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2. Overlap (roll-over) Weld metal that has rolled over at the edges and not fused to the parent metal. May be face or root: Weld bead too large, current too high, travel speed too slow, prevalent in horiz.– vert. welds, inadequate cleaning: 201: Porosity: Gas entrapped in weld metal giving a cavity. May be localised, uniformly distributed or aligned 2020-01-09 This type of welding defect occurs when there’s a lack of proper fusion between the base metal and the weld metal.

Due to the insufficient fusion, molten metal can not reach all areas of the weld and thus creates the gap. This kind of weld defects weakens the structure. Either the weld puddle is too large (travel speed too slow) and/or the weld metal has been permitted to roll in front of the arc. Again, the arc must be kept on the leading edge of the puddle. When this is done, the weld puddle will not get too large and cannot cushion the arc. Another cause is the use of a very wide weld … Attached is a crude drawing of the weld joint ( desired on left and cold-roll or overlap on the right ) and two pictures of one section where this defect was found. This is a particularly egregious example, in a hand welded section.

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•Defects seen on the surface of the weld can extend deep into the weld. For this reason, the defect must be removed. After the defect has been removed, the area must be re-inspected before a repair can be attempted. Separation along the original weld plane (rather than tearing at a weld button) occur when stampings are stronger than the weld nugget.

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Either the weld puddle is too large (travel speed too slow) and/or the weld metal has been permitted to roll in front of the arc. Again, the arc must be kept on the leading edge of the puddle. When this is done, the weld puddle will not get too large and cannot cushion the arc. Another cause is the use of a very wide weld joint.

By using large electrodes this defect may occur. 3. High welding current. Remedies for Overlap: 1. Using a proper technique for welding. 2. Overlap (roll-over) Weld metal that has rolled over at the edges and not fused to the parent metal.
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This creates a gap under the joint or in between adjoining weld beads. Due to the insufficient fusion, molten metal can not reach all areas of the weld and thus creates the gap. This kind of weld defects weakens the structure. Either the weld puddle is too large (travel speed too slow) and/or the weld metal has been permitted to roll in front of the arc. Again, the arc must be kept on the leading edge of the puddle.

Crater- It occurs when the creator is not filled before the arc is Classification of cracks to DIN 8524 part 3 - Welding defects · Classification of Insufficient fill on the root side (suckback) - Welding defects · Insufficient fill or Fatigue life assessment of the above mentioned three types of cold lap defects was carried out using finite element and crack growth analysis in 2D and 3D. In the BAD CRANE WELDS, COMMON: New York probe examines failed welds on collapsed crane's turntable KEEP A ROLL OF DUCT TAPE IN THE TRUNK.
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There are several types of weld defects which may fall under different classifications depending on their location, size and shape in a particular consideration.

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Causes of Overlap: 1. Improper welding technique. 2. By using large electrodes this defect may occur. 3.

from roller straightening and head hardening. It can also result from the rail welding since expansion and contraction occurs during the weld process. Residual stresses can be found in any location within the rail section.