What Causes A Weld To Crack?-Let’s Get An Idea

Weld cracks are serious faults that typically need to be repaired or reworked. When a fracture appears, the strength of a welded junction is drastically reduced, necessitating repair in most cases.

Have you ever considered the question, “What causes a weld to crack?” Although there are many reasons for weld cracking, improper welding practices before, after, and even during the welding process are the most common culprits.

Weld cracks are concerning, but there are numerous ways to avoid them. If you comprehend how they develop and take the appropriate precautions prior to, during, and occasionally after welding, you may drastically lower weld cracking. Let’s come down and be more specific.

What Causes A Weld To Crack?

Numerous issues, including pollution and quick cooling, can lead to cracking. However, the internal strains outweigh either your base metal, your weld, or both in virtually all instances, which leads to cracking.

The base metal and weld start to shrink as they cool after welding. Internal pressures result from this. It won’t be able to keep itself together and would start to crack if you somehow made your base material or weld-less strong than the strains.

“Weld cracking in steel is frequently brought on by improper workpiece preparation, incorrect welder settings, poor part fitment, and polluted filler materials.” Fortunately, there is some good news. 

The majority of these problems can be remedied by simply being more cautious when welding. For instance, hydrogen can damage the metal material in the HAZ or heat-affected zone.

Further, factors such as poor weld geometry, insufficient material ductility, stress concentration, inappropriate heat treatment, or others can push base metal or welds over their natural limits.

The connection may become weaker due to residual stress, and the load applied may end up being the straw that cuts the camel’s back or, in the scenario of welding, creates a tear. Internal residual stresses exist in the HAZ and weld joint.

The metal expands and contracts during the weld, causing them to form. The weld metal expands when heated to the melting point, as does the joint’s surface—however, the metal contracts as it begins to cool.

As a result, the joint has residual internal stress as the weld metal “drags” on the surrounding metal material in the HAZ. However, a joint is subject to other forces in addition to residual stress. Loads will be applied to the welded member during regular use.

What Causes A Weld To Crack Down The Middle?

Segregation-induced, surface profile-induced, or bead-shape-induced cracking are all causes of centerline cracking. Sadly, all three phenomena manifest in the same kind of crack, making it challenging to pinpoint the origin.

Experience has also revealed that interactions between two or perhaps all three occurrences frequently worsen the cracking issue. To know more information regarding “what causes a weld to crack,” keep reading this blog post.

Types Of Cracks In Welding

After welding, cracks don’t usually appear immediately, and some types of cracks can not be seen from the weld surface. Weld cracks are divided into two categories in order to facilitate comprehension of the numerous weld crack causes;

  • Hot Weld Cracks
  • Cold Weld Cracks

Hot Weld Cracks

When weld metal is torn along partially welded grain boundaries of incompletely formed welds, hot cracks are the result. Although they don’t always happen in perfect symmetry in the middle of the weld line, these cracks are typically longitudinal.

There are various other hot cracking layouts as well. If your weld is going to hot crack, you are not required to wait. Hot cracking in welding may occur when temperatures exceed 1000°F during or right after welding.

The molten and fragile grain boundaries shatter as the weld metal freezes and shrinks. The main contributors to hot cracking are high levels of stress and low melting points of components in the liquid metal.

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Further, sulfur, quick chilling of the weld puddle, and sudden drop of the welded material are also primary contributors. When one or more of these elements come into play, poor grain boundaries result from the low melting elements being rejected into the weld’s center.

In addition, the filler material cools, and it wants to shrink, which causes tension that readily fractures the partially welded grain boundaries. Longitudinal cracks, crater cracks, and lamellar tears are the most typical types of hot cracks.

  • Hot cracking is most frequently related to “longitudinal cracks .”These cracks extend the entire width of the weld and appear during or right after welding. Longitudinal fractures are particularly prone to occur in welds with extreme concavity. However, the second most likely options are steels with high sulfur and low manganese contents and metals with phosphorus and high carbon contents.
  • The base of the weld is where “crater cracks” most frequently develop, but they can swiftly extend across the full weld’s entire length to produce longitudinal fractures. Improper weld metal quantity, along with the other causes of hot cracks we previously mentioned, is the most frequent cause of crater cracks.
  • “Lamellar tears” develop in the parent substance below the welded joint. The parallel fusion border between the workpiece and the weld metal, the high sulfur content in metal, low starting metal ductility, and transverse shrinkage stresses are all common causes of it. Additionally, only rolled metal bars can experience lamellar ripping. To withstand lamellar tearing, the steel must have an “STRA” value higher than 20%. This indicates that the steel contains little sulfur.

Cold Weld Crack 

Due to the delay in the development of the cracks, cold cracking is much trickier than hot cracking. Cold cracks can emerge in several minutes, days, weeks, or even hours. Cold cracks may not appear until a particular load is placed on the welded piece.

Cold fractures also develop inside the HAZ and the weld rather than on the surface. Since they may be difficult to perceive, a non-destructive method (radiographic testing) is required to find these cracks.

However, these x-ray examinations are often carried out many weeks after welding since cooler fissures take a long time to form. Although there are additional physical weld testing techniques, x-rays are the most frequently used.

Hydrogen reacts in the metal of the weld and disperses into the HAZ, causing cold cracks to emerge. The heat from the arc splits the molecule of stable hydrogen into two single or unstable hydrogen atoms (H).

The unstable atoms are pushed toward HAZ grain boundaries as the welded joint cools. These lone hydrogen atoms gradually pass through the HAZ and eventually reform as sturdy molecular hydrogen links.

Cold cracks develop when too many atoms or molecules cluster of hydrogen in one area. Cold cracking is also known as hydrogen cracking or delayed cracking since it requires a while for hydrogen molecules to develop and cause cracks.

Elevated steels are particularly vulnerable to hydrogen, so extra care must be taken to avoid it in the joint. But hydrogen by itself doesn’t lead to fractures. Stress is once more to a fault. Simply put, the hydrogen renders the metal more brittle and prone to fracture.

Thus, a microstructure susceptible to hydrogen and the amount of hydrogen are necessary conditions for cold cracking. Oil, grease, filth, rust, enamel, coatings, cleaning agents, filler material, and electrodes are the most typical sources of hydrogen. Root, transverse, toe, and fusion-line cracks are frequently produced by cold cracking.

  • Due to steel’s hydrogen embrittlement, “under bead or root cracks” can also occur, often relying on the joint geometry. For this reason, cold cracking is also known as under-bead cracking.
  • High-strength steels frequently develop “transverse cracks.” Low magnification can even be used to observe these fissures. Therefore, an x-ray examination might not be required.
  • “Fusion-line cracks” do not occur as frequently as the three cracks mentioned above, but when they do, they directly correspond to the fusion zone of the weld.
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Can You Weld Over A Cracked Weld?

The most typical form of repair is to fuse a filler metal by welding compatible with the base material over the damaged area. The tension that led to the crack must be relieved by heating the repaired joint. In some circumstances, the complete weld portion might need to be replaced.

By employing the proper welding techniques, developing the joint appropriately, and avoiding placing too much stress on the joint while it is in use, weld cracks in steel and metals can be avoided. Keep scrolling down to see more techniques for avoiding welding cracks.

How To Prevent Crack In Welding?

Both the two weld cracks can be prevented in many ways. Therefore we’ll discuss them generally. You don’t need to be worried about it! You can’t avoid heat cracking by causing cold cracking, and the opposite is also true.

  • Warm Up The Metal

Steel can be preheated to lessen cooling strains and let hydrogen escape from the HAZ and connection. This lessens the development of crack-causing hydrogen migration and molecular bonds. Examine the requirements document provided by the supplier because preheating needs vary depending on the type of steel.

  • Reduce The Rate Of Cooling

Utilize heat blankets to reduce the rate at which filler material and the metal remarkable to enhance hydrogen diffusion further and aid it in leaving the weld metal. If required, you can also employ induction heating apparatus and welding ovens.

  • Select The Appropriate Filler Material.

To avoid cracking, use the proper filler material for the metal that has been welded. If you have fissures, filler material is the first item you should consider. While welding mild steel seems more forgiving, the filler metal must be precisely matched to the metal when welding stainless steel, aluminum, and various other exotic materials.

To prevent hydrogen infusion, maintain filler rods, cables, and stick electrodes dry at all times. Consider low-hydrogen welding electrodes, such as E7018, when high-strength steel welding or if you wish to lessen the risk of hydrogen-induced splitting.

It is essential to take into account seven essential factors when choosing a filler metal: base metal to be welded, regulatory codes and specifications, the welding position, shielding gas, design requirements, post-weld preheating, and welding equipment.

  • Ferrous Metals And Hydrogen

When ferrous welding metals such as carbon steel, avoid using hydrogen in the shielding gas mixture. Avoid using hydrogen as a shielding gas unless it is necessary to increase penetration.

  • Avoid Travelling Too Quickly.

Concave welds are caused by excessive travel speed, which lowers the weld throat. Slow down the travel speed to refill or cover the joint and provide a proper weld thickness.

  • Avoid Beads With Extreme Concavity Or Convexity.

Concave beads are not filled with metal and are not made of enough substance to endure residual shocks. This may result in cracking. High convexity beads, however, do not provide a solution.

There is too much filler material provided by excessive weld reinforcing. Therefore, internal tensions are more significant than in “typical” welds because of the enormous volume of metal shrinking as it solidifies.

The issue arises at the weld toes, though, because overly strengthened welds frequently don’t have a successful transition into the metal present in the surrounding. A stress raiser point (stress concentration) is created by this abrupt change, which results in cracking.

  • Apply The Proper Width-To-Depth Welding Ratio

The possibility of cracks forming increases if an incorrect width-to-depth proportion is used on a material susceptible to hot cracking. The form of the beads determines the pattern of metal crystallization and the associated stresses.

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For substances with low melting points, such as sulfur, a width-to-depth proportion outside of 0.5 to 0.8 seems to be more likely to drive them into the midline and result in cracks.

  • Use High-Quality Materials

You can also lessen weld cracking by employing high-quality parent and filler materials. Cracks may form if the metal’s additives are improperly blended, unknown, or dispersed unevenly.

Rust can also develop when metal is incorrectly stored. Additionally, its grain and structure chemical makeup may have changed if it has already been subjected to mechanical or thermal treatment. These problems might all result in weld cracking.

  • Do Not Weld High Sulphur Steel

Steel with a high sulfur content is more vulnerable to hot cracking because sulfur has a low melting point (239°F). As a result, it becomes more viscous during the weld crystallization and settles near the midline, which is more brittle and susceptible to cracking.

  • The Stresses Of Expansion And Contraction

During the welding process and the cooling interval that follows, do not constrain the welded components; instead, make leeway for some expansion and contraction of the metal to keep the weld from splitting due to high internal tensions.

  • Effectively Finish A Weld Bead

When finishing the bead, ensure that you fill the welding crater to its full inter (to match the remainder of the weld), as inadequate filler metal implantation leads to crater cracking.


What causes a weld to crack?–Weld cracking can occur for various reasons, but the most frequent causes are poor welding techniques used throughout the welding process. You need to fix the joint if there are weld cracks. Weld cracks should only extremely rarely be disregarded. Therefore, taking preventative action is essential to preventing costly rework. Weld cracks cause resource waste and delay in the completion of jobs if you own a welding shop. However, even amateur welders should know the fundamentals of weld crack avoidance. An unstable joint has cracks in it. Therefore, you need to match the filler metal to the base material, wipe the connection properly, warm the metal, and use a suitable welding technique.


How To Fix Cracks In Welding?

Stopping martensite formation is the best way to avoid cold cracking. Martensite develops as a result of the weld metal’s quick solidification and cooling. Hence you must apply enough preheat to the nearby base metal to reduce the cooling rate.

What Are Types Of Cracks In Welding?

Cracks typically come in two different varieties: The first one is hot cracks; these cracks develop at temperatures that can reach as 10000 degrees Celsius during welding or crystallization. The next one is cold cracks; these cracks can form during the crystallization process or after the welding process is complete.

What Causes Longitudinal Cracks In Welds?

High shrinkage strains, particularly in the final stages, or a hot cracking process are typically to blame for these cracks. Root cracks extend halfway through the weld from the root. Due to the first weld bead’s modest size, they comprise the most common form of longitudinal crack.

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