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Handbook - Weld Defects 03

Lack of fusion is a weld defect where there is no fusion between the weld metal and the surfaces of the base plate. It can occur due to poor welding technique where the weld puddle is too large or the weld metal is allowed to roll in front of the arc. Making the joint narrower or directing the arc towards the side wall can help prevent lack of fusion when welding wide joints. Lack of fusion can also be caused by too low of a travel speed, too large of a weld bead, or too low of a welding voltage.

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178 views1 page

Handbook - Weld Defects 03

Lack of fusion is a weld defect where there is no fusion between the weld metal and the surfaces of the base plate. It can occur due to poor welding technique where the weld puddle is too large or the weld metal is allowed to roll in front of the arc. Making the joint narrower or directing the arc towards the side wall can help prevent lack of fusion when welding wide joints. Lack of fusion can also be caused by too low of a travel speed, too large of a weld bead, or too low of a welding voltage.

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Danilova Sonja
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8/13/13 Handbook - Weld Defects

Variations-
Metal
Transfer

Equipment
LACK OF FUSION

Lack of fusion, also called cold lapping or cold shuts, occurs when there is no fusion between the weld metal
Power and the surfaces of the base plate. This defect can be seen in Figure 10-2. The most common cause of lack
Supply of fusion is a poor welding technique. Either the weld puddle is too large (travel speed too slow) and/or the
weld metal has been permitted to roll in front of the arc. Again, the arc must be kept on the leading edge of
the puddle. When this is done, the weld puddle will not get too large and cannot cushion the arc.
Shielding
Gases Another cause is the use of a very wide weld joint. If the arc is directed down the center of the joint, the
molten weld metal will only flow and cast against the side walls of the base plate without melting them. The
heat of the arc must be used to melt the base plate. This is accomplished by making the joint narrower or by
Wire directing the arc towards the side wall of the base plate. When multipass welding thick material, a split bead
Electrodes
technique should be used whenever possible after the root passes. Large weld beads bridging the entire
gap must be avoided.

Safety Lack of fusion can also occur in the form of a rolled over bead crown. Again, it is generally caused by a very
low travel speed and attempting to make too large a weld in a single pass. However, it is also very often
caused by too low a welding voltage. As a result, the wetting of the bead will be poor.
Welding When welding aluminum, the common cause of this type of defect is the presence of aluminum oxide. This
Techniques
oxide is a refractory with a melting point of approximately 35000F (19270C). It is also insoluble in molten
aluminum. If this oxide is present on the surfaces to be welded, fusion with the weld metal will be hampered.
Welding
Conditions

Introduction
Economics
Incomplete
Penetration
Lack of
Weld Fusion
Defects Undercutting

Porosity Continued on next page...


Mig Spot
Welding Longitudinal
Cracking

3
Tables

www.esabna.com/EUWeb/MIG_handbook/592mig10_3.htm 1/1

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