Rig Fab Educational Services
Welder’s Handbook
Incomplete Fusion
Cause
Prevention
Insufficient heat input
Use correct type or size of electrode; proper joint design; and proper gas shielding
Incorrect electrode position
Maintain proper electrode position
Weld metal running ahead of the arc
Reposition work; lower current; increase weld travel speed
Trapped oxides or slag on weld groove or weld face
Clean weld surface prior to welding
Effects
The presence of slag causes concentrated stress which reduces the durability and productivity of the weld metal.
Corrective Action
Place ceramic tape or approved metal backing strap on the bottom side of the hole. Weld repair the first side of the hole from the easiest side to weld Once sufficient weld metal has been deposited on the easiest top side; grind or carbon arc the other side of the hole to sound metal. Weld the other side of the hole to the appropriate size or height
Inspection & Standards
Radiography Test (RT) Incomplete fusion will be detected as a thin, dark line with sharply defined edges.
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