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10

Technical Services

Weld Profiles

Weld Profile Troubleshooting Guide

Problem

Example (Groove Weld)

Example (Fillet Weld)

Possible Solution

Excessive Convexity/

Reinforcement

Reduced fatigue strength

Increase arc length

Increase torch angle

Increase travel speed

Insufficient Leg Length

Reduced mechanical

properties

N/A

Change torch angle

Change torch position

1

Insufficient Throat/Underfill

Reduced mechanical

properties

Reduce cooling rate

Increase electrode feed rate

Decrease travel speed

Decrease arc length

Undercut

Reduced mechanical

properties

Change torch position

to compensate for:

Dissimilar section sizes

Dissimilar thermal conductivity

Out-of-position welds

Overlap

Severe reduction

in fatigue strength

Increase voltage

Decrease wire speed

Increase travel speed

Incomplete Penetration/

Lack of Fusion

Reduced weld strength

and increased sensitivity

to crack propagation

Increase amperage

Decrease arc length

Decrease torch forehand angle

Increase travel speed

(1) For example, the thermal conductivity of 5083 is 32% less than that of 6061 because of the higher magnesium content. This requires more heat input

into the 6061 alloy.

Base Thickness

T ≤ 3/8

3/8 < T ≤ 3/4

T > 3/4

Max Reinforcement

3/32

1/8

3/16

Width of Weld Face

≤ 5/16

>5/16 to <1

≥1

Max Convexity

1/16

1/8

3/16

Acceptable Weld Profile Criteria per AWS D1.2