using the wrong welding technique may both lead to undercutting on a weld joint. Below are some of the major causes of undercut welding:
1. High travel speed
When the travel speed is very high, the weld bead will appear very peaked. This is because of its extreme fast degree solidification.
What happens here is that the forces of surface tension draws the molten metal directly along the edges of the weld bead and pilled it up at the center. this same way, the metal portions of the base material are also affected.
The Undercut groove is formed where the melted base material is drawn into the weld and not allowed to wet-back properly because of its rapid solidification. But decreasing the arc travel-speed gradually reduces the size of the undercut and slowly eliminate it.
Where only small undercut is present, raising the voltage or using a leading torch angle can eliminate the undercuts, making the weld bead flatter and improving the wetting as well.
2. Too High arc Voltage
While raising the arc voltage could help eliminate undercut, raising it to excessive levels may cause the undercut to reappear again.
This occasionally occurs in spray arc welding. By the time the arc becomes very long, it as well becomes very wide, leading to an increase in the amount of the base metal being melted. In such a case, the heat transfer of a long arc to the weld zone is comparably poor.
This cause the outermost areas to quickly cool down, preventing proper wetting. Note: The Arc length should always be kept short, not only to prevent undercutting but also to increase the penetration depth and weld strength.
3. Too high welding current
Too high welding current can lead to the formation of undercut on a weld. This is because the arc force, heat, and penetration will be so intense that the base plate under the arc could be blown away.
Crater Cracks In Welding
When this occurs, the outermost area of the base metal is melted and solidifies fastly. In such a case, puddle turbulence and surface tension avoid the puddle from wetting properly.
Therefore, to prevent this from happening, it is always required for the welder to remain within the current ranges specified for each wire size.
How to Prevent Undercutting in Welding
Undercutting in welding has always been a serious problem, especially in the steel welding industries.
A number of efforts have been made recently to resolve this welding problem. Some of which include reducing the welding current, voltage, and reducing the travel speed to the appropriate rate that allows the molten metal to fill in the joint completely.
Also, using a weaving technique; where the welder pauses slenderly at each side of the weld bead helps to prevent this type of a weld defect.
Below are the 7 important measures for preventing the problem of undercutting in welding.
1. Appropriate heat input
Extremely high heat settings is one of the leading causes of undercut grooves in welding. The major disadvantage of high heat settings is that it could lead to the overheating and melting of previous weld metal. To avoid this from happening, the welder must carefully reduce the weld heat by regulating the current whenever he’s approaching thinner and free edges.
2. Correct Electrode Angle
It’s generally known that welding angles play a crucial role in producing flaws-free welds. If the welder uses an incorrect angle which transfers more heat to the free edges more than the required, the weld is likely to be prone to undercut. Therefore, one is advised to use the correct angles in order to transfer the appropriate heat to the free edges.
3. Correct selection of Gas shielding
In the case of MAG process, the wrong choice of gas shielding can also lead to undercutting. Therefore, the welder must ensure the correct gas composition according to the requirement of the metal type and thickness. The use of inert gas (especially argon) in conjunction with Carbon dioxide (CO2) usually delivers quality results in carbon steel welding.
4. Moderate Travel speed
Welding with high travel speed is also one of the major causes of weld undercutting. What happens while welding with high travel speed is that some portion of the parent material is drawn into the molten metal and never came back because of its extremely fast solidification rate, leaving a depression along the edges. In order to avoid this, one is advised to weld with an average travel speed, neither too fast nor too slow. This is because too high travel speed causes undercutting, whereas slow travel speed does not always give a satisfactory result.
5. Suitable welding position
Sometimes weld undercuts may arise when the welder makes a fillet weld in a horizontal-vertical position. The Undercut is formed as a result of inadequate metal filling along the edges of the joint being welded. In order to prevent this from happening, it’s recommended to weld in a flat position.
6. Appropriate welding technique
Also, the problem of undercuts can arise when the welder makes a weld run with excessive weaving style. It’s recommended to maintain the width of weaving according to the size of the electrode. I.e. The size of the weaving should not exceed the acceptable limit, if not, the weld may be liable to undercut grooves. To prevent this, the welder must ensure that the size of weaving is maintained within its acceptable limits.
7. The use of multi-run technique
One of the best methods to adopt in order to minimize the level of undercuts in welding is to employ the multi-run technique. This technique supports all of the above-mentioned preventions and can also help achieve satisfactory results with improved mechanical properties.
Welding defects can be said to be the irregularities formed in a given weld metal as a result of incorrect welding patterns, wrong welding process, or due to poor welding skills from the welder’s part. Weld flaws may come in different sizes, shapes, and degrees of severity.
There are different types of welding defects that can transpire during the welding process. From porosity and cracking, to burn through and undercut, each has several causes.
However, regardless of the application and material on which they occur, one thing remains true to all of them; they’re common, costly, cause downtime and loss of productivity.
Luckily enough, there are various remedies that can help welders minimize these welding defects. In this article, we shall be discussing the seven most common welding defects, causes, and remedies plus 2 others.
Keep reading!
What are welding defects?
Welding defects/flaws can be defined as weld surface irregularities, imperfections, discontinuities, or inconsistencies that are formed in welded parts.
These defects differ from the desired weld bead size, shape, and quality. Welding defects could occur either from the outside or inside the weld metal.
Defects in weld joints could cause the rejection of parts and assemblies, an increase in the cost of maintenance, a reduction in performance and could cause catastrophic failures posing the risks of loss of life and property.
Welding defects and remedies
Mistakes sometimes occurs during a welding process. These could lead to different forms of welding defects. As a guide, We present to you the seven most common welding defects and their preventive measures.
1. Porosity
Porosity usually occurs as a result of weld contamination. This happens when gas is trapped inside or along the surface of the weld metal. Just like other weld defects, Porosity results in weak welds that may easily collapse.
• Causes of Porosity:
Often, Contaminated or inadequate shielding gas is the common cause of porosity.
However, Porosity could also be caused by using too high gas flow, longer arc, inadequate electrode deoxidant, and the presence of paint, rust, grease, or oil.
At the same time, having a dirty base metal or extending the welding far beyond the nozzle could cause porosity.
Additionally, air currents from cooling fans may contaminate the shielding gas envelope around the weld-puddle, thereby causing porosity.
Another common cause of this welding flaw is poor seal (loose-fitting) in the shielding gas channel.
• Remedies for Porosity:
You can remedy the porosity of a weld by; cleaning the materials to be welded before you begin welding, using correct arc distance, employing the proper welding technique, and using the right electrodes.
Again, ensure that there is adequate gas flow and replace any gas hoses that may be causing leaks. Also, when welding outside or in drafty areas, place a welding screen around the work area. This will help ameliorate porosity issues.
2. Undercutting
Undercutting is a crater or groove that is formed near the toe of the weld. In this case, the weld metal fails to fill-in the grooved area resulting in a weak-weld that is liable to cracking along the toes.
• Causes of Undercutting:
Wrong filler metal, excessive heat, fast weld speed, as well as poor welding technique, may all leads to undercut welding defect on a welding joint.
Also, very high weld current, incorrect use of shielding gas and using the wrong electrode could cause undercuts.
• Remedies for Undercutting:
Undercutting in welding can be avoided by employing the right welding technique that does not involve excessive weaving.
Lowering the arc length and minimizing the travel speed of the electrode can also help prevent undercutting.
Another remedy to undercutting problem is adjusting the angle of the gun to point directly towards the weld joint.
3. Burn Through
As the name implies, burn through occurs when the weld metal penetrates through the base metal, burning through it. This kind of welding flaw is most common with soft or thin metals, especially those that are 1/4″ or less. Also too much weld penetration can often lead to burn through.
• Causes of burn through:
The primary cause of burn through is excessive heat. Also having too large root opening on the weld joint can results in burn through.
• Remedies for burn through:
When burn through occurs, the easiest way to rectify the problem is to lower the voltage and the wire feed speed.
Also increasing the travel pace can help remedy the problem, especially when welding on aluminum material.
Increasing the wire extension and using a weaving technique while welding can also help minimize the potential for burn through.
4. Incomplete Penetration
Incomplete joint penetration (lack of penetration) happens when there is a shallow fusion between the base metal and filler metal, rather than full penetration of the joint. It results in a gap, cracks, or even joint failure.
• Causes of incomplete joint penetration:
Incomplete joint penetration could occur when the groove you are welding is too narrow, and the weld metal does not reach the bottom of the joint.
Improper joint preparation and insufficient heat input are the two primary causes of lack of penetration. Improper shielding gas mixture and welding wire diameter can also be a factor.
Also, if you leave too much space between the two metals you are welding, the metals will not melt together on the first pass and hence results in incomplete penetration.
• Remedies for incomplete penetration:
There are a number of remedies for incomplete joint penetration; this includes; using higher wire feed speed and voltage, reducing the travel pace to allow more weld metal penetrates through the joint, and proper joint design and preparation.
The joint should be prepared in such a way to allow the welder to maintain the proper wire extension and still access the bottom of the weld joint. Again, ensure that ‘the wire type and diameters’ and ‘the gas and the gas mixture’ are compatible.
5. Cracks
Weld Cracks are the most serious type of welding defects. Weld Cracks are not acceptable in the welding industry.
However, a crack may occur just about everywhere in a weld; in the weld metal, on the plate next to the weld metal, or anyplace affected by intense heat.
The three major types of weld cracks are: Hot cracks, cold cracks, and crater cracks
• Causes of weld cracks:
Weld Crack could be caused by so many things such as base metal contamination, poor joint design, failure to preheat before welding, low welding current, high welding speed, using hydrogen when welding ferrous materials and welding at too high voltage.
• Remedies for weld cracks:
You can prevent this type of weld flaw by using the right metal. Proper joint design and preparation is also another way to prevent cracking. Crater cracking can be prevented by using a backfilling technique. Right Selection of filler metal and shielding gas can also help prevent cracking problems.
6. Incomplete Fusion
Incomplete fusion occurs when the weld metal fails to properly fuse with the base metal, or when the individual weld beads don’t fuse together. This type of weld defect is also referred to as cold lap.
• Causes of incomplete fusion
Incorrect gun angle is the most common cause of incomplete fusion. However, contaminants on the base metal and insufficient heat can also cause this weld defect.
In some instances, too short arc length, very high travel speed, too low welding amperage or when the electrode size is too small for the thickness of the metal you are welding, all could result to incomplete fusion.
• Remedies for incomplete fusion:
The very first thing to do to prevent this weld flaw is to properly clean the base metal before you start the welding; make sure that the base metal is free of oil, grease, dirt or other debris.
Make sure the weld angle is between 0 to 15 degrees; this will allow you to fully access the groove of the weld.
Also, for joints that require weaving technique, holding the arc on the sidewall for some time is very vital to help prevent this type of defect. Ensure that there is enough heat input to coalesce the base metal and the weld metal fully.
7. Slag Inclusions
Slag is the waste material that is usually formed while welding, bits of this solid waste material may accidentally be incorporated into the weld and causes contamination.
• Causes of slag inclusions:
Some of the common causes of slag inclusions include failure to properly clean a welding pass before applying the next pass, incorrect welding angle, incorporation of flux from stick welding electrode, and too low welding amperage.
8. Warpage
Warpage is an unwanted distortion in the shape of a piece of metal. This occurs when the welder fails to properly control the expansion and contraction of the base material.
• Causes of warpage:
Warpage may arise when the welder clamps the welding joints too tightly, welding a piece of metal over and over again can also cause the metal to warp.
When welding a T-joint, the vertical part of the ‘T’ may sometimes pull itself towards the weld. Also, the more heat input you use, the more the chances you have to end up with a warpage.
• Remedies for warpage:
Warpage can be prevented by using only the required amount of heat. Opting for moderate travel speed and wire feed speed while welding can also help curtail the problem of warpage.
9. Overlap
overlap occurs when the weld face extends far above the weld toe. In this case, the weld metal rollout and forms an angle less than 90 degrees.
• Causes of Overlap
Overlap welding defect can arise when using large electrodes greater than the metal size. High welding current and the use of improper welding technique can also cause this defect.
Crater Defect In Welding
• Remedies for Overlap
Respirator For Galvanized Fume
Overlap welding defect can be avoided by employing the correct welding Technique, using small Welding electrode and less welding has.
Conclusion
While welding defects and discontinuities may arise due to the welder’s poor welding skills, however, even the most skilled and experienced welders may in one way or another experience weld defects.
But the only way to stop these welding irregularities from negatively affecting productivity and increasing the cost of operations is by identifying and rectifying the problems as quickly as possible.