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Flaw which compromises a weld's structural integrity
metalworking, a welding defect is any flaw that compromises the usefulness of a weldment. There are many different types of welding defects, which are classified
Welding_defect
Quality control process in welding
catastrophic failure. The practice of welding inspection involves evaluating the welding process and the resulting weld joint to ensure compliance with established
Welding_inspection
Vitreous material produced as a byproduct of some arc welding processes
Welding slag is a form of slag, or vitreous material produced as a byproduct of some arc welding processes, most specifically shielded metal arc welding
Slag_(welding)
Welding metal at elevated pressure
Hyperbaric welding is the process of extreme welding at elevated pressures, normally underwater. Hyperbaric welding can either take place wet in the water
Hyperbaric_welding
Fabrication process for joining materials
methods include solvent welding (of thermoplastics) using chemicals to melt materials being bonded without heat, and solid-state welding processes which bond
Welding
Submarine builder for U.S. Navy
support for shipyard infrastructure. In the early 1980s, structural welding defects had been covered up by falsified inspection records, and this led to
General Dynamics Electric Boat
General_Dynamics_Electric_Boat
Welding of semi-finished plastic materials
Plastic welding is welding for semi-finished plastic materials, and is described in ISO 472 as a process of uniting softened surfaces of materials, generally
Plastic_welding
Irregularity in a metal casting process
gas porosity, shrinkage defects, mould material defects, pouring metal defects, and metallurgical defects. The terms "defect" and "discontinuity" refer
Casting_defect
welding, undercutting is when the weld reduces the cross-sectional thickness of the base metal. This type of defect reduces the strength of the weld and
Undercut_(welding)
Spinning a tool to mix metal workpieces together at the joint, without melting them
accommodate the extensive deformation during welding. This may result in long, tunnel-like defects running along the weld, which may occur on the surface or subsurface
Friction_stir_welding
Industrial welding process
Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) and metal active gas (MAG) is a welding process in which an
Gas_metal_arc_welding
Dissimilar friction stir welding (DFSW) is the application of friction stir welding (FSW), invented in The Welding Institute (TWI) in 1991, to join different
Dissimilar friction stir welding
Dissimilar_friction_stir_welding
Welding process
tungsten arc welding (GTAW, also known as tungsten inert gas welding or TIG, and heliarc welding when helium is used) is an arc welding process that uses
Gas_tungsten_arc_welding
Hot-gas welding is a manual plastic welding process for joining thermoplastic materials. A hot-gas torch is used to direct hot air to both the joint surface
Hot_gas_welding
(stick welding) processes, or fabrication of weld joints which primarily involves GMAW (MIG welding). Welding defect Industrial radiography Robot welding Pipeline
Weld_quality_assurance
Pattern-recognition performance metrics
Tripicchio, Paolo; Camacho-Gonzalez, Gerardo; D'Avella, Salvatore (2020). "Welding defect detection: coping with artifacts in the production line". The International
Precision_and_recall
Semi-automatic or automatic arc welding process
Flux-cored arc welding (FCAW or FCA) is a semi-automatic or automatic arc welding process. FCAW requires a continuously-fed consumable tubular electrode
Flux-cored_arc_welding
Type of analysis technique
in the weld causing it to fail. The typical welding defects (lack of fusion of the weld to the base metal, cracks or porosity inside the weld, and variations
Nondestructive_testing
Manual arc welding process
Shielded metal arc welding (SMAW), also known as manual metal arc welding (MMA or MMAW), flux shielded arc welding or informally as stick welding, is a manual
Shielded_metal_arc_welding
Pyrotechnic composition of metal powder and metal oxide
his process. Today, thermite is used mainly for thermite welding, particularly for welding together railway tracks. Thermites have also been used in
Thermite
Small defects from welding propagate into failures after repeated loading
form an assembly. During welding, joints are formed between two or more separate pieces of material which can introduce defects or residual stresses. Under
Fatigue_of_welded_joints
Toronto streetcar model operated by the TTC
order to correct a welding defect. The work is needed to allow the streetcars to last 30 years, their contractual service life. Some welds were not properly
Flexity_Outlook_(Toronto)
Disciplines into which the field of engineering is conventionally divided
materials Fusion welding – arc welding, laser welding, electron beam welding Solid-state welding – friction welding, friction stir welding, diffusion bonding
List_of_engineering_branches
British Standard in metallurgy
is a British Standard code of practice for the assessment of flaws (weld defects in particular) using fracture mechanics principles. The technique is
BS_7910
Testing method for plastic welds
applications. K. Kim et al. studied its ability to identify weld defects in laser welding polycarbonate to acrylonitrile butadiene styrene copolymer.
Plastic weld non-destructive examination
Plastic_weld_non-destructive_examination
designer will be able to predict where such defects can be found by examining the tool or product. Weld lines are not found in other manufacturing methods
Weld_line
Non-destructive inspection method
detection capability. LPI is used to detect casting, forging and welding surface defects such as hairline cracks, surface porosity, leaks in new products
Dye_penetrant_inspection
Incident at Gröna Lund in Stockholm
from a subcontractor that lacked certification, was manufactured with weld defects reducing its strength. When the accident occurred, forces during ride
2023 Jetline roller coaster accident
2023_Jetline_roller_coaster_accident
Welding by passing electric current through work pieces
Electric resistance welding (ERW) is a welding process in which metal parts in contact are permanently joined by heating them with an electric current
Electric_resistance_welding
Controlled process of reheating materials
that occur after welding has been completed. During the welding process, a high temperature gradient is experienced between the weld metal and the parent
Post_weld_heat_treatment
Properties of steel and cast iron
commonly this concept is used in welding, but it is also used when heat treating and casting cast iron. In welding, equivalent carbon content (C.E) is
Equivalent_carbon_content
Aluminium alloy with copper
resistance. It is weldable only through friction welding because of the likelihood of solidification defects that may arise during fusion welding. Due to poor
2024_aluminium_alloy
Welding using heat from X-ray
X-ray welding is an experimental welding process that uses a high powered X-ray source to provide thermal energy required to weld materials. The phrase
X-ray_welding
Russian carrier rocket model used from 1967 to 2012
1965 GTO no Maiden flight of Briz-M upper stage. Contaminants from welding defect in the turbopump caused the second-stage engine No. 3 to catch fire
Proton-K
Chemical compound
oxide is used as an addition to tungsten electrodes for Gas Tungsten Arc Welding. It provides advantages over pure Tungsten electrodes such as reducing
Cerium(IV)_oxide
Vessel for pressurised gases or liquids
"Beyond the Weld: Quality Assurance in Pressure Vessel Welding". Red-D-Arc. 20 February 2024. Retrieved 28 July 2025. "Types of Welding Used in Pressure
Pressure_vessel
Winding technology for electric motors
condition. Relative height and lateral offset of the hairpin end can cause welding defects. These can be prevented by corrective processes that are dependent
Hairpin_technology
Materials testing procedure
depth combined with dimension and orientation of defect/crack/inhomogeneity in material. Laser welding of plastics is a progressive technology of connecting
Active_thermography
Device that removes dissolved gases from liquids
assist deaerating water. Welding of the steel pressure vessels during the manufacturing process sometimes requires Post weld heat treatment, XRAY, Dye
Deaerator
the welds made on these materials are important in ensuring people receive safe products. There are not codes made specifically for the welding of advanced
Testing of advanced thermoplastic composite welds
Testing_of_advanced_thermoplastic_composite_welds
Method of inspection using remotely operated tools
method of girth weld scanning is designed to detect the following weld defects: Planar defects (e.g., lack of fusion, cracks) Volumetric defects (e.g., porosity
Robotic non-destructive testing
Robotic_non-destructive_testing
Class of New York City Subway car
at their plant in Lapa, Brazil, near São Paulo, after discovering welding defects. The first 5-car set of R160As (8653–8657) was delivered on November
R160 (New York City Subway car)
R160_(New_York_City_Subway_car)
American manufacturer of trailer axles, brakes and related components
Administration (NHTSA), including recalls citing issues such as potential weld defects or assembly errors affecting axle or wheel-end integrity. "About". Dexter
Dexter_Axle
Metal-joining technique
pieces together. Brazing differs from welding in that it does not involve melting the work pieces. In welding, the original metal pieces can be fused
Brazing
over traditional methods of weld quality assurance, which can be arbitrary or overly conservative. During welding, defects or flaws can develop. In some
Engineering Critical Assessment
Engineering_Critical_Assessment
Metalworking techniques used by underwater divers
salvage and clearance diving applications. Most underwater welding is direct current wet stick welding, and most underwater metal cutting is immersed oxygen-arc
Underwater cutting and welding
Underwater_cutting_and_welding
Thermal welding technique for joining thermoplastics
Hot plate welding, also called heated tool welding, is a thermal welding technique for joining thermoplastics. A heated tool is placed against or near
Hot_plate_welding
Express train running between Stockholm and Arlanda airport
was travelling at 178 km/h when a welding joint in the movable crossing of a switch ruptured due to welding defects and fatigue cracks. The second to
Arlanda_Express
One of the four Mogami class cruisers
plagued with technical problems due to their untested equipment and welding defects, and also proved to be top-heavy with stability problems in heavy weather
Japanese_cruiser_Kumano
Streetcar network in Ontario, Canada, since 1861
Ben (July 3, 2018). "Most new TTC streetcars to be recalled to fix welding defect, Bombardier says". Toronto Star. Retrieved July 4, 2018. Munro, Steve
Toronto_streetcar_system
2016 Android phablet developed by Samsung Electronics
Samsung stated that these batteries had suffered from a manufacturing defect in the welding process, which pushed electrodes up and caused damage to the separation
Samsung_Galaxy_Note_7
Spinning one metal workpiece against another to join them
friction welding (RFW) is a type of friction welding, which uses friction to heat two surfaces and create a non-separable weld. For rotary friction welding, this
Rotary_friction_welding
Lead ship of the Mogami-class of cruisers
were plagued with technical problems due to untested equipment and welding defects and also proved to be top-heavy with stability problems in heavy weather
Japanese cruiser Mogami (1934)
Japanese_cruiser_Mogami_(1934)
Rail infrastructure
thermite welding after 1899, the process became less labour-intensive and ubiquitous. (1895) Hans Goldschmidt developed exothermic welding (1899) the
Railway_track
UK based structural steel contractor
"New A1 bridge found to have defects". BBC News. Retrieved 13 March 2025. Morby, Aaron (27 November 2024). "Severfield welding crisis hits five National
Severfield
Removing contaminants from vicinity of welding joint
vapours that might oxidize or contaminate a welding joint as it is being welded and immediately after welding. Stainless steels, duplex steels, titanium-
Weld_purging
Ben (July 3, 2018). "Most new TTC streetcars to be recalled to fix welding defect, Bombardier says". Toronto Star. Retrieved July 4, 2018. Spurr, Ben
Toronto streetcar system rolling stock
Toronto_streetcar_system_rolling_stock
Offline nuclear power plant located in Somerset, England
station's reactors were shut down in order to inspect the boilers for weld defects that had been found in power stations using similar boiler designs. Due
Hinkley Point B nuclear power station
Hinkley_Point_B_nuclear_power_station
Third ship in the Mogami class of Japanese heavy cruisers
were plagued with technical problems due to their untested equipment, welding defects, and also proved to be top-heavy with stability problems in heavy weather
Japanese cruiser Suzuya (1934)
Japanese_cruiser_Suzuya_(1934)
Practice in pipeline transportation
accomplish the service. Surface pitting and corrosion, as well as cracks and weld defects in steel/ferrous pipelines are often detected using MFL pigs. Other "smart"
Pigging
Indian academic
welding of aluminium alloys, magnesium alloys, and dissimilar materials. His work on tunneling and kissing bond defects during friction stir welding was
Arshad_Noor_Siddiquee
Alloy steel
HY-80 is welded with an AWS ER100S-1 welding wire. The ER100S-1 has a lower Carbon and Nickel content to assist in the dilutive effect during welding discussed
HY-80
Non-destructive material testing using ultrasonic waves
are converted into electrical signals which indicate the presence of the defect." To characterize microstructural features in the early stages of fatigue
Ultrasonic_testing
US Navy Nimitz-class aircraft carrier
NNSY for a docked PIA. The ship received many system upgrades. Minor weld defects in the reactor plants were repaired. She left the yard in December and
USS_Harry_S._Truman
cracking that initiated at the edge of the longitudinal seam weld at a likely preexisting weld defect. Contributing to the failure was the loss of pipe coating
List of pipeline accidents in the United States in the 2000s
List_of_pipeline_accidents_in_the_United_States_in_the_2000s
Manufacturing process
often performed by examining defective parts for specific defects and addressing these defects with the design of the mould or the characteristics of the
Injection_moulding
Steel-arch bridge between West Memphis, Arkansas, and Memphis, Tennessee, US
years, the recent inspection efforts to identify welding defects at the tie girder thickness transition welds, and no evidence of observed fatigue crack growth
Hernando_de_Soto_Bridge
Australian underwater naval vessel
of Collins' bow and escape tower sections in Sweden, multiple defects in the hull welding were discovered. Different reasons were given by different parties
Collins-class_submarine
International standard for automotive management systems
goal of the standard is to provide for continual improvement, emphasizing defect prevention and the reduction of variation and waste in the automotive industry
IATF_16949
Solid-state welding technique
Diffusion bonding or diffusion welding is a solid-state welding technique used in metalworking, capable of joining similar and dissimilar metals. It operates
Diffusion_bonding
2005–2009 sculpture by Thomas Heatherwick
metallurgical analysis, to discover the stresses being placed on the steel. Weld defects were identified within the sculpture, which cracked when wind blew through
B_of_the_Bang
Type of non-destructive testing
in special techniques where known defects are best revealed by a different alignment of the beam. The length of weld under examination for each exposure
Industrial_radiography
Welding technique
Friction stud welding is a solid phase welding technique involving a stud or appurtenance being rotated at high speed while being forced against a substrate
Friction_stud_welding
Edge of a structure that is not perpendicular to the faces of the piece
of defects between manufacturing steps. Beveling and chamfering (along with other profiles) are applied to thicker pieces of metal prior to welding, see
Bevel
Steel-related engineering problem
Hydrogen safety TWI – The Welding Institute. "What is high temperature hydrogen attack (HTHA) / hot hydrogen attack?". TWI – The Welding Institute. Retrieved
High-temperature hydrogen attack
High-temperature_hydrogen_attack
1993 Collins-class submarine
section of the first boat was being assembled in Sweden, multiple defects in the hull welding were discovered. Different reasons were given by different parties
HMAS_Collins
powder bed fusion and directed energy deposition; FLOW-3D WELD, a simulation tool for laser welding processes including keyhole dynamics and melt pool behavior;
Flow_Science,_Inc.
American journalist
Times. Willman, David (July 3, 1996). "Experts' Tests Uncover Coliseum Weld Defects". Los Angeles Times. Willman, David (March 12, 1994). "Original Firms
David_Willman
Goods intended to be used up
process. For arc welding one uses a consumable electrode. This is an electrode that conducts electricity to the arc but also melts into the weld as a filler
Consumables
Ability of a structure to support a designed structural load without breaking
World War II, over 200 welded-steel ships broke in half due to brittle fracture, caused by stresses created from the welding process, temperature changes
Structural integrity and failure
Structural_integrity_and_failure
American metallurgist (1951–2009)
Stir Welding to Repair Weld Defects and to Help Avoid Weld Defects in Intersecting Welds", US Patent 6,230,957, May 15, 2001 "Friction Stir Welding as a
William_Arbegast
Process that helps an equipment operator avoid mistakes
mechanism in a process that helps an equipment operator avoid mistakes and defects by preventing, correcting, or drawing attention to human errors as they
Poka-yoke
Prevention of railway accidents by examining rail tracks for flaws
expand, or initiate corrosion. Parts of a rail where defects can be found: head web foot switchblades welds bolt holes A majority of the flaws found in rails
Rail_inspection
Bridges in Manhattan, New York
it was announced that the bridge's completion was delayed due to a weld defect, and would not be completed before spring 2019. In May 2019, the first
West Street pedestrian bridges
West_Street_pedestrian_bridges
Metal degradation processes
generally of weldments. Hydrogen enters the metal during fusion-welding and produces this defect during subsequent stressing. Steel containment vessels exposed
Hydrogen_damage
commissioned by the American Welding Society Welding Fume Product Liability — Viewpoint of plaintiffs on welding rod litigation Welding Rod Litigation Information
Manganese_poisoning
Type of geomembrane
particularly for cold climates. While torch welding is the most common practice, electrically powered hot-air-welding is an established alternative for applications
Bituminous_geomembrane
Topics referred to by the same term
is inaccessible using a straight tool Undercut (welding), a defect that reduces the strength of a weld Undercut (novel), a Peter Niesewand novel Undercut
Undercut
Bridge in Ohio and Chester, West Virginia
discovered cracking in two welds on the steel bridge structure. In the end, 20 defects were found in the T-1 steel welds used to build the bridge. The
Jennings_Randolph_Bridge
system upgrades, and underwent preventative maintenance to repair minor weld defects originating from the initial construction of the reactor plants. On 4
Carrier Strike Group Ten 2004–09 operations
Carrier_Strike_Group_Ten_2004–09_operations
Non-destructive testing method
beam angle and focal distance, this method is very efficient regarding the defect detection and speed of testing. Apart from detecting flaws in components
Phased_array_ultrasonics
about the many types of welding equipment and techniques that exist today. A spectrum of capabilities exists between welders and weld inspectors. Practicing
List of metalworking occupations
List_of_metalworking_occupations
Resistance welding — Resistance welding equipment — Mechanical and electrical requirements ISO/R 670:1968 Straight resistance spot welding electrodes
List_of_ISO_standards_1–1999
lifecycles. Industrial robots are widely used in automated welding which includes arc, spot and laser welding. Due to their repeatability and precision. Robots
Intelligent manufacturing systems
Intelligent_manufacturing_systems
3D printing technique
formation and thermal fluid flow-induced porosity during laser fusion welding in titanium alloys: Experimental and modelling". Acta Materialia. 126:
Selective_laser_melting
"Ruptured Yellowstone Oil Pipeline Was Built With Faulty Welding in 1950s Poor safety, defects may have added risks to pipeline that spilled up to 40,000
Low-frequency electric resistance weld
Low-frequency_electric_resistance_weld
Quickly heats semiconductor wafers to high temperatures
situ pyrometry to effect real time control. Used for melting iron for welding purposes. Rapid thermal anneal (RTA) in rapid thermal processing is a process
Rapid_thermal_processing
Welding process
fusion welding techniques. The bonding process produces joints with a uniform composition profile, tolerant of surface oxides and geometrical defects. The
Transient liquid phase diffusion bonding
Transient_liquid_phase_diffusion_bonding
a sensitive and accurate method for the nondestructive testing of welds for defects. TOFD originated from tip diffraction techniques which were first
Time-of-flight diffraction ultrasonics
Time-of-flight_diffraction_ultrasonics
Process of joining metal pieces with heated filler metal
Standard Welding Terms and Definitions Including Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutting, and Thermal Spraying, American Welding Society
Soldering
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