What effect does using inadequate filler material have on weld strength?

Using inadequate filler material directly impacts weld strength by compromising the structural integrity of the weld. When the filler material does not meet the required specifications in terms of composition, strength, or compatibility with the base materials, it can lead to various problems such as incomplete fusion, porosity, or excessive dilution. These issues degrade the mechanical properties of the weld, making it more susceptible to failure under load.

Inadequate filler material may fail to create a strong bond between the joined materials, which is crucial for the weld to perform as intended. For instance, weak filler can lead to cracks or fractures, especially in high-stress applications, ultimately reducing the overall reliability and safety of the welded structure. Understanding the role of filler material is essential for ensuring that the weld can withstand the intended service conditions and loads.