Weld Reinforcement Height Tool
A simple QC tool for welding inspectors and welders to check if the weld reinforcement (cap height) meets the common requirements of structural welding codes like AWS D1.1.
More is Not Always Better: The Problem with Excessive Reinforcement
Weld reinforcement is the extra weld metal on top of the base material in a groove weld. While some reinforcement is necessary, excessive reinforcement is a defect. It does not add strength to the weld. Instead, it creates a sharp angle at the "toe" of the weld, which acts as a stress concentration point. This can significantly reduce the fatigue life of the joint, making it more prone to cracking under cyclic loading.
For this reason, welding codes like AWS D1.1 (Structural Welding Code - Steel) strictly limit the maximum allowable reinforcement height, typically to 3mm (1/8 inch).