1. WELD DEFECTS 1. POROSITY 2. LACK OF PENETRATION 3. UNDERCUT 4. CRACKED WELDS 5. DISTORTION 6. BURN THROUGH 7. LACK OF FUSION 8. SPATTER 9. MAGNETIC / ARC BLOW 10. SLAG INCLUSION

2. POROSITY WHY ? - 1. SHORT ARC WITH INCLUSION OF HYDROGEN 2. HIGH RATE OF WELD FREEZING 3. DIRTY BASE METALS 4. IMPROPER ARC LENGTH OR CURRENT 5. POOR ELECTRODE QUALITY WHAT TO DO ? 1. CHECK IMPURITIES IN THE BASE METAL 2. PREHEAT OR INCREASE THE HEAT INPUT 3. CLEAN JOINT SURFACES 4. OBTAIN BETTER CONTROL ON WELDING PARAMETERS 5. USE PROPER ELECTRODES FOR THE JOB & BAKE THE ELECTRODES

3. LACK OF PENETRATION WHY ? - 1. TRAVEL SPEED TOO FAST 2. LESS CURRENT 3. ELECTRODE DIAMETER TOO LARGE 4. FAULTY PREPERATION 5. HIGH ARC LENGTH WHAT TO DO ? 1. UNIFORM TRAVEL SPEED WITH ENOUGH CURRENT 2. SELECT DIA. OF ELECTRODE ACCORDING TO WELDING GROOVE SIZE. 3. LEAVE PROPER FREE SPACE AT THE BOTTOM OF THE WELD

4. UNDER CUT WHY ? - 1. TOO HIGH CURRENT 2. HIGH TRAVEL SPEED 3. HIGH ARC LENGTH 4. ANGLE OF THE ELCTRODE WHAT TO DO ? 1. USE MODERATE CURRENT 2. UNIFORM TRAVEL SPEED 3. AVOID EXCESSIVE WELDING 4. HOLD ELECTRODE IN A PERFECT ANGLE

5. CRACKS WHY ? - 1. DEFECTIVE / WRONG ELECTRODES 2. HIGH CONTENT OF IMPURITIES IN BASE METAL 3. CRATER CRACKS WHAT TO DO ? 1. USE DRY AND PROPER ELECTRODES AS PER THE BASE METAL 2. PREHEAT THE BASE METAL; USE LOW HYDROGEN ELECTRODES 3. FILL IN CRATER PRIOR TO WITHDRAWING THE ELECTRODE

6. DISTORTION WHY ? - 1. UNEVEN HEATING 2. IMPROPER SEQUENCE 3. DEPOSITED METAL SHRINKS WHAT TO DO ? 1. TACK OR CLAMP PART PROPERLY 2. DISTRIBUTE WELDING TO PREVENT UNEVEN HEATING 3. DEVELOP A PROPER SEQUENCE

7. BURN THROUGH WHY ? - 1. HIGH CURRENT 2. HIGHER ELECTRODE DIA ON THIN SECTIONS 3. TOO SLOW WELDING WHAT TO DO ? 1. SET MODERATE CURRENT 2. SELECT SIZE OF ELECTRODE ACCORDING TO THE SECTIONS 3. PROPER WELDING SPEED

8. LACK OF FUSION WHY ? - 1. LESS CURRENT 2. LOWER DIA OF ELECTRODE 3. SURFACES COVERED WITH DIRT & OIL WHAT TO DO ? 1. SET MODERATE CURRENT 2. USE PROPER DIA OF ELECTRODE 3. CLEAN THE SURFACES PROPERLY

9. SPATTER WHY ? - 1. HIGH CURRENT 2. HIGH ARC LENGTH 3. WRONG POLARITY 4. WET ELECTRODES WHAT TO DO ? 1. SET MODERATE CURRENT 2. KEEP CORRECT ARC LENGTH 3. SET SPECIFIED POLARITY 4. BAKE THE ELECTRODES

10. ARC BLOW

11. SLAG INCLUSION WHY ? - 1. FALIURE TO REMOVE SLAG FROM PREVIOUS DEPOSIT 2. ENTRAPMENT OF REFRACTORY OXIDES 3. IMPROPER JOINT DESIGN WHAT TO DO ? 1. CHIP OFF SLAG COMPLETELY AFTER WELDING 2. CLEAN THE SURFACE THOROUGHLY BEFORE WELDING 3. INCREASE INCLUDED ANGLE OF “V” GROOVE