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Module 9Module 9

Weld and Base MetalWeld and Base MetalDiscontinuitiesDiscontinuities

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DiscontinuityDiscontinuity

Any interruption in the uniform nature of anAny interruption in the uniform nature of an

itemitem

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DiscontinuitiesDiscontinuities Seams and lapsSeams and laps

LaminationsLaminations

Weld undercutWeld undercut Weld cracksWeld cracks

Weld porosityWeld porosity

Many othersMany others

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DefectDefect

A nonA non--conforming discontinuityconforming discontinuity

All discontinuities are not defects.All discontinuities are not defects.

All defects are discontinuities.All defects are discontinuities.

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Discontinuity CriticalityDiscontinuity Criticality LinearLinear -- nonnon--linearlinear

End conditionEnd condition -- sharpnesssharpness

SurfaceSurface -- subsub--surfacesurface LoadingLoading -- uniform, nonuniform, non--uniformuniform

Fatigue

Impact

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

CrackCrack

A fracture type discontinuity characterizedA fracture type discontinuity characterized

by a sharp tip and high ratio of length andby a sharp tip and high ratio of length andwidth (depth) to opening displacementwidth (depth) to opening displacement

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Crack TypesCrack Types Hot /coldHot /cold

Delayed / underbeadDelayed / underbead

LongitudinalLongitudinal TransverseTransverse

Throat /toe / rootThroat /toe / root

HAZ / base metalHAZ / base metal and many moreand many more

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Longitudinal CrackLongitudinal Crack

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Transverse CrackTransverse Crack

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Throat CrackThroat Crack

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Toe Crack

Toe Crack

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Crater Cracksin Aluminum WeldCrater Cracksin Aluminum Weld

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Propagation of Crater CrackinPropagation of Crater Crackin

Aluminum WeldAluminum Weld

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UnderbeadUnderbeadCracksCracks

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Underbead Cra

cking

Underbead Cra

cking

Often delayed crackingOften delayed cracking

Caused by hydrogenCaused by hydrogen

Difficult to detectDifficult to detect Avoid with low H2 processAvoid with low H2 process

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Incomplete Fu

sion

Incomplete Fu

sion

A weld discontinuity in which fusion did A weld discontinuity in which fusion did

not occur between weld metal and fusionnot occur between weld metal and fusionfaces or adjoining weld beadsfaces or adjoining weld beads

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Location

sofIncomplete Fu

sion

Location

sofIncomplete Fu

sion

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Incomplete Fu

sion at

Weld Fa

ce

Incomplete Fu

sion at

Weld Fa

ce

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Incomplete Fusion BetweenIncomplete Fusion Between

Weld Metal and Base MetalWeld Metal and Base Metal

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Radiograph ofSideRadiograph ofSide--WallWallIncomplete FusionIncomplete Fusion

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Incomplete Jo

intP

enetration

Incomplete Jo

intP

enetration

Weld metal does not extend entirely throughWeld metal does not extend entirely through

the joint thickness. The term is used only forthe joint thickness. The term is used only forgroove welds.groove welds.

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Examples ofIncomplete JointExamples ofIncomplete JointPenetrationPenetration

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Incomplete Jo

intP

enetration

Incomplete Jo

intP

enetration

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Radiograph ofPenetration FaultsRadiograph ofPenetration Faultsat Bead Starts and Stopsat Bead Starts and Stops

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Part

ial Jo

intP

enetration

Part

ial Jo

intP

enetration

Penetration not required to be complete byPenetration not required to be complete by

designerdesigner

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Inclusi

onsI

nclusi

ons

Entrapped foreign solid material such asEntrapped foreign solid material such asslag,

flux, tung

sten or ox

ide

slag,

flux, tung

sten or ox

ide

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

SurfaceS

lagInclusi

onS

urfaceS

lagInclusi

on

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Radiograph of Elongated SlagRadiograph of Elongated Slag

InclusionsInclusions

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Radiograph of TungstenRadiograph of Tungsten

InclusionsInclusions

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Poro

sity

Poro

sity

Cavity type discontinuitiesformed by gasCavity type discontinuitiesformed by gas

entrapped during weld metal

solidific

ationentrapped dur

ing weld metal

solidific

ation

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Scattered

SurfaceP

orosi

tySc

atteredS

urfaceP

orosi

ty

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Linear Surface Porosity withLinear Surface Porosity withConnecting CrackConnecting Crack

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Isolated

SurfaceP

orosi

tyIs

olatedS

urfaceP

orosi

ty

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ElongatedS

urfaceP

orosi

tyElongatedS

urfaceP

orosi

ty

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Rad

iograph o

fSc

atteredP

orosi

tyR

adiograph o

fSc

atteredP

orosi

ty

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Rad

iograph o

fClu

ster

Poro

sity

Rad

iograph o

fClu

ster

Poro

sity

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Rad

iograph o

fLi

nearP

orosi

tyR

adiograph o

fLi

nearP

orosi

ty

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Under

cut

Under

cut

A groove melted into the base metal adjacentA groove melted into the base metal adjacent

to the weld toe or weld root and left un

filledto the weld toe or weld root and le

ft un

filledby weld metalby weld metal

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Typic

al Appearance o

fU

ndercutTyp

ical Appearan

ce o

fU

ndercut

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Under

cut Adja

cent to F

illet

Weld

Under

cut Adja

cent to F

illet

Weld

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Radiograph ofSurface UndercutRadiograph ofSurface Undercut

Surface undercut should be found withVT, NOT RT !

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Under

fill

Under

fill

A condition in which the weld face or theA condition in which the weld face or the

rootsurfaceis

below the adjacent

surface o

froot

surfaceis

below the adjacent

surface o

fthe base metalthe base metal

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Underfill inUnderfill inGroove WeldsGroove Welds

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Overlap

Overlap

The protrusion of weld metal beyond theThe protrusion of weld metal beyond the

weld toe or weld rootweld toe or weld root

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Overlap inOverlap in

Fillet andFillet andGroove WeldsGroove Welds

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Overlap Example

sOverlap Example

s

Overlap

Overlap

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Undercut & Overlap in Fillet WeldUndercut & Overlap in Fillet Weld

Overlap

Undercut

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Fillet

Weld Con

vexityF

illet

Weld Con

vexity

The maximum distance from the face of aThe maximum distance from the face of acon

vex

fillet weld perpend

icular to a l

ine

con

vex

fillet weld perpend

icular to a l

inejoining the weld toesjoining the weld toes

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Fillet

Weld Con

vexityF

illet

Weld Con

vexity

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Weld

R

einforcement

Weld

R

einforcement

Weld metal in excess of the quantityWeld metal in excess of the quantity

required to

fill a jo

intrequ

ired to

fill a jo

int

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Face and

R

ootR

einforcementFa

ce and

R

ootR

einforcement

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Face Reinforcement on both sidesFace Reinforcement on both sides

when welded from both sideswhen welded from both sides

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Effect ofWeldEffect ofWeld

ReinforcementReinforcementangle on Fatigueangle on Fatigue

StrengthStrength

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Improper and AcceptableImproper and Acceptable

Treatment ofWeld ReinforcementTreatment ofWeld Reinforcement

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Module 9Module 9 -- 5656

AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Photomicrograph of MartensiticPhotomicrograph of Martensitic

Structure Produced by an ArcStrikeStructure Produced by an ArcStrike

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

S

patterS

patter

Metal particles expelled duringfusionMetal particles expelled duringfusion

welding that do not

form part o

fthe weldweld

ing that do not

form part o

fthe weld

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Crack Formed at Weld SpatterCrack Formed at Weld Spatter

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

L

ami

nati

onL

ami

nati

on

A discontinuity with separation or weaknessA discontinuity with separation or weakness

generally ali

gned parallel to the work

edgenerally ali

gned parallel to the work

edsurface of a metalsurface of a metal

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Cracking andCracking andD

elami

nati

onD

elami

nati

onDue toDue toLaminationLamination

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

D

elami

nati

onD

elami

nati

on

Separation of a lamination under stressSeparation of a lamination under stress

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

L

amellar TearL

amellar Tear

A subsurface terraceA subsurface terrace -- and stepand step--likelikes

eparati

oni

n the bas

e metal, parallel to thes

eparati

oni

n the bas

e metal, parallel to thesurface, caused by tensile stressesin thesurface, caused by tensile stressesin thethroughthrough--thickness direction.thickness direction.

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Module 9Module 9 -- 6363

AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

L

amellar Teari

ngL

amellar Teari

ng

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Module 9Module 9 -- 6464

AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

S

eams

andL

apsS

eams

andL

aps

Longitudinal base metal surfaceLongitudinal base metal surface

disc

onti

nui

ti

es

f

oundi

n wrought produc

ts

disc

onti

nui

ti

es

f

oundi

n wrought produc

ts

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Deep Seam on Surface ofSemiDeep Seam on Surface ofSemi--

Finished Rolled ProductFinished Rolled Product

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Cluster Seams on Surface ofCluster Seams on Surface of

SemiSemi--Finished Rolled ProductFinished Rolled Product

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

L

ap onS

urf

ac

e of

R

olledS

teel Bi

lletL

ap onS

urf

ac

e of

R

olledS

teel Bi

llet

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AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Di

mensi

onalDi

mensi

onal Size irregularitiesSize irregularities

Shape imperfectionsShape imperfections

Distort

ion

Distort

ion

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Module 9Module 9 -- 6969

AAA m e r i c a nm e r i c a nm e r i c a n WWW e l d i n ge l d i n ge l d i n g SSS o c i e t yo c i e t yo c i e t y

Discontinuitiesin EBWandDiscontinuitiesin EBWandL

BWL

BW

Unique to the special attributes of the highUnique to the special attributes of the high--energy beams and narrow weld widthenergy beams and narrow weld width

Beam deflection (missed joint)Beam deflection (missed joint) Root PorosityRoot Porosity

Shrinkage voidsShrinkage voids

Hot cracksHot cracks

Lack offusion (spiking)Lack offusion (spiking)