Let's have a look at the flaws found in conventional welding techniques

Euro Industrial • April 22, 2019

Discontinuities/flaws are disruptions that occur in the structure of an object. They may occur in the base metal, weld material, or ‘heat affected’ parts.

There are varied types of discontinuities including:


  • Cold lap – Here, the weld filler metal improperly fuses with the base metal.
  • Porosity – Appearance of dark round or irregular spots singularly, in rows, or in groups on a radiograph. It arises due to entrapment of gas in the solidifying metal.
  • Cluster porosity – It is similar to the porosity issue. But the spots will group together very closely on a radiograph.
  • Slag inclusions – Appearance of dark, jagged asymmetrical shapes on a radiograph. It occurs due to entrapment of non-metallic solid material in weld metal or between base metal and weld.
  • Incomplete penetration/lack of penetration – It is one of the most offensive flaws where the weld fails to penetrate the joint. This incomplete penetration leads to the occurrence of cracks.
  • Incomplete fusion – Here, the weld filler improperly fuses with the base metal.
  • Internal concavity or suck back – Here, the weld metal contracts as it cools and draws up into the root of the weld.
  • Internal or root undercut – Here, the destruction of base metal occurs next to the root of the weld.
  • External or crown undercut – Here, the destruction of base metal occurs next to the crown of the weld.
  • Offset or mismatch – It occurs when two pieces to be welded together are not properly aligned.
  • Inadequate weld reinforcement – Here, the thickness of the weld metal is less than the thickness of base material.
  • Excess weld reinforcement – Here, weld metal is added excessively in an area of a weld.
  • Cracks – It appears as jagged and very faint irregular lines.


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