7 Most Common Welding Defects, Causes and Remedies

• Weld Crack. 1.1 Causes of cracks: 1.2 Remedies:
• Porosity. 2.1 Causes of porosity: 2.2 Remedies:
• Undercut. 3.1 Causes: 3.2 Remedies:
• Incomplete Fusion. 4.1 Causes: 4.2 Remedies:
• Incomplete Penetration. 5.1 Causes: 5.2 Remedies:
• Slag Inclusion. 6.1 Causes: 6.2 Remedies:
• Spatter.

Most Common Types of Welding Defects

• Incomplete Penetration. Incomplete penetration happens when your filler metal and base metal aren’t joined properly, and the result is a gap or a crack of some sort.
• Incomplete Fusion.
• Undercutting.
• Slag Inclusions.
• Flux Inclusions.
• Porosity.
• Cracks.
• ✓ Hot cracks:

The distance from the tip of the welding electrode to the adjacent surface of the weld pool.

Cause. Porosity is caused by the absorption of nitrogen, oxygen and hydrogen in the molten weld pool which is then released on solidification to become trapped in the weld metal. Nitrogen and oxygen absorption in the weld pool usually originates from poor gas shielding.

Arc Length Too Short This weld was laid with the end of the rod covered by the molten slag. The surface of the weld is uneven where it has been dragged along by the rod, and the weld will be low on power and contain slag inclusions.

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Increased voltage increases the arc length and gives a wider weld bead. Undercut is a sign of too high a voltage. If short arc welding is used a higher voltage reduces the short circuit frequency, which will give larger drops and more spatter.

The voltage and arc length are closely related. The shorter the arc, the lower the arc voltage and the lower the temperature produced, an as the arc lengthens, the resistance increases, thus causing a rise in the arc voltage and temperature.

There are two general methods of striking the arc:

• Scratching.
• Tapping.

The various equipments required for electric arc welding are:

• Welding Machine: The welding machine used can be A.C. or D.C. welding machine.
• Electrode Holders: ADVERTISEMENTS:
• Cables or Leads:
• Cable Connectors and Lugs:
• Chipping Hammer:
• Wire Brush, Power Wire Wheel:
• Protective Clothing:
• Screen or Face Shield:

There are two types of electrodes, cathodes, and anodes. Cathode attracts the positively charged cations. Anode attracts negatively charged anions. Electrodes are commonly made of metals such as platinum and zinc.

Arc rays can burn eyes and skin and noise can damage hearing permanently. Use approved earplugs or ear muffs if noise level is high. Wear a welding helmet fitted with a proper shade of filter lens (see ANSI Z49. 1 listed in Safety Standards) to protect your face and eyes when welding or watching.

Answer. Correctly striking an arc takes practice. The main difficulty in confronting a beginner in striking the arc is sticking the electrode to the work. If that does not work, quickly unclamp the holder from the electrode, and turn off the machine.

Use an audible signal such as “cover” to indicate to others that you plan to strike an arc. 18. If an electrode sticks, try to twist it free. If twisting fails to free the electrode, release the electrode from the electrode holder.

Welding Safety Precautions

• Welding helmets with side-shields. Welding helmets protect you from UV radiation, particles, debris, hot slag and chemical burns.
• Respirators. Respirators protect you from fumes and oxides that the welding process creates.
• Fire resistant clothing.
• Ear protection.
• Boots and gloves.

Your safety is a priority.

• Check all equipment for damage.
• Check your surrounding area for hazards.
• Ensure you are following safety procedures.
• Always wear the appropriate PPE.

Health hazards associated with welding, cutting, and brazing operations include exposures to metal fumes and to ultraviolet (UV) radiation. Safety hazards associated with these processes include burns, eye damage, electrical shock, cuts, and injury to toes and fingers.

Without wearing the proper PPE (personal protective equipment), welders can experience a variety of physical hazards, including eye damage, cuts, burns or even crushed fingers and toes. These injuries should be taken seriously, as they can put a welder out of work in some cases.

Personal protective equipment (PPE) is important for welders because there are hazards when welding, cutting, and brazing. These hazards can include exposure to metal fumes and UV radiation, burns, shocks, cuts, and broken toes.

ELECTRIC SHOCK can kill. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RAYS can burn eyes and skin.

A safe and healthy workplace not only protects workers from injury and illness, it can also lower injury/illness costs, reduce absenteeism and turnover, increase productivity and quality, and raise employee morale. In other words, safety is good for business. Plus, protecting workers is the right thing to do.

Safety is the state of being safe from harm or danger. The report goes on to make a number of recommendations to improve safety on aircraft. Synonyms: security, protection, safeguards, assurance More Synonyms of safety. 2. uncountable noun [oft preposition NOUN]

Financial: Managing health and safety At some point in our career we will all have heard that the three key reasons for managing health and safety in our organisation are: legal, moral and financial.

• Safety hazards. Safety hazards is number one on the list of 6 types of workplace hazards.
• Biological hazards. The definition of biological hazards, commonly known as biohazards, can be any biological substance that could cause harm to humans.
• Physical hazards.
• Ergonomic hazards.
• Chemical hazards.
• Work organization hazards.

Five Elements of an Effective Safety Culture

• Responsibility. Companies with strong safety cultures share the value of responsibility.
• Accountability. Managers must be held accountable to lead by example each and every day.
• Clear Expectations.
• Ethics.
• Next Steps.

5 Important Safety Measures Every Construction Worker Must Remember

• Always Double Check your Work Area.
• Be Attentive when Working With Electricity and Equipment.
• Prevent Fires and Maintain Fencing.
• Wear Appropriate Safety Apparel and Gear.
• First Aid Kits Should Be Readily Available.

Breaking Down the Safety-First Rule The safety-first rule involves creating a minimum acceptable return, or threshold return. By fixing a threshold return, an investor aims to reduce the risk of not achieving the investment return.

Seven Basic General Industry Safety Rules

• Keep work areas clean.
• Use the proper tool for the job.
• Always wear the proper PPE for the work task.
• Never work on live equipment.
• Make sure chemicals are properly labeled and stored.
• Communicate hazards to other personnel.
• Stop work when needed to address hazards.

Always be responsible for the safety of yourself and others. Always remember all accidents are preventable. Always follow company rules, regulations and procedures. Always take the safest path, never take shortcuts.