Weld Failure Analysis

Welding is a metal joining process that is used in all industries and all manufacturing equipment. Weld failure analysis labs perform investigations to identify the root cause when a welded assembly fails or fractures during service. Welding is an essential process to repair equipment and assemble everything from train cars to automobiles to skyscrapers.

When a weld joint fractures or is near a fracture the possibility of the weld contributing to the failure is high. Many weld designs create stress concentrations where the stresses from service are focused to the weld joint. Any weld imperfections can initiate a crack that can propagate into a fracture. Non-destructive testing such as radiography, magnetic particle inspection or liquid penetrant inspection are typically used to identify discontinuities that cause stress concentrations within weld joints. A weld failure analysis laboratory can help identify the root cause of a fractured weld joint.

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Weld Joint Defects

Insufficient Weld Penetration
Insufficient Weld Fusion
Poor Weld Leg Fit Up
Cracking
Weld Toe Undercut
Excessive Porosity
High Heat Affected Zone Hardness (HAZ)
Weld Repairs

Weld defects are common. Weld procedure qualifications and welder certifications in accordance with the American Welding Society (AWS) are used to maintain the quality of weld joints. Our laboratory performs AWS weld testing for many different industries. The ASME Boiler and Pressure Vessel Code is another association that is used to maintain weld quality in the manufacturing, construction and operation of boilers and pressure vessels. Our Laboratory performs ASME Section IX weld testing to prevent pressure vessel weld failures.

Weld repairs are another source of weld fractures. Our experience at ASAP Metal Testing with fractures initiating from weld repairs are that the repairs are not documented. Many times maintenance departments attempt to “help” get a piece of production equipment back into service by using a weld repair, but without a qualified welding procedure. Many times the component is submitted to our weld failure analysis laboratory without any history that repair welding was performed. The weld repair may have “looked” acceptable but without non-destructive testing the sub-surface quality cannot be confirmed. Call ASAP Metal Testing to help identify the cause of your welding failure.