High speed fusion weld bead defects

Abstract A comprehensive survey of high speed weld bead defects is presented with strong emphasis on the formation of humping and undercutting in autogenous and non-autogenous fusion welding processes. Blowhole and overlap weld defects are also discussed. Although experimental results from previous studies are informative, they do not always reveal the physical mechanisms responsible for the formation of these high speed weld bead defects. In addition, these experimental results do not reveal the complex relationships between welding process parameters and the onset of high speed weld bead defects. Various phenomenological models of humping and undercutting have been proposed that were based on observations of events in different regions within the weld pool or the final weld bead profile. The ability of these models to predict the onset of humping or undercutting has not been satisfactorily demonstrated. Furthermore, the proposed formation mechanisms of these high speed weld bead defects are still being questioned. Recent welding techniques and processes have, however, been shown to be very effective in suppressing humping and undercutting by slowing the backward flow of molten metal in the weld pool. This backward flow of molten weld metal may be the principal physical phenomenon responsible for the formation of humping and undercutting during high speed fusion welding.