Weld Sample Defect Plate (WSD-1)

Three-Dimensional Training Aid Interpretation Sheet

Flame Cut Edge, Location A1 thru A3

Semi-automatic oxy-fuel cut. Torch tip was too close to the plate. Surface finish approximately 750 micro-inches.

T-Joint, A1 thru A3
Location A1 - ½”X5/8” fillet weld leg size.
Location A2 - 3/8” fillet weld leg size.
Location A3 - ¼” fillet weld leg size.

T-Joint, B1 thru B3
Location B1 - Cluster porosity; 2 @ 1/8”, 2 @ 3/32”, 1 @ 1/16” holes in 1 linear inch.
Location B2 - Random porosity; 2 @ 3/32”, 2 @ 1/8” holes in 1 linear inch. 
Location B3 - Linear porosity; 2 @ 1/16”, 2 @ 3/32”, 1 @ 1/8”.
Note: Porosity measurements are approximate. These holes were made to resemble realistic porosity and actual measurements are left up to the instructor. 

Beads on Plate, B1 thru B3
The two welds on this side were made with 3/32” E-6010 electrodes.
Weld reinforcement = 1/32”.
Poor bead tie-in between the 6010 welds and also between the adjoining 7018 welds.

Location B1 - Poor weld termination, pinhole in weld crater, weld stopped short of the plate end and one “fingernail’ in the weld bead.
Location B2 - Two “fingernails”. 
Location B3 - One “fingernail” and an arc strike.

Beads on Plate, C1 thru C3
The two welds on this side were made with 1/8” E-7018 electrodes.
Weld reinforcement = 1/8”.
Poor bead tie-in to the 6010 passes; good bead tie-in between the 7018 passes.

Location C1 - Acceptable bead profile. 
Location C2 - Acceptable bead profile. 
Location C3 - Acceptable bead profile and an arc strike.

Lap Joint, D1 thru D4

Location D1 - SMAW weld made with a 5/32” E-7024 electrode.
Transverse cracking and severe longitudinal cracking.
Location D2 - FCAW weld made with 0.035” E71T-1 electrode, Argon gas.
“Pockmarks” with porosity. Crater crack.
Location D3 - GTAW weld with 1/16” ER 70S-6 electrode, Argon gas.
Undercut along both weld toes.
Location D4 - GMAW weld with 0.035” E70S-3 electrode, CO2 gas.
Overlap at toes of the weld.

Flame Cut Edge, E1 thru E2
Location E1 - Poor quality manual oxy-fuel cut, note gouges into the base metal.
Location E2 - Average quality manual oxy-fuel cut.