Chapter 8 Manual Welding Techniques
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Fillet Weld Defects and Corrective Actions
Common fi llet weld defects may be noticed during the welding operation or later during the inspection of
the completed weld. These defects are listed and illustrated with suggestions for corrective actions.
Lack of penetration. Insuffi cient weld metal penetration into the joint intersection.
How to correct:
• Maintain slight forward torch angle.
• Increase amperage.
• Decrease arc length.
• Decrease size of weld deposit.
• Use stringer beads
• Do not make weave beads on root passes.
Lack of fusion. Occurs in multiple-pass welds where layers do not fuse.
How to correct:
• Remove oxides and scale from previous
weld passes.
• Increase amperage.
• Decrease arc length.
• Decrease travel speed.
Overlap. Occurs in horizontal, multiple-pass fi llet welds when too much weld is placed on the bottom layer.
How to correct:
• Remove oxides and scale from weld area.
• Reduce the size of the weld pass.
• Increase travel speed.
Undercut. Occurs at the top of the weld bead in horizontal fi llet welds.
How to correct:
• Make a smaller weld.
• Make a multiple-pass weld.
• Decrease amperage.
• Decrease arc length.