Pemerintah Provinsi Jawa Timur

Dinas Tenaga Kerja dan Transmigrasi

UPT BALAI LATIHAN KERJA KEDIRI

Ds. Gedangsewu Kec. pare Kab. Kediri PO box 130 Telp. 0354-391583 Fax. 0354-391583
Website: www.kediri.disnakertrans.jatimprov.go.id,
KEDIRI - 64214

PELATIHAN PLATE WELDER SMAW 3G

K3 PENGELASAN
Alvinura Fajrin, 2022
OUTLINE

• Weld Defect Classification

• Fault in Fusion Weld
• Mechanical Damage
• Set Up Irregularities
TUJUAN INSTRUKSIONAL

1. Mengenal potensi bahaya dan

RISIKO aktivitas pengelasan,
pemotongan dan penggerindaan
2. Melakukan pengendalian RISIKO
3. Bekerja aman sesuai dengan
Standard Operational Procedure
(SOP)c
REFERENSI

1. Welding Imperfections, The Welding

Institute, 2005
 Weld Defect Classification
Defects can be grouped under three main
classifications
Planar Defects: linear from at least one dimension
• Cracks
• Lack of fusion
Linear Volumetric Defects: Linear in length with volume
• Slag lines
• lack of fusion with associated slag
• Piping.
Non-planar defects: rounded indications without significat length
• Slag inclusions
• Gas pores/blow holes.
• Other matallic and non-metallic inclusions
 Faults in Fusion Welds
Defects which may be detected by visual inspection
can be grouped under the following headings

 Cracks  Lack of fusion

 Solid inclusions  Mechanical damage

 Surface and profiles  Parent material damage

 Misalignment (set-up  Miscellaneous

irregularities)

 Gas pores and porosity

 Cracks

Copyright © 2005 TWI Ltd World Centre for Materials Joining Technology
 Cracks

Weld Metal Hydrogen Cracking HAZ Hydrogen Cracking

Solidification Cracking Lamellar Tearing

 Cracks
Cracks that may occur in welded materials are caused
generally by many factors and may be classified by
shape and position, cracks are classed as planar.

Classified by Shape Classified by Position

 Longitudinal  HAZ
 Transverse  Centreline

 Branched  Crater

 Chevron  Fusion zone

 Parent metal
Transverse crack Longitudinal crack
Inclusions
 Gas Cavities
Gas pore <1.5mm Blow hole.>1.6mm
Gas pore Cluster porosity
 Loss of gas shield

 Damp electrodes

 Contamination
Blow hole
Herringbone porosity  Arc length too large

 Damaged electrode flux

 Moisture on parent material

 Welding current too low

Root piping / wormholes
Gas Cavities

Porosity

Root piping
Cluster porosity Herringbone porosity
 Solid Inclusions
Slag inclusions are defined as a non-metallic inclusion
caused by some welding process
 Slag originates from welding
flux
 MAG and TIG welding
process produce silica
Slag inclusions Lack of sidewall inclusions
fusion with
associated slag
 Slag is caused by
inadequate cleaning
 Other inclusions include
tungsten and copper
inclusions from the TIG and
Parallel slag lines Lack of interun
fusion + slag MAG welding process
 Solid Inclusions

Lack of interun fusion + slag

Lack of sidewall fusion + slag
Interpass slag inclusions Elongated slag lines
Lack of Fusion
 Lack of Fusion

 Poor welder skill

 Incorrect electrode
manipulation
Incomplete filled groove
+ Lack of sidewall fusion  Arc blow
 Incorrect welding

1 current/voltage
2
 Incorrect travel speed
1. Lack of sidewall fusion  Incorrect inter-run cleaning
2. Lack of inter-run fusion
 Lack of Fusion

Lack of sidewall fusion + incomplete filled groove

 Overlap
An imperfection at the toe or root of a weld caused by
metal flowing on to the surface of the parent metal
without fusing to it

 Contamination

 Slow travel speed

 Incorrect welding technique

 Current too low

 Overlap

Toe Overlap
Butt weld

Toe Overlap
Fillet weld
 Weld Root Defects

 Low Amps/volts

 Large Root face

 Small Root Gap

Lack of root fusion
 Fast Travel Speed

 Incorrect Electrode Angle

 Contamination
Incomplete root penetration
 Arc blow
 Weld Root Defects

Lack of root fusion Incomplete root

Penetration
Lack of root penetration Lack of root fusion
Surface & Profile
 Weld Profile Defects

Incomplete filled groove Poor cap profile

Poor cap profiles and excessive

cap reinforcements may lead to
stress concentration points at
the weld toes and will also
contribute to overall poor toe
blend Excessive cap height
 Weld Profile Defects

Poor Cap Profile & Poor Toe Blend

Excess cap reinforcement Incomplete filled groove
 Weld Profile Defects

Poor stop/starts
Miscellaneous Defects
Miscellaneous Defects
Spatter

 Excessive current

 Damp electrodes

 Contamination

 Incorrect wire feed speed

when welding with the MAG
welding process

 Arc blow
 Miscellaneous Defects

 Accidental striking of the arc

onto the parent material

 Faulty electrode holder

 Poor cable insulation

 Poor return lead clamping

Arc strike
 Cap & Root Undercut
An irregular groove at the toe of a weld run in the
parent metal
 Excessive amps/volts

 Excessive travel speed

 Incorrect electrode angle

 Excessive weaving

 Incorrect welding technique

 Electrode too large

 Cap Undercut

Intermittent Cap Undercut

Root undercut Cap undercut
 Weld Root Defect

A shallow groove caused by contraction in the weld

metal along each side of the penetration bead

 Insufficient weld metal

deposited in the root pass

 Too fast a cooling rate during

the application of the root
bead pass
Shrinkage groove  Poor welding technique
 Weld Root Defect
A shallow groove, which may occur in the root of a butt weld

 Root gap too large

 Excessive back purge pressure

during TIG welding

 Excessive root bead grinding

before the application of the
Concave root
second pass
 Weld Root Defect

Concave Root
 Weld Root Defect

Root penetration bead in excess in accordance with the

relevant specification being used

 Root faces too small

 Root gap too large

 Excessive amps/volts

Excessive root penetration  Slow travel speed

Weld Root Defect

Excessive root
penetration
Concave root Excess root penetration
 Weld Root Defect

A localized collapse of the weld pool due to excessive

penetration resulting in a hole in the root run

 High Amps/volts

 Small Root face

 Large Root Gap

 Slow Travel Speed

Burn through
Weld Root Defect
Burn Through
Oxidized Root (Root Coking)

 Loss or insufficient back

purging gas

 Most commonly occurs

when welding stainless
steels

 Purging gases include

argon, helium and
occasionally nitrogen
Crater Pipe

Weld crater

Crater pipe
 Crater Pipe
Crater pipe is a shrinkage defect and not a gas defect, it
has the appearance of a gas pore in the weld crater

Crater cracks  Too fast a cooling rate

(Star cracks)
 Deoxidization
reactions and liquid to
solid volume change

 Contamination
Crater pipe
Mechanical Damage
 Mechanical Damage
Mechanical damage can be defined as any surface material
damage cause during the manufacturing process.
This can included damage caused by:

 Grinding

 Hammering

 Chiselling

 Chipping

 Breaking off welded attachments (torn surfaces)

 Using needle guns to compress weld capping runs

 Mechanical Damage
Chipping Marks

Mechanical Damage/Grinding Mark

Set-up Irregularities
 Unequal Leg Lengths

A variation of leg lengths on a fillet weld

Note: Unequal leg lengths on a fillet weld may be specified

as part of the design, in which case it will not be
considered as a defect.
 Set-up Irregularities

Linear misalignment is
measured from the lowest
plate to the highest point.

Plate/pipe Linear Misalignment

(Hi-Lo)

Angular misalignment is
measured in degrees

Angular Misalignment
Set-up Irregularities

Linear Misalignment
Set-up Irregularities

Linear Misalignment
Any Questions
 Questions
Weld Defects
QU 1. Give two main causes for the occurrence of a burn through

QU 2. Give two main causes for the occurrence of excessive root

penetration on a single-V butt weld

QU 3. Give five defects, which may occur when welding carbon

steel using the MMA welding process with the current
setting to low

QU 4. Give three possible causes for the occurrence of lack of

side wall fusion

QU 5. Sketch the following defects

a. Lack of root wall fusion b. Lack of root penetration
c. Incomplete filled groove d. Concave root