Weld Defect Atlas – 18 Defects, Cross Sections, Causes, Fixes (Digital Download)

Eighteen weld defects, drawn so you can actually tell them apart.

Every defect gets both views: a cross-section showing what is happening inside the joint, and a bead view showing what it looks like on the surface. Concealed features are drawn dashed, so you can see what the face is hiding. Each one carries its likely causes and the corrective check to run.

WHAT IS COVERED
Porosity - wormholes and elongated pores - undercut - overlap and cold lap - lack of sidewall fusion - lack of inter-run fusion - incomplete root penetration - slag inclusions - burn-through - weld-metal cracks - HAZ and toe cracks - crater cracks and crater pipe - underfill - excessive face reinforcement - excessive root penetration - root concavity and suck-back - excessive spatter - arc strikes.

Original vector artwork drawn for this sheet. Not clip art, not photographs. Base metal, weld metal, heat-affected zone and the feature itself are each color-coded so the geometry reads at a glance from across the shop.

WHAT YOU GET - four files
- 8.5 x 11 PDF - all eighteen on one page, for a sheet protector, binder or toolbox door
- 18 x 24 PDF poster - for the wall above the bench
- 24 x 36 PDF poster - for a shop or classroom wall
- 20-page letter field guide - every defect expanded, with references and fuller notes

Print at home, at a print shop, or at any office supply counter.

Instant download. No physical item is shipped.

READ THE FEATURE. VERIFY THE CAUSE. APPLY THE WPS.

Drawn by a working metal fabricator. Schematic geometry, colors and feature sizes are exaggerated for teaching. An imperfection becomes a defect only when it exceeds the applicable acceptance criteria - no universal acceptance limits are implied here, and surface appearance cannot rule out internal flaws. This is a learning and identification aid, not an inspection standard.

Want the whole set? Every chart in the shop is available as one bundle at a steep discount - see the shop.

Free welding calculators and reference guides at testtalkhq.com