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Welding Efficiency &
Learning Defects
(W.E.L.D) Cards
1033480-01A
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Ideal weld path and look for tee and butt joints
Definition
The proper weld filament, consistent path and fusion.
Tee Joint
V-Groove Joint
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W.E.L.D – Define, then check your welder and technique
Porosity
Causes
Improper shielding
Contaminated metal
Check Your Welder
Adjust shielding gas flow
Clean nozzle from spatter
Clean diffuser from spatter
Check Your Technique
Keep Contact-To-Work distance ¼” to ½”
Keep nozzle out of the weld puddle
Clean base metal
Definition
The presence of inclusions or gas pockets in a weld.
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W.E.L.D – Define, then check your welder and technique
Undercut
Causes
Improper settings
Improper work angle
Fast travel speed
Rust
Check Your Welder
Decrease voltage or increase wire feed speed
Check Your Technique
Keep work angle around 45* for a fillet weld and 90* for a groove weld
Slow down travel speed
Clean base metal
Definition
A groove melted into the base metal adjacent to the toe or root of a weld and left unfilled by weld metal.
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W.E.L.D – Define, then check your welder and technique
OverlapCauses
Improper settings
Improper work angle
Fast travel speed
Rust
Check Your Welder
Decrease voltage or increase wire feed speed
Check Your Technique
Keep work angle around 45* for a fillet weld and 90* for a groove weld
Slow down travel speed
Clean base metal
Definition
The overhang of weld metal beyond the bond at the toe of a weld.
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W.E.L.D – Define, then check your welder and technique
Incomplete Joint Penetration
Causes
Improper settings
Fast travel speed
Improper work angle
Too long wire stick out
Improper (too steep) travel angle
Improper joint penetration
Check Your Welder
Adjust settings for the thickness of the base metal
Increase voltage if paired with overlap
Increase wire feed speed if paired with undercut
Check Your Technique
Increase root opening
Align metal in joint to be even and square
Assure proper bevel angle, if necessary
Keep work angle around 45* for a fillet weld and 90* for a groove weld
Keep travel angle at 0* - 15*
Keep contact-to-work distance ¼” to ½”
Slow down travel
Definition
When during/after a weld, the filler metal fails to penetrate and fuse with an area of the weld joint.
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W.E.L.D – Define, then check your welder and technique
Incomplete Fusion
Causes
Improper settings
Travel speed to fast
Improper work angle
Contamination base metal
Improper (too steep travel angle)
To long wire stick out
Check Your Welder
Adjust setting for the thickness of the base metal
Increase voltage if bead is large and ropey
Increase wire feed speed if bead is small and using proper travel speed
Check Your Technique
Keep work angle around 45* for a fillet weld and 90* for a groove weld
Keep travel angle at 0* -15*
Keep contact-to-work distance ¼” – ½”
Slow down travel speed
Clean base metal
Definition
When during a weld, the failure of a welding process to fuse, or join together, layers of weld metal or weld metal and base metal.
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W.E.L.D – Define, then check your welder and technique
SpatterCauses
Improper settings
Too long wire stick out
Improper work angle
Contaminated base metal
Improper travel angle
Check Your Welder
Adjust settings for the thickness of the base metal
Decrease voltage if paired with undercut
Check Your Technique
Keep work angle around 45* for a fillet weld and 90* for a groove weld
Keep travel angle at 0*-15*
Keep contact –to work distance ¼” – ½”
Clean base metal
Definition
The metal particles expelled during arc and gas welding which do not form a part of the weld.
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W.E.L.D – Define, then check your welder and technique
CracksCauses
Stress in the weld and HAZ
Improper bead contour
Fast cooling
Improper travel speed
Improper filler
Improper weld termination
Check Your Welder
Use filler metal with a matching tensile strength and similar composition as base metal
Check Your Technique
Allow metal to cool on its own
Preheat metal
Adjust travel speed so that contour of weld is proper
Pause at end of weld to fill crater
Definition
A narrow break in the weld metal, base metal, or the crater formed at the end of a weld bead.
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W.E.L.D – Define, then check your welder and technique
Excessive Concavity or Insufficient Reinforcement
Causes
Improper settings
Fast travel speed
Check Your Welder
Increase wire feed speed
Check Your Technique
Slow down travel
If multi-pass weld, weld more passes to fill
Definition
When the distance from the weld face perpendicular to a line joining the weld toes curves inward toward the weld joint.
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W.E.L.D – Define, then check your welder and technique
Excessive Convexity or Reinforcement
Causes
Improper settings
Slow travel speed
Improper travel (too steep) angle
Check Your Welder
Decrease wire feed speed
Check Your Technique
Speed up travel
If multi-pass weld, weld less passes
Grind to proper size
Keep travel angle at 0*-15*
Definition
When the distance from the weld face perpendicular to a line joining the weld toes curves outward and away from the weld joint.
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