common welding defects

Identifying common welding defects
Preventing and fixing problems with your welds

If I could wave my magic filler rod and make it so that all your welds would be strong, clean, and sharp-looking, I’d certainly do it. But the last time I went to the welding supply shop and asked to buy a magic filler rod, they looked at me like I was nuts, so for now you just have to live with the fact that some of your welds will be imperfect. Don’t worry about it too much; after all, no welder is perfect, and welding can be a tricky endeavor. What I can do is fill you in on some of the most common weld flaws so that when they show up, you realize that you’re dealing with the same kinds of challenges that hundreds of thousands of welders have cursed and spat about since the first guy figured out how to strike an arc. These are the kinds of defects that you’re likely to notice only after you’ve finished a weld (either a single pass or a complete weld, depending on the defect). Most are prettyeasy to detect, and — thankfully — relatively easy to adjust for and prevent. To help prevent welding defects before they happen, be sure your welding materials are clean and in good shape before you start a project. The metal you’re planning to weld should be free of any material that may contaminate the weld. Remove any grease, paint, or oil from the metal. You should also
put the pieces to be welded in place to make sure they fit together and line up properly.

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