6 Common Welding Defects and How to Fix Them

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Flawless Steel Welding
https://fsw-denver.com/6-common-welding-defects-and-how-to-fix-them/
6 Common Welding
Defects And How To Fix
Them
B L O G  |  F L A W L E S S  S T E E L  C O M P A N Y
https://fsw-denver.com/
Welding is one of the most important
processes in metal fabrication. This is
why you must always be on the
lookout for any welding defects that
may arise. With the proper strategy,
you can prevent any problems from
occurring. But first, you must know
the causes of welding defects.
Here are the most common welding
defects, their causes, and what you
can do to fix them:
1. Spatter
Spatter is a welding flaw that happens
when little drops of molten material
dribble on the metal. This problem is
most common in gas metal arc
welding or GMAW. 
Some of the main causes of welding
spatters are high running amperage,
low voltage settings, contaminated
surface, incorrect polarity, or when
the arc is too long. 
There are a few strategies that can
help you avoid spatters in the future.
These include cleaning the surface
before welding, reducing the length of
the arc, using proper polarity, and
increasing the electrode angle.
2. Porosity
Porosity is a condition that occurs
when nitrogen, oxygen, and
hydrogen are absorbed in the molten
welding material. This will cause
solidification inside the welded metal
and cause problems in the process.
Porosity is caused by inadequate
electrode de oxidant, using a longer
arc, too much moisture, incorrect
surface treatment, surface
contamination, and the presence of
rust, grease, or paint.
To avoid porosity you must clean the
welding materials before usage,
always use dry electrodes, use the
correct arc length, and make sure that
the gas flow meter is optimized with
proper pressure and flow. Using the
right electrodes and proper welding
technique will also help prevent this
problem.
3. Undercut
Undercut is one of the welding defects
that occur when the voltage of the arc
is too high. 
It can also occur when the speed of the
weld is too fast or if you use the wrong
angle, leading to more heat on the
edges. Incorrect usage of gas shielding
and poor welding techniques can also
be the cause of undercut.
In order to prevent this problem from
happening, be mindful of the speed of
the weld, use the proper angle of the
electrode, reduce arc length, reduce
the current when you are approaching
thinner areas of the metal, and use the
multi-pass technique.
4. Deformation
This issue usually happens during the
cooling and hardening part of the
welding process. When the welding
sequence does not fit the weld, it will
lead to insufficient clamping before
welding.
To prevent deformation from
happening, make sure to weld both
sides of the joint from the center out,
going in opposite directions. You can
also use a large electrode or change
the sequence of the welds if you notice
any sign of deformation.
5. Cracks
Cracks are one of the most overlooked
issues. They begin small and grow
larger over time. 
If you want to fix a crack in the
welding job, it will take you more
than just filling the gap with material.
The best strategy is to prevent it from
happening at all.
The common causes of cracks are the
use of hydrogen when you weld
ferrous metals, contamination of the
base metal, high welding speed, not
preheating the equipment before
welding, and a poor joint design.
In order to avoid cracks, do not rush
the grinding, cleaning, and filing of
the plate edges so they fit well
together.
Reheat all sides of the joint, make sure
that you have the right temperature,
and double check if you have just the
right amount of heat before welding.
In order to check the heat accurately,
you can test the settings of your
machine.
6. Incomplete Penetration and
Fusion
Incomplete fusion occurs when the
weld does not fuse one side of the joint.
But, when both sides are not fused, it’s
called incomplete penetration. 
These issues occur because of low heat
input, contaminated surface, incorrect
electrode angle, and incorrect electrode
diameter.
The best way to solve incomplete
fusion and penetration is to use a
wider root gap, clean the metal
properly before welding, and use the
correct electrode diameter for the
thickness of the material you are
welding. It will also help if you lower
the travel speed and carefully weave
in between the edges.
Knowing all the bad welds and causes
is important to ensure that the welding
job is strong, safe, and of high quality.
For all of your general welding needs,
Flawless Steel Welding provides the
best steel fabrication in Colorado. 
We offer commercial and structural
solutions such as welding, steel
erection, steel fabrication, and
structural steel services. If you want to
know more about our services, visit
our website or contact us now!
email@fsw-denver.com
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