WELDING DEFECTS

GROUP 1

IQBAL RUSDAN ARIEF 4215100004

DEWI PURWANINGRUM 4215100009

FEBRIAN ROHIIM 4215100014

M. ADHITYA MUSLIM 4215100015

ELFRINSEN GUSTAF ADWINDA 4215100016

JURUSAN TEKNIK SISTEM PERKAPALAN

FAKULTAS TEKNOLOGI KELAUTAN

INSTITUT TEKNOLOGI SEPULUH NOPEMBER

SURABAYA
1. Defetcs
 a flaw or flaws
 by nature or accumulated effect renders a part or product unable to meet minimum
applicable acceptance standards or specifications.
 the term designates rejectability

2. Cold and Hot Cracking

 Cold cracking is cracking that occurs as the result of hydrogen dissolving in the weld
metal and then diffusing into the heat affected zone (HAZ).
 Cold weld cracking occurs at temperatures well below 600°F.

 Hot cracking is the formation of shrinkage cracks during the solidification of weld metal.
This phenomenon occurs in almost all metals
 The causes of the defect:
a. The rapid cooling of the welding happens
b. Heat input is too low
c. The current is too low
d. The welding speed is too high
 Prevention Solutions :
a. Avoid rapid cooling
b. Set the current appropriately

3. Incomplete Fusion
 Incomplete fusion occurs when the liquid weld does not compound with the workpiece.
  The causes of the defect :
a. Wrong welding position
b. The current is too low
c. The welding gap is too small
d. The welding speed is too high
 Prevention Solutions :
a. Improve welding position
b. Set the current appropriately
c. Use appropriate welding gap
d. Reduce the welding speed
4. Overlap
 Overlap is imperfection of welding. The weld beads does not coumpond with the base
material.

 The causes of the defect :

a. The welding speed is too slow
b. Incorrect welding technique
c. The current is too low
 Prevention Solution :
a. Reduce the welding speed
b. Improve welding position
c. Set the current appropriately
5. Porosity
 Porosity is a bunch of gas bubbles trapped in the weld
 Porosity can happen due to the compaction process too quickly
 Porosity in form of cavities-small ball-shaped cavity that were clumped on the
weld locations.
  The causes of the defect :
a. The arc length is too long
b. The current is too low
c. The welding speed is too high
d. Sulfur content is too high
e. Condition at the time of welding does not support
f. The rapid cooling of the welding happens
 Prevention Solutions :
a. Shorten the arc length
b. Set the current appropriately
c. Reduce the welding speed
d. Using steel with low sulfur content
e. Reduce humidity by means of giving pre heat
f. Avoid rapid cooling
6. Slag Inclusion
 Slag inclusions is non metal oxides and other objects stuck on metal welding
 Slag inclusions can be caused by contamination from outside
air or less clean slag when weld with many layers

 The causes of the defect :

a. The workpiece is unclean
b. The arc length is too long
c. The welding speed is not appropriate
 Prevention Solution :
a. Use clean workpiece
b. Maintain appropriate arc length
c. Move the electrodes with the right welding speed
7. Lack of Penetretion
 Defect that occurs because the metal failed to reach connection and failed connect
to the root surface thoroughly.
  The causes of the defect :
a. Wrong in choosing electrode
b. The current is too low
c. Heat input is too big
d. Wrong technique
 Prevention Solutions :
a. Use right electrode
b. Set the current appropriately
c. Set the heat input appropriately
d. Use right technique
8. Undercut
 Undercut is a term used to describe a Groove of the workpiece that melts and is
located on the edge of the welding beads which the workpiece melting is
not filled by the liquid welding.

 The Causes of the defect :

a. The current is too high
b. The welding speed is too high
c. The position of the electrodes while welding is not appropriate
d. Irregular swing of electrode while welding
 Prevention Solutions :
a. Set the current appropriately
b. Reduce the welding speed
c. Maintain the proper arc length
d. Swing the electrode regularly
9. Overspatter
 Over Spatter is a small metal spots due to welding electrode melted liquid in the form
of a spray.
 The causes of the defect :
a. The current is too high
b. The arc length is too far
c. Electrode absorbs steam
 Prevention Solution
a. Reduce the current
b. Set the arc length appropriately