Weld imperfections · Coating flaws · NDT radiographs — with code limits and remediation
Insufficient weld metal deposition at the root, caused by low heat input, excessive travel speed, or improper joint preparation and root gap.
Excessive welding current or travel speed melts the base metal at the weld toe without sufficient filler deposition to fill the groove.
Entrapped non-metallic flux residues from improper inter-pass cleaning, low amperage, or excessive arc length.
Trapped moisture or gas pressure under the coating film from surface contamination, inadequate surface preparation, or osmotic blistering driven by soluble salts.
UV degradation of the binder resin causing surface powdering, accelerated by over-thinning, under-curing, or prolonged sun exposure.
Air or solvent entrapment during film formation due to excessive application thickness, rapid curing, or improper spray technique.
Gas entrapment from moisture, contaminated consumables, or inadequate shielding gas flow during welding.
Insufficient heat input or improper bead placement prevents metallurgical bonding between weld passes or to the side wall.
Tungsten electrode tip fragments from excessive current, contact with the weld pool, or poor electrode grinding.
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