What are common causes of weld defects?

Improper technique and contamination are significant contributors to weld defects. When a welder does not follow the correct procedures—whether in terms of angles, speed, or heat settings—it can lead to inadequate penetration, poor fusion between the base materials, or the introduction of weaknesses in the weld joint. Additionally, contamination from oils, rust, dirt, or moisture on the surfaces to be welded can interfere with the quality of the weld. It prevents proper fusion, leading to porosity, inclusions, or lack of fusion.

In contrast, excessive polishing and buffing may not directly pertain to the welding process itself but rather to post-weld finishing. Overuse of filler material can lead to issues, but it does not address the fundamental welding techniques or the cleanliness of the materials being welded, which are key factors. Additionally, relying exclusively on advanced welding robots does not guarantee defect-free welds if the underlying process or material preparation is flawed. Therefore, understanding the impact of technique and contamination is crucial for ensuring high-quality welds.