Ways to Prevent Weld Failures


Weld failures can occur at any time and in many different ways but the most common cause is from simple oversights which can be the result of improper training of the required techniques for that particular material or joint style.

Each weld failure affects the welding operations overall productivity and profitability so it’s important that the problem has been identified so improvements can be made. There are some different precautions that welders can carry out to hep protect against a weld failure.

Here’s our top tips for preventing weld failures.

Use Low Hydrogen Filler metals when possible

Many filler metal manufacturers offer a variety of products that produce low levels of diffusible hydrogen. Low hydrogen filler metals are a great defense against weld failures caused by hydrogen cracking. Hydrogen cracking is also known as cold cracking and typically occur once the weld has cooled. Alternatively, thicker materials are often more prone to weld failures because they create a high restraint.

Match Filler Metal and Base Material strengths

Carefully matching the filler metal and base material strengths can reduce the risk of weld failures dramatically. If welding a lower strength material to a higher one, always match the filler material to the lowest. This is because it will allow for greater ductility and help reduce the risks of a cracking weld.

Proper Part fit-up and good Joint design

Both proper part fit-up and joint design are crucial steps for ensuring weld failures do not occur. When possible, design the joint so that the welding operator has easy access to the root. This ensures a proper bead depth to width ratio.

Appropriate Training for the task-in-hand

Above all, making sure you have the sufficient training for a job is very important. Training is how you gain technique and make the right decisions. A trained welder should be able to solve common weld defects, such as:

  • Slag inclusions
  • Undercutting
  • Porosity

Along with weld defects, a welder should be able to be able to solve any special requirements of the alloys that they may encounter during a job.

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