…And How They Happen
A quality weld is designed to create a strong, dependable connection, but when something goes wrong, weld failures can compromise the strength and safety of a structure, piece of equipment, or trailer. Understanding some of the most common failures can help you spot problems early.
Cracking
Cracks can develop from excessive stress, improper welding techniques, rapid cooling, or fatigue over time. Even a small crack can continue to grow when the welded area is subjected to repeated loads or vibration.
Porosity
Small holes or pockets can form inside a weld when gases become trapped during the welding process. Moisture, contamination, improper shielding gas, or dirty metal can all contribute to porosity and weaken the finished weld.
Lack of Fusion or Penetration
If the weld does not properly bond with the base metal—or penetrate deeply enough—the joint may not have the strength it needs. This can result from incorrect heat settings, poor technique, or improper joint preparation.
Undercutting
Undercutting occurs when a groove forms along the edge of a weld, reducing the thickness of the base metal. This can create a weak point where cracking or failure may eventually occur.
Fatigue & Wear
Even a properly completed weld can eventually develop problems when exposed to years of vibration, repeated heavy loads, impacts, or harsh operating conditions.
The key is to address welding damage early. If you notice cracking, separation, deformation, or another questionable area, have it professionally inspected before continuing to put it under stress.
At Blue Arc Metals, we provide professional welding and repair services to help identify the problem, determine the appropriate repair, and get your equipment or project back to work.