9 Most Common Welding Defects, Types, Causes, and Remedies

No matter if you are a beginner or a professional welder, welding defects are common and you may face them regularly. These defects can become significant issues if not taken care of. The good news is, you can learn to identify these defects and eliminate them and thus don’t have to worry about their significance. Here we discussed some of the most common welding issues, what causes them and how you can avoid those entirely.

How to Check Welding Defects

It is essential to identify welding defects before it is too late and being able to recognize those separates professionals from beginners. Usually, since welding defects can be visually different from a perfect weld, most of them are easier to identify. Moreover, fillet welding gauge, magnifying glass, flashlight, and similar tools help you with checking defects.

We highly recommend you use tools to identify major welding defects rather than only depending on your eyesight. The smallest of issues can be significant and recognizing those is crucial.

9 Common Welding Defects

Bad Penetration

When the bottom of the groove does not fill properly, it is called an incomplete penetration. It means the weld has not filled all the way through and results in bad welding.

Causes

Remedies

Spatter

Usually, in gas metal arc welding, welding particles spread around the weld and are thus called spatter. Spatter is very common in welding and you will get a small amount no matter what. But if you are getting a lot of spatter you can try to prevent it with a few remedies.

Causes

Remedies

Undercut

If grooves appear at the weld toe of your weld, it results in an undercut, which is a very common pipe welding issue. This type of defect can weaken the weld and reduce the lifetime of the piece you are welding.

Causes

Remedies

Incomplete Fusion

When the fusion between the weld metal and base metal is incomplete and does not have a proper joint, it is called an incomplete or bad fusion. It is different from incomplete penetration since the joint disturbance appears on the sides, not at the bottom.

Causes

Remedies

Cracks

Weld cracks are one of the worst types of defects you can have and should always be avoided! Cracks can happen during the weld when the temperature is too high, or after your weld when the temperature lessens.

Causes

Remedies

Slag Inclusions

Usually appearing during fluxed-cored arc welding, submerged arc welding, and stick welding tasks, slag inclusions are melted flux that is easily visible on the weld.

Causes

Remedies

Overlap

When the weld face ‘overlaps’ or extends the weld toe far too much, it is considered as welding overlap and seems to be a very common issue you may face while welding.

Causes

Remedies

Porosity

When the trapped gases inside the weld create a bubble-filled weld, it can weaken and result in porosity, which is one of the worst types of bad welding defects.

Causes

Remedies

Burn Through

One of the usual defects that occur while welding thin materials is burned through when the weld material penetrates the base metal.

Causes

Remedies

Final Note

It is always better to identify these defects sooner rather than later. Moreover, understanding the severity of each defect can help you make decisions that will matter the most. Lastly, ensuring proper welding technique (using the right welding angle, the proper settings, the right materials, etc.) and making sure no contamination is on the materials can eliminate most of the defects you may encounter.