Common Types of Welding Defects and Their Solutions Part 2

Date Posted:5 December 2022

Welding defects are an important consideration for any welding project, as they can have a major impact on the success of the project. Welding defects can range from aesthetic issues to structural failures, making it essential to avoid them. In this sequel article, we will discuss more of the various types of welding defects and how to prevent them.

6 - Spatter

Weld spatter is a common yet annoying welding defect that can significantly impact the quality of a weld and the safety of the welders. It occurs when excessive welding current is used and can cause weld contamination, welding defects, and other issues. Fortunately, there are steps you can take to prevent it.

First, make sure to use the proper welding techniques. This includes setting the correct current, voltage, and wire speed for the type of material you are welding. These settings should be checked and adjusted as needed to ensure that the weld is not too hot or too cold.

Second, make sure to properly prepare the weld. This means ensuring that the surface of the material is clean and free of contaminants such as rust, dirt, and paint. Additionally, the weld should be free of any surface defects, such as burrs or gouges.

Third, inspect the weld area before and after welding. Make sure to check for any signs of spatter, such as small particles of metal on the surface of the weld. If any is present, it should be removed or ground down before continuing with the weld.

Finally, make sure to use the proper welding equipment. This includes the right type of welding torch and the right type of welding helmet. A good welding helmet will provide the welder with protection from the intense light and heat of the welding arc.

7 - Lack of Fusion

Lack of fusion is a common weld defect that occurs when the weld metal does not properly bond with the base metal. This can be caused by a variety of factors, including incorrect welding parameters, improper pre-cleaning of the weld area, or incorrect welding technique. To prevent this type of weld defect, make sure to use the correct welding parameters and pre-clean the weld area to remove any contaminants. Also follow the manufacturer’s instructions for the specific type of welding being performed. Finally, make sure to inspect the weld area both before and after welding to ensure that all welds are properly fused.

8 - Burn Through

Burn-through is a weld defect that occurs when the weld metal melts through the base metal due to excessive heat or current. To prevent this type of weld defect, make sure to use the correct welding parameters and adjust the current and voltage accordingly. Additionally, make sure to use the proper welding technique and keep the arc length as short as possible. Finally, analyze the weld to ensure that no burn-through has occurred.

9 - Whiskers

Whiskers are weld defect that occurs when small, thin pieces of weld metal protrude from the surface of the weld. This can be caused by inadequate cleaning of the weld area, incorrect welding technique, or incorrect welding parameters. To prevent this type of weld defect, make sure to use the correct welding parameters and pre-clean the weld area to remove any contaminants.

Conclusion

It is important to be aware of these defects and the factors that cause them to prevent them from occurring. To prevent welding defects, the welder should practice proper welding techniques, test the material being welded, use the correct welding materials and equipment, and ensure that the work area is clean and free of debris. Taking the time to ensure these factors are in place will help ensure a successful welding job.

If you need welding parts, contact National Welding and Industrial Supplies. Let us help set everything you need for a successful project!

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