Welding Defects Definition, Diagram, Types, Causes & Remedies

2025.3.26

Welding is a fabrication technique that joins materials and creates strong, permanent bonds. However, the complexity of welding leads to the potential for defects and imperfections that can compromise the quality and safety of welded joints. This guide introduces the most common types of welding defects with definitions, diagrams, detection methods, causes, preventive measures, and effective remedies.

What Are Weld Defects?

Weld defects, which are irregularities that occur during the welding process, can stem from inappropriate techniques, unsuitable materials, poor workmanship, and a lack of proper training or experience. These defects can manifest both on the surface of the weld bead and within the weld metal itself. 

How to Check and Detect Welding Defects?

Welding defects can be identified using various inspection methods, which can be broadly categorized into non-destructive testing (NDT) and destructive testing.
Non-Destructive Testing (NDT) Methods
1. Visual Inspection
The simplest and most cost-effective NDT method, where a trained inspector examines the weld visually for surface defects such as cracks, porosity, and misalignment.

2. Radiographic Testing
Uses X-rays or gamma rays to create an image of the welded joint, revealing internal defects such as cracks, porosity, and incomplete fusion.

3. Ultrasonic Testing
Employs high-frequency sound waves to detect flaws within the welded joint. Sound waves are directed into the material, and reflections from defects are analyzed.

4. Magnetic Particle Inspection
Identifies surface and near-surface defects in ferromagnetic materials by magnetizing the weld and applying fine magnetic particles that gather at defect sites.

5. Liquid Penetrant Testing
Detects surface-breaking defects by applying a liquid dye that seeps into cracks or voids. After removing excess dye, a developer is applied to highlight the defect.

6. Eddy Current Testing
Uses electromagnetic induction to detect surface and near-surface defects. Changes in the eddy current field caused by defects are measured.

7. Remote Visual Inspection (RVI)
Extends visual inspection capabilities by using cameras and robotic systems to access hard-to-reach areas.

8. Phased Array Ultrasonic Testing (PAUT)
A advanced form of UT that uses multiple sensor arrays to generate and receive ultrasonic waves from different angles, providing detailed cross-sectional images of the weld.

Destructive Testing Methods
1. Tensile Testing
A sample of the welded joint is subjected to tensile force until it fails, measuring its strength and ductility.

2. Bend Testing
The welded joint is bent to a specified radius to evaluate its ductility and the quality of the fusion zone.

3. Charpy Impact Testing
Measures the energy absorbed by a notched specimen when struck by a pendulum, assessing the material’s toughness.

4. Macroetch Testing
The welded joint is etched with acid to reveal the macrostructure, allowing visual inspection of defects such as porosity and incomplete fusion.

5. Fracture Testing
The welded joint is fractured and examined under a microscope to identify fracture mechanisms and defects.

Different Types of Weld Defects with Images – Welding Defects Causes and Remedies

Understanding these welding defects and imperfections, their causes, and the remedies is essential for ensuring high-quality welds.
1. Undercut
The undercut welding defect is characterized by a groove or recess that forms at the toe of the weld bead, which remains unfilled. This defect typically occurs at the edges of welded joints, particularly at the corners of fillet welds, where the weld metal is not deposited adequately, creating a weakened area that can compromise the structural integrity of the weld. Refer to industry standards such as AWS D1.1, which specifies that undercuts deeper than 1/16″ (1.6mm) are typically unacceptable.

Causes

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Remedies

2. Misalignment
Misalignment is a welding defect characterized by an improper alignment of the welded joint at the root, which can lead to weakened structures and compromised integrity. This defect manifests when two plates being welded do not align correctly, resulting in either linear or angular misalignment. Linear misalignment occurs when the plates are not parallel, while angular misalignment arises from different angular deformations between the plates. It is hard to repair the misalignment inside of pipes, so it is important to prevent the defect.

Causes

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Remedies

3. Overlap
An overlap welding defect occurs when the weld face extends beyond the toe of the weld, resulting in excess material that creates an irregular weld contour. This defect is primarily a weld bead geometry issue, where the excess material protrudes from the intended weld toe, leading to a non-uniform appearance and potential structural weaknesses. Overlapping can compromise the integrity of the welded structure during its service life.

Causes

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4. Burn Through
Burn-through is an undesirable defect characterized by an open hole that completely penetrates the base metal during the welding process. This defect occurs when excessive heat or welding current causes the weld material to become overly fluid, resulting in a hole that can extend through the entire thickness of the welded plate. Burn-through holes may be visible to the naked eye or may remain hidden within the welding joint, it is essential to detect the structural integrity of the weld. Non-destructive testing methods can be employed to identify these hidden defects.

Causes

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5. Incomplete Fusion (Lack of Fusion)
Incomplete fusion is a welding defect characterized by the failure of the weld metal to form a cohesive bond with the parent metal, resulting in gaps or voids between these two materials. This defect can manifest in various forms, such as a lack of side wall fusion, where the weld does not adequately bond with the sides of the joint, or a lack of root fusion, where the weld fails to connect at the root of the joint. Additionally, inter-run fusion issues occur when there is insufficient bonding between successive weld passes, leading to weak joints that can compromise the structural integrity of the weld.

Causes

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Remedies

6. Slag Inclusion
There are two types of inclusion defects on welded parts: slag and tungsten. The slag inclusion is characterized by the entrapment of slag within the weld metal, which can compromise the integrity and strength of the weld. This defect typically occurs in welding processes that utilize slag as a protective medium, such as submerged arc welding (SAW) and shielded metal arc welding (SMAW). Slag, which forms as a byproduct of the welding process, can become trapped between layers of weld metal or within the weld itself, especially during multi-layer or multi-pass welding. Slag inclusions may lead to reduced mechanical properties, increased porosity, and potential failure of the weld.

Causes

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Remedies

7. Spatter
A spatter welding defect refers to small particles of weld metal that are expelled during the welding process and adhere to the surface of the parent metal. This phenomenon typically occurs when the arc length is too high, causing the metal droplets to become globular. When these droplets fall into the weld pool, there is a risk of molten metal being pushed outside the intended weld area, resulting in spatter. This defect can compromise the appearance and integrity of the weld, leading to additional issues if not addressed.

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8. Porosity
Porosity is a welding defect characterized by the presence of small gas bubbles or voids within the weld metal. These tiny imperfections can compromise the integrity and strength of a weld, leading to potential failures under stress. Porosity typically occurs when the welding process is disrupted, allowing gases to become trapped during solidification. This can manifest in various welding techniques, including gas metal arc welding and flux-cored arc welding, where inadequate shielding or contamination of the base material contributes to the defect.

Causes

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Remedies

9. Cracks
Crack welding defects are planar discontinuities characterized by a significant length-to-opening displacement ratio. These cracks can occur in the weld metal, the heat-affected zone (HAZ), or the base material and may manifest in various orientations. They are typically formed due to thermal stresses during the welding process, either at elevated or low temperatures. Cracks are considered one of the most detrimental weld discontinuities because they act as severe stress concentrators, leading to potential failure. The presence of cracks indicates a loss of metallurgical control, making them unacceptable according to most fabrication codes, regardless of their size. There are many different types of crack defects in welding, including root crack, crater crack, fusion zone crack, fusion line crack in HAZ, underbead crack in HAZ, transverse crack in HAZ, longitudinal crack in weld, and transverse crack across weld.

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10. Arc Strike
Arc strike defects occur when an electric arc unintentionally contacts the base metal outside of the intended weld zone, often as a result of carelessness or lack of attention during the welding process. This can happen when the welder inadvertently scratches the workpiece with a live electrode, leading to discontinuities in the metal. Arc strikes can create micro-cracks not only in the weld area but also in the surrounding base metal, especially in structures subject to cyclic loading. These cracks can propagate over time, compromising the integrity of the weld and the overall structure. The presence of arc strikes poses a significant risk, as inspectors may require costly repairs or removals of affected sections.

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11. Insufficient Fill
An insufficient fill welding defect, also known as underfill or under filled, is a type of welding defect where the weld surface is below the adjacent surface of the workpiece material. This can occur on either the front or back side of the weld. When it occurs on the back side, it is also known as suck back welding defect or under fill welding defect.

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12. Insufficient (Incomplete) Penetration
Lack of penetration, also known as incomplete penetration, is a welding defect characterized by insufficient fusion between the base metal and the weld metal, resulting in a gap at the root of the weld joint. This defect typically occurs in groove welds when the weld metal does not fully penetrate the joint, leading to reduced strength and potential failure under load. To identify lack of penetration, visual inspection may reveal an incomplete fill at the joint, while more detailed assessments can be conducted using non-destructive testing methods such as ultrasonic testing or radiographic inspection, which can detect the presence and extent of the voids within the weld.

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Remedies

13. Excessive Reinforcement
Excessive reinforcement in welding is a defect characterized by an overabundance of weld metal beyond the specified size or profile, leading to dimensional inaccuracies and potential stress concentration points in the welded joint that can compromise structural integrity and performance. This defect typically manifests as protrusions, uneven or overly pronounced weld beads that extend beyond acceptable dimensions, creating surface irregularities such as bumps or ridges. The excessive weld metal deposition not only affects the appearance but also creates areas of stress concentration that may lead to fatigue and failure under operational loads.

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