150 GMAW/FCAW Handbook Copyright Goodheart-Willcox Co., Inc. Weld Defects and Corrective Action Certain defects are common to particular welds. Defects affecting groove, fi llet, plug, and spot welds are fi described next, along with suggestions for correcting each problem. Defects and corrective actions are similar for GMAW and FCAW procedures. More than one corrective action may be needed for any given defect. Groove Weld Defects Lack of (or incomplete) penetration. A weld that does not properly penetrate into the weld joint. How to correct: • Open the groove angle. • Decrease the root face. • Increase the root opening. • Increase the amperage. • Decrease the voltage. • Decrease the travel speed. • Change the gun angle. • Decrease the electrode stickout. • Keep the arc on the leading edge of the molten pool. Lack of fusion. A failure of the weld metal to properly join with the base metal or adjoining weld beads. How to correct: • Clean the weld joint before welding. • Remove oxides from the previous welds. • Open the groove angle. • Decrease the root face. • Increase the root opening. • Increase the amperage. • Decrease the voltage. • Decrease the travel speed. • Change the gun angle. • Decrease the electrode stickout. • Keep the arc on the leading edge of the molten pool. Overlap. Weld metal that has fl owed over the edge of the joint and improperly fused with the base metal. fl How to correct: • Clean the edge of the weld joint. • Remove oxides from the previous welds. • Reduce the size of the bead. • Increase the travel speed. Goodheart-Willcox Publisher Goodheart-Willcox Publisher Goodheart-Willcox Publisher