Overview of Weld Defects

Provided by: ToolingU

“Overview of Weld Defects” provides a comprehensive introduction to the most common varieties of weld discontinuities and distortion. It illustrates the causes of each of the twenty different weld discontinuities and defects and suggests effective solutions. In addition, it presents an overview of six different kinds of cracks and demonstrates how to prevent cracking and distortion in a finished weld. This class is especially crucial for beginning welders who do not yet have the skills or knowledge to avoid many of the mistakes that the class illustrates. Beginning welders will find this class particularly useful because it defines the reasons why defects or discontinuities may occur as well as the ways in which welders may rectify them.

Course Objectives:

  • Distinguish between defects and discontinuities
  • Describe misalignment, undercut, and overlap
  • Describe excessive spatter and arc strikes
  • Describe slag inclusion, tungsten inclusion, and porosity
  • Describe incomplete fusion, incomplete joint penetration, excessive reinforcement, and improper leg size
  • Describe non-uniformity, gas marks, craters, and burnthrough
  • Describe weld distortion
  • Explain how to minimize distortion and shrinkage
  • Describe backstep welding
  • Contrast longitudinal and transverse cracking
  • Identify less common types of weld cracks
  • Describe visual weld inspection
  • Describe destructive weld testing
  • Describe nondestructive weld testing
  • Explain the importance of detecting discontinuities and defects.

Recommended Background

  • Recommended for manufacturing personnel, including engineers, technicians and managers, particularly handling welding operations.

Course ID







Communication, Critical Thinking, Personal Effectiveness, Welding, Avoiding Mistakes, Safety

Method of Delivery


Estimated Effort

2.5 hrs



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