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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In March 2004, the Maryland State Highway Administration (MDOT SHA) discontinued the testing of welders at their facility and adopted a regional welder certification program in conjunction with the Federal Highway Administration's Mid-Atlantic Structural Committee for Economic Fabrication (SCEF).

Welders must certify at an AWS Accredited Test Facility (ATF), in order to perform D1.5 Bridge Welding Code work on highway projects in the Mid-Atlantic region, including the State of Maryland. Welders needing certification for bridge welding must contact an ATF center and request to be tested in accordance with D1.5 Bridge Welding. This certification will be accepted by the following States Department of Transportation (DOT): Maryland, Delaware, Virginia, West Virginia, Washington D.C. and Pennsylvania. 
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Earlbeck Gases & Technologies is Maryland's first ATF center, and can test you in accordance with the bridge welder certification requirements. 

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. The American Welding Society (AWS) has established a program to help with this requirement in some industries.

Under this program, referred to as the Accredited Test Facility (or ATF) program. This program establishes high standards for test facilities, their personnel, and equipment to qualify for accreditation to test and qualify welders. Once you successfully pass a certification test at an ATF center, you will receive a card from AWS which can be taken to any employer without having to recertify. You will be also listed in the National Registry of Welders, where potential employers can search to find certified welders in their area.

On April 27, 2009, the Earlbeck Technical Center was awarded accreditation as an AWS Accredited Test Facility. 

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. 

If you need to take a welding certification test, you might be wondering which test do I take? This is the big question. There is not a single welding certification test that will certify you to weld everything. Most welding certification tests are done under the codes written by AWS (the American Welding Society) or ASME (American Society of Mechanical Engineers.) There is a specific code written for virtually every application of welding- AWS has published 240 codes alone. Knowing which code to be certified to is essential, as welders are only certified to weld within the code parameters of the test they have taken.
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There are two common scenarios in which someone will seek certification- you would like to add to your credentials, or it is required for a specific job.

If you would like to get a certification to add to your credentials, you should seek a certification that would cover you for the type of welding you most frequently use. You will need to know what welding process (Stick, TIG or MIG), material types and thickness, and what positions you will use in production. 

One of the most common welding codes is AWS D1.1, which covers structural steel welding like I-beams, channel, or a handrail. If you test and pass on a 3/8" thick plate, using a single vee groove with backing in the vertical position, you would then be qualified to weld in the flat, horizontal and vertical positions on 1/8"-3/4" thick steel members. The test is also offered in 1" thick plate which would also cover all positions, but with no limits on the plate thickness.

If you are welding pipe that is being used to contain fluid or gas, such as a high pressure water line, then ASME Section IX is probably the way to go. If you test and pass on a 5" Schedule 80 (3/8" thick wall) steel pipe in the 6G (45 degree incline position), you will be qualified to weld 2.875" OD pipe, 3/4" wall thickness and less, in all positions.
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If neither AWS D1.1, nor ASME Section IX would cover the work you most commonly do, it is best to speak to a welding engineer or CWI to help with your selection. 

If you are seeking certification for a specific job, check the blueprints or project documents to see if a specific code is referenced and if there is not, please consult with the customer to determine which code they intend for you to use.

Once you have identified the code you will be working to, you will need to determine if you need to have a Welding Procedure Specification (WPS) written for you. All code work requires written welding procedures. A WPS is essentially the recipe for a weld. It documents the combination of variables that are to be used in production such as welding process, base material, travel speed, position, etc. Once the WPS is written, it will need to be tested to ensure that these variables are being combined to make a sound weld. The next step is to test each welder that will be welding in production using the parameters in the WPS. To go back to the recipe analogy, this is like a team of chefs being individually quizzed on their ability to follow through a recipe. 

Some codes have "pre-qualified" procedures, meaning they already have the recipe written for you, using known variables that have a long history of producing quality welds. Because of this, it bypasses the requirement for the WPS to be tested. However, it does not bypass the requirement for each welder to be individually tested following the WPS. Testing is still required for the WPS if any variables are changed from the accepted pre-qualified procedures.

If you need help selecting the applicable code and certification test, or need to have a procedure written, it is recommended to work with a welding engineer. Please give us a call for any questions you may still have, we have a team of engineers and CWI's that can assist you with any problems you face. 

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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