We've compiled a list of the most common weld discontinuities and how to correct them. A discontinuity is a flaw in the weld, but they are only considered to be weld defects when they exceed the limit allowed by the welding code. Learn more about welding codes here. Each code determines the extent of the discontinuity before it is classified as a defect and must be repaired. 

For example, if a welding code acceptance criteria allows for undercut up to 1/32" deep and the welding inspector measures undercut that is 1/16" deep, then that weld is rejectable. If the undercut measured was 1/32" or less, then the weld is acceptable. 

All defects are discontinuities, but not all discontinuities are defects. Understanding this forms the key to the proper analysis of any weld performed in accordance with the requirements of a welding code or specification. 

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Concave root surface is a groove weld exhibiting underfill at the root surface.

Possible Causes
Too Much Current
Arc Length Too Long
Root Face Too Small
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Possible Cures
Reduce Current
Maintain Proper Arc Length
Use Proper Joint Fitup ​

Overlap is extra filler metal that spreads out beyond the weld bead.

Possible Causes
Travel Speed Too Slow

Possible Cures
Use Proper Travel Speed​

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Most welding codes require that each manufacturer or contractor certify their own welders. This means a welding test taken for XYZ Company cannot be transferred to another company if you change employment.  So, if XYZ Company had you take a test to become certified for the work you were doing there, it is not at all valid under another company. You will have to start the certification process from scratch at a new employer. ​

If you did not take your test through an ATF center, or elected not to take the ATF upgrade, you will not need to submit maintenance forms. However, you still must keep an auditable record of welding activity within every 6 month period. 

Not sure if you took an ATF test? An easy way to check is if you received a wallet card from AWS . If necessary, call the center that you tested with to verify. 

Unlike the plumbing or electrical crafts, welding certification is not a "license". There is not a single welding certification test that will certify you to weld everything. In order to become a certified welder, you need to take a welding test to a specific code. This test is a practical exam that explores your ability to make sound welds. There is no written test for any commonly used code.*

In the US, most organizations accept and operate under the codes written by AWS (the American Welding Society). The first step is to identify which welding code to be certified to, as welders are only certified to weld within the code parameters of the test they have taken. For more information on how to select a welding code to test to, please visit our other blog article, What Welding Certification Do I Need?

AWS has accredited test facilities (commonly known as ATFs) throughout the US, where a welder certification test can be taken. For more information on the ATF program, as well as where to find one in your area, please visit AWS's website-AWS ATF Program. Earlbeck Gases & Technologies operates Maryland's only ATF center.

A certification test can also be administered at a test center that is not accredited by AWS, however, they do not have the ability to issue AWS certified welder ID cards and your certifications will not be listed under the national AWS certified welder registry. These certifications done by non-ATF facilities are still valid under audit, however they are not portable between employers.
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Once you have selected your testing center, call to set up an appointment. When you arrive, they will give you instructions on the fit-up required for your test. Once the piece is in position and welding begins, it must remain in that position until completed. This includes grinding. Though none of the Codes impose a time limit on the welding of a test piece, most qualification tests can be completed by a skilled welder in less than 4 hours. When completed, the weld will be visually inspected as well as bend tested. If the test passes, you will receive your certification for that code.

* No AWS or ASME code requires a written exam for welder certification. The only commonly used code that does is the Department of Denfense's military publication NAVSEA S9074-AQ-QIB-010/248 which is typically used for welding machinery on military shops.

Though you can work as a professional welder without ever becoming certified, there are quite a few reasons to become a certified welder. There is no single certification that certifies a welder for all process, metals or positions. However, even having one certification can expand opportunities for the welder.
By becoming a certified welder, you will open more career opportunities. Certified welders are in demand in a variety of industries, including construction, manufacturing, automotive, aerospace, and more. 

Many employers will hire certified welders because it is a tangible record of skill. Certification is a great way to demonstrate the welders level of training and experience while job hunting. A certified welder is also more appealing to an employer because statistics have shown that those that are certified have a lower rate of on the job incidents and injuries in comparison to non certified welders. 
Once you've acquired a job, you will be able to command a higher rate of pay. Bureau of Labor statistics indicate a certified welder can earn up to 60% more than non certified welders. You will also have better job security. When companies reduce their welding staff, they're more likely to retain a certified welder because their certification makes them harder to replace in the future. 

Most importantly, a certification may be required if it is called out in a contract or project blueprints. If this is the case, it is imperative that the welder doing the work is certified to the correct code specified. If awarded a project, make sure you have read all requirements and you are in compliance with the requirements. 
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