Learn to spot the difference between a quality weld and one with defects. Visual guide for MIG, TIG, Stick, and Flux-Core welders.
The weld bead maintains the same width throughout its length. This indicates steady travel speed and proper technique.
TIG welds should have uniform "stacked dimes" appearance. MIG welds should show consistent ripple patterns without gaps or bunching.
The weld should blend smoothly into the base metal at the toes (edges) without grooves, overlap, or gaps.
The weld should be slightly raised above the base metal (reinforced), but not excessively. Too flat = underfill. Too high = waste and stress.
Small holes or pits visible on the weld surface. Caused by gas contamination from wind, moisture, or shielding gas issues. Weakens the weld.
A groove melted into the base metal along the weld edges. Caused by too much heat or wrong angle. Creates stress concentration points.
Any visible crack in the weld or heat-affected zone. Critical defect - automatic failure in inspections.
Metal balls scattered around the weld. Usually indicates wrong settings (voltage/wire speed) or dirty base metal. Cosmetic issue but can indicate other problems.
Width varies throughout the weld. Caused by inconsistent travel speed or shaky hand. May still pass inspection if within tolerance.
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