Defects are common in any type of manufacturing, welding included.

In the process,
there can be deviations in the shape and size of the metal structure. It can be caused
by the use of the incorrect welding process or the wrong welding technique. Learn
about the 7 most common welding defects, their types, causes and remedies, below.

WELD CRACK
The most serious type of welding defect is a weld crack and it’s not accepted almost by
all standards in the industry. It can appear on the surface, in the weld metal or the area
affected by the intense heat.
There are different types of cracks, depending on the temperature at which they occur:
HOT CRACKS
These can occur during the welding process or during the crystallization process of the
weld joint. The temperature at this point can rise over 10,000C.
COLD CRACKS
 These cracks appear after the weld has been completed and the temperature of the
metal has gone down. They can form hours or even days after welding. It mostly
happens when welding steel. The cause of this defect is usually deformities in the
structure of steel.
CRATER CRACKS
These occur at the end of the welding process before the operator finishes a pass on
the weld joint. They usually form near the end of the weld. When the weld pool cools
and solidifies, it needs to have enough volume to overcome shrinkage of the weld metal.
Otherwise, it will form a crater crack.
Causes of cracks:
 Use of hydrogen when welding ferrous metals.
 Residual stress caused by the solidification shrinkage.
 Base metal contamination.
 High welding speed but low current.
 No preheat before starting welding.
 Poor joint design.
 A high content of sulfur and carbon in the metal.
Remedies:
 Preheat the metal as required.
 Provide proper cooling of the weld area.
 Use proper joint design.
 Remove impurities.
 Use appropriate metal.
 Make sure to weld a sufficient sectional area.
 Use proper welding speed and amperage current.
 To prevent crater cracks make sure that the crater is properly filled.

POROSITY
 Porosity occurs as a result of weld metal contamination. The trapped gases create a
bubble-filled weld that becomes weak and can with time collapse.
Causes of porosity:
 Inadequate electrode deoxidant.
 Using a longer arc.
 The presence of moisture.
 Improper gas shield.
 Incorrect surface treatment.
 Use of too high gas flow.
 Contaminated surface.
 Presence of rust, paint, grease or oil.
Remedies:
 Clean the materials before you begin welding.
 Use dry electrodes and materials.
 Use correct arc distance.
 Check the gas flow meter and make sure that it’s optimized as required with proper
with pressure and flow settings.
 Reduce arc travel speed, which will allow the gases to escape.
 Use the right electrodes.
 Use a proper weld technique.

UNDERCUT
 This welding imperfection is the groove formation at the weld toe, reducing the cross-
sectional thickness of the base metal. The result is the weakened weld and workpiece.
Causes:
 Too high weld current.
 Too fast weld speed.
 The use of an incorrect angle, which will direct more heat to free edges.
 The electrode is too large.
 Incorrect usage of gas shielding.
 Incorrect filler metal.
 Poor weld technique.
Remedies:
 Use proper electrode angle.
 Reduce the arc length.
 Reduce the electrode’s travel speed, but it also shouldn’t be too slow.
 Choose shielding gas with the correct composition for the material type you’ll be
welding.
 Use of proper electrode angle, with more heat directed towards thicker
components.
 Use of proper current, reducing it when approaching thinner areas and free edges.
 Choose a correct welding technique that doesn’t involve excessive weaving.
 Use the multipass technique

INCOMPLETE FUSION
 This type of welding defect occurs when there’s a lack of proper fusion between the
base metal and the weld metal. It can also appear between adjoining weld beads. This
creates a gap in the joint that is not filled with molten metal.
Causes:
 Low heat input.
 Surface contamination.
 Electrode angle is incorrect.
 The electrode diameter is incorrect for the material thickness you’re welding.
 Travel speed is too fast.
 The weld pool is too large and it runs ahead of the arc.
Remedies:
 Use a sufficiently high welding current with the appropriate arc voltage.
 Before you begin welding, clean the metal.
 Avoid molten pool from flooding the arc.
 Use correct electrode diameter and angle.
 Reduce deposition rate.

INCOMPLETE PENETRATION
 Incomplete penetration occurs when the groove of the metal is not filled completely,
meaning the weld metal doesn’t fully extend through the joint thickness.
Causes:
 There was too much space between the metal you’re welding together.
 You’re moving the bead too quickly, which doesn’t allow enough metal to be
deposited in the joint.
 You’re using a too low amperage setting, which results in the current not being
strong enough to properly melt the metal.
 Large electrode diameter.
 Misalignment.
 Improper joint.
Remedies:
 Use proper joint geometry.
 Use a properly sized electrode.
 Reduce arc travel speed.
 Choose proper welding current.
 Check for proper alignment.

SLAG INCLUSION
Slag inclusion is one of the welding defects that are usually easily visible in the weld.
Slag is a vitreous material that occurs as a byproduct of stick welding, flux-cored arc
welding and submerged arc welding. Is can occur when the flux, which is the solid
shielding material used when welding, melts in the weld or on the surface of the weld
zone.
 Causes:
 Improper cleaning.
 The weld speed is too fast.
 Not cleaning the weld pass before starting a new one.
 Incorrect welding angle.
 The weld pool cools down too fast.
 Welding current is too low.
Remedies:
 Increase current density.
 Reduce rapid cooling.
 Adjust the electrode angle.
 Remove any slag from the previous bead.
 Adjust the welding speed.

SPATTER
Spatter occurs when small particles from the weld attach themselves to the surrounding
surface. It’s an especially common occurrence in gas metal arc welding. No matter how
hard you try, it can’t be completely eliminated. However, there are a few ways you can
keep it to a minimum.
Causes:
 The running amperage is too high.
 Voltage setting is too low.
 The work angle of the electrode is too steep.
 The surface is contaminated.
 The arc is too long.
 Incorrect polarity.
 Erratic wire feeding.
Remedies:
 Clean surfaces prior to welding.
 Reduce the arc length.
 Adjust the weld current.
 Increase the electrode angle.
 Use proper polarity.
 Make sure you don’t have any feeding issues.

When welding, the aim is to produce compliant welds, not perfect welds. Some
discontinuities are allowed in compliant welds but too many will result in a defective
weld. Ensure you pay attention to all variables to reduce inconsistencies and the risk of
a defective weld.
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 Deciphering Weld Symbols

Deciphering Weld Symbols

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Weld symbols are often used among welders and engineers. Learn how to read common welding symbols and their meaning.

Common weld symbols and their meanings

When welds are specified on engineering and fabrication drawings, a cryptic set of symbols is used as a sort of shorthand for
describing the type of weld, its size and other processing and finishing information. Here we will introduce you to the common
symbols and their meaning. The complete set of symbols is given in a standard published by the American National Standards
Institute (ANSI) and the American Welding Society (AWS): ANSI/AWS A2.4, Symbols for Welding and Nondestructive Testing.

The structure of the welding symbol

The horizontal line — called the reference line — is the anchor to which all the other welding symbols are tied. The instructions
for making the weld are strung along the reference line. An arrow connects the reference line to the joint that is to be welded. In
the example above, the arrow is shown growing out of the right end of the reference line and heading down and to the right, but
many other combinations are allowed.

Quite often, there are two sides to the joint to which the arrow points, and therefore two potential places for a weld. For example,
when two steel plates are joined together into a T shape, welding may be done on either side of the stem of the T.
The weld symbol distinguishes between the two sides of a joint by using the arrow and the spaces above and below the
reference line. The side of the joint to which the arrow points is known (rather prosaically) as the arrow side, and its weld is made
according to the instructions given below the reference line. The other side of the joint is known (even more prosaically) as the
other side, and its weld is made according to the instructions given above the reference line. The rule that below the line equals
the arrow side and above the line equals the other side applies regardless of the arrow’s direction. The flag growing out of the
junction of the reference line and the arrow is present if the weld is to be made in the field during erection of the structure. A weld
symbol without a flag indicates that the weld is to be made in the shop. In older drawings, a field weld may be denoted by a filled
black circle at the junction between the arrow and the reference line.

The open circle at the arrow/reference line junction is present if the weld is to go all around the joint, as in the example below.

The tail of the weld symbol is the place for supplementary information on the weld. It may contain a reference to the welding
process, the electrode, a detail drawing or any information that aids in the making of the weld that does not have its own special
place on the symbol.
Types of welds and their symbols

Each welding position has its own basic symbol, which is typically placed near the center of the reference line (and above or
below it, depending on which side of the joint it's on). The symbol is a small drawing that can usually be interpreted as a
simplified cross-section of the weld. In the descriptions below, the symbol is shown in both its arrow-side and other-side
positions.

Fillet Weld Groove Welds Plug Welds and Slot Welds

Fillet welds

The fillet weld (pronounced "fill-it") is used to make lap joints, corner joints and T joints. As its symbol suggests, the fillet weld is
roughly triangular in cross-section, although its shape is not always a right triangle or an isosceles triangle. Weld metal is
deposited in a corner formed by the fit-up of the two members and penetrates and fuses with the base metal to form the joint.
(Note: for the sake of graphical clarity, the drawings below do not show the penetration of the weld metal. Recognize, however,
that the degree of penetration is important in determining the quality of the weld.)
The perpendicular leg of the triangle is always drawn on the left side of the symbol, regardless of the orientation of the weld itself.
The leg size is written to the left of the weld symbol. If the two legs of the weld are to be the same size, only one dimension is
given; if the weld is to have unequal legs (much less common than the equal-legged weld), both dimensions are given and there
is an indication on the drawing as to which leg is longer.
The length of the weld is given to the right of the symbol.

If no length is given, then the weld is to be placed between specified dimension lines (if given) or between those points where an
abrupt change in the weld direction would occur (like at the end of the plates in the example above).

For intermittent welds, the length of each portion of the weld and the spacing of the welds are separated by a dash (length first,
spacing second) and placed to the right of the fillet weld symbol.
Notice that the spacing, or pitch, is not the clear space between the welds, but the center-to-center (or end-to-end) distance.

Groove welds

The groove weld is commonly used to make edge-to-edge joints, although it is also often used in corner joints, T joints, and
joints between curved and flat pieces. As suggested by the variety of groove weld symbols, there are many ways to make a
groove weld, the differences depending primarily on the geometry of the parts to be joined and the preparation of their edges.
Weld metal is deposited within the groove and penetrates and fuses with the base metal to form the joint. (Note: for the sake of
graphical clarity, the drawings below generally do not show the penetration of the weld metal. Recognize, however, that the
degree of penetration is important in determining the quality of the weld.)
The various types of groove weld are:

Square groove welds

The groove is created by either a tight fit or a slight separation of the edges. The amount of separation, if any, is given on the
weld symbol.

V-groove welds

The edges of both pieces are chamfered, either singly or doubly, to create the groove. The angle of the V is given on the weld
symbol, as is the separation at the root (if any).
If the depth of the V is not the full thickness — or half the thickness in the case of a double V — the depth is given to the left of
the weld symbol.

If the penetration of the weld is to be greater than the depth of the groove, the depth of the effective throat is given in
parentheses after the depth of the V.
Bevel groove welds

The edge of one of the pieces is chamfered and the other is left square. The bevel symbol's perpendicular line is always drawn
on the left side, regardless of the orientation of the weld itself. The arrow points toward the piece that is to be chamfered. This
extra significance is emphasized by a break in the arrow line. (The break is not necessary if the designer has no preference as to
which piece gets the edge treatment or if the piece to receive the treatment should be obvious to a qualified welder.) Angle and
depth of edge treatment, effective throat and separation at the root are described using the methods discussed in the V-groove
section.
U-groove welds

The edges of both pieces are given a concave treatment. Depth of edge treatment, effective throat and separation at the root are
described using the methods discussed in the V-groove section.

J-groove welds

The edge of one of the pieces is given a concave treatment and the other is left square. It is to the U-groove weld what the bevel
groove weld is to the V-groove weld. As with the bevel, the perpendicular line is always drawn on the left side and the arrow
(with a break, if necessary) points to the piece that receives the edge treatment. Depth of edge treatment, effective throat and
separation at the root are described using the methods discussed in the V-groove section.
Flare-V groove welds

Commonly used to join two rounded or curved parts. The intended depth of the weld itself is given to the left of the symbol, with
the weld depth shown in parentheses.
Flare bevel groove weld

Commonly used to join a round or curved piece to a flat piece. As with the flare-V, the depth of the groove formed by the two
curved surfaces and the intended depth of the weld itself are given to the left of the symbol, with the weld depth shown in
parentheses. The symbol's perpendicular line is always drawn on the left side, regardless of the orientation of the weld itself.

Common supplementary symbols used with groove welds are the melt-thru and backing bar symbols. Both symbols indicate
that complete joint penetration is to be made with a single-sided groove weld. In the case of melt-thru, the root is to be reinforced
with weld metal on the back side of the joint. The height of the reinforcement, if critical, is indicated to the left of the melt-thru
symbol, which is placed across the reference line from the basic weld symbol.
When a backing bar is used to achieve complete joint penetration, its symbol is placed across the reference line from the basic
weld symbol. If the bar is to be removed after the weld is complete, an "R" is placed within the backing bar symbol. The backing
bar symbol has the same shape as the plug or slot weld symbol, but context should always make the symbol's intention clear.

Plug and slot welds

Plug welds and slot welds are used to join overlapping members, one of which has holes (round for plug welds, elongated for
slot welds) in it. Weld metal is deposited in the holes and penetrates and fuses with the base metal of the two members to form
the joint. (Note: for the sake of graphical clarity, the drawings below do not show the penetration of the weld metal. Recognize,
however, that the degree of penetration is important in determining the quality of the weld.) For plug welds, the diameter of each
plug is given to the left of the symbol and the plug-to-plug spacing (pitch) is given to the right. For slot welds, the width of each
slot is given to the left of the symbol, the length and pitch (separated by a dash) are given to the right of the symbol, and a detail
drawing is referenced in the tail. The number of plugs or slots is given in parentheses above or below the weld symbol. The
arrow-side and other-side designations indicate which piece contains the hole(s). If the hole is not to be completely filled with
weld metal, the depth to which it is to be filled is given within the weld symbol.
For more information, see ANSI/AWS A2.4, Symbols for Welding and Nondestructive Testing.

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Updated: April 14, 2021

Published: May 1, 2007

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