Weld Imperfection Severity Tool
An educational tool for inspectors and welders to understand the relative severity of different weld defects and their typical acceptance criteria.
Reasoning:
Cracks are sharp notches that act as extreme stress concentrators. They can propagate under load and lead to sudden, catastrophic failure.
Typical Acceptance Criteria:
Almost universally unacceptable. Any crack found must be completely removed and repaired.
Not All Defects Are Created Equal
In the world of welding quality control, not all imperfections are treated with the same level of concern. Some are cosmetic, while others are critical flaws that can compromise the safety of the entire structure. The "Fitness-for-Service" concept is an engineering assessment that determines whether a flaw is acceptable or must be repaired. This assessment depends heavily on the type, size, and location of the imperfection.
This tool provides a simplified overview of this concept, ranking common defects by their typical severity. The geometry of the defect is key: sharp, crack-like flaws are far more dangerous than rounded, blunt flaws like porosity because they concentrate stress much more effectively.