Common welding defects are a frequent concern across many of Malaysia’s industrial sectors, from construction and oil and gas to automotive and shipbuilding.
Even with skilled workmanship, flaws in the welding process can occur, leading to structural weaknesses, costly repairs, or unexpected project delays.
Understanding the causes and prevention of these defects is essential to ensuring safety, durability, and quality.
What Are Welding Defects?
Welding defects refer to any irregularity or imperfection that compromises the strength, function, or appearance of a weld. These defects may be visible on the surface or hidden inside the weld and can significantly affect structural integrity.
In Malaysia’s high-risk environments, such as the infrastructure and energy sectors, minimising welding defects is critical to operational safety and efficiency.
Read More: Essential Training Programmes for Engineers in Malaysia: What XPERT Offers
Common Welding Defects in Malaysia
1. Porosity
Porosity refers to small holes or cavities in the weld caused by trapped gas. It’s among the most common welding defects found in Malaysian workshops and construction sites, often due to contamination or insufficient shielding during welding.
Causes:
- Contaminated base material
- Moisture in consumables
- Inadequate shielding gas
Prevention:
- Clean all work surfaces before welding
- Store electrodes and flux in dry conditions
- Use proper shielding gas and monitor gas flow
2. Cracks
Cracks are serious defects that can occur during or after welding and may result in complete weld failure if undetected.
Causes:
- Excessive stress during welding
- Improper joint design
- Rapid cooling of the weld
Prevention:
- Preheat thicker sections before welding
- Allow controlled cooling
- Apply suitable welding techniques and materials
3. Incomplete Fusion
Incomplete fusion occurs when the weld metal fails to fully bond with the base metal or prior weld passes. It compromises weld strength and is often flagged during quality checks.
Causes:
- Low heat input
- Dirty surfaces
- Incorrect electrode angle
Prevention:
- Increase welding current if required
- Clean surfaces thoroughly
- Adjust technique for full fusion
4. Undercut
An undercut is a groove left unfilled at the weld toe, weakening the joint and potentially leading to cracking.
Causes:
- High welding current
- Fast travel speed
- Poor manipulation of the torch or electrode
Prevention:
- Optimise current and travel speed
- Use weaving techniques to ensure complete filling
- Maintain steady hand movement
5. Slag Inclusions
Slag inclusions are non-metallic particles trapped inside the weld, often resulting from improper cleaning between passes or poor technique.
Causes:
- Failure to remove slag between passes
- Inadequate welding angles
- Low amperage
Prevention:
- Clean each weld layer thoroughly
- Use correct angles and techniques
- Ensure proper heat input
Read More: How Ferrite Testing Benefits Your Business in Malaysia
Ensure Welding Quality with XPERT Malaysia
By recognising and addressing common welding defects, Malaysia’s industrial players can ensure safer, more durable structures and reduce costly rework.
Whether you’re overseeing large-scale industrial projects or handling day-to-day fabrication tasks, investing in proper training, equipment, and inspection processes makes all the difference.
Don’t let avoidable defects compromise your work—prioritise quality at every stage of the welding process. For expert advice, inspections, or welding solutions, reach out to us today.
