Weld Imperfection Risk Assessor
An educational tool to understand how welding parameters can increase the risk of common defects. Select your conditions to see a qualitative risk assessment.
Understanding Common Weld Defects
A perfect weld is strong, clean, and free of defects. However, many factors can lead to imperfections that compromise the weld's integrity. This tool helps visualize the cause-and-effect relationship between welding parameters and common defects.
Porosity
Porosity appears as small holes or bubbles in the weld bead. It is caused by gas getting trapped in the molten weld pool as it solidifies. The primary culprits are inadequate shielding gas coverage (allowing air to contaminate the weld) or contaminants on the base metal (like oil, rust, or paint) that burn off and release gas.
Undercut
Undercut is a groove melted into the base metal next to the weld toe, which is not filled by weld metal. It acts as a stress concentrator and weakens the joint. It is most often caused by using excessively high amperage, an incorrect electrode angle, or traveling too quickly, which doesn't allow the weld pool to fill the melted area.