Welding defects and failures can be a source of significant financial losses and inconveniences. In simple terms, if a weld fails, you will need to plan for repairs. The restoration process will require special equipment, materials and expertise. In addition, when a welded joint breaks, the fabricated metal can be rendered unusable for a period until the repairs are complete. Therefore, if you are preparing for welding work, it is important to ensure that the process is carried out correctly. Here are simple precautions to help you minimise the risk of weld failures.

1. Clean the Base Material

One of the common causes of weak welds is the inadequate preparation of the materials. In general, if the metal to be welded is dirty and contaminated, the joining procedure will not be consistent or smooth. In addition, the contaminants will increase the risk of the weld deteriorating prematurely. These problems can be attributed to the uneven heating of the material. If there are foreign materials like rust and dirt, the melting point of the metal will change. Therefore, it is advisable to ensure that the base material is cleaned thoroughly before welding begins.

2. Choose the Right Filler Metal

The choice of filler material has a significant impact on the quality of the weld. If you choose a filler material which is incompatible with your base material, the weld is bound to have defects, and it will fail with time. When choosing your filler material, it is important to evaluate the tensile strength of the base. The tensile strength of the two metals should be as similar as possible for a seamless and strong weld. In some case, you might want to join two materials with different levels of strength. If this is your case, your filler material should be matched to the weaker metal. This choice will ensure increased flexibility of the weld. Consequently, the risk of cracking will be mitigated.

3. Preheat the Materials

Welding requires preheating of the base material before beginning the actual joining of the joint. If you do not preheat the base metal, the cooling process of the weld will be compromised. Simply speaking, when the filler material melts and fills the joint, there will be quick cooling due to the lower temperature of the base metal. As a result, the weld will not be stable. There will be a high risk of cracking. Therefore, it is important to preheat the area to be welded before starting. The right preheating procedure will depend on your welding method. 

For more information on welding repairs, contact your local welding shop today.