Holes and a few projecting globules are found in a weld. What action should be taken?

Holes and a few projecting globules are found in a weld. What action should be taken?

• A. Remove all of the old weld, and reweld the joint
• B. Grind to smooth and leave as is
• C. Patch with epoxy filler
• D. Apply a coat of primer

Answer: (A)

When a weld shows holes and projecting globules, the weld quality is seriously compromised and surface smoothing won’t fix the underlying porosity or improper fusion. The safest, most reliable repair is to remove all of the old weld and reweld the joint, ensuring clean base metal, proper fit-up, and correct technique to produce a sound weld. Grinding it down or leaving it as is would not remove internal defects that can lead to failure. Epoxy filler isn’t appropriate for structural weld repairs, and applying primer doesn’t address weld integrity.

When a weld shows holes and projecting globules, the weld quality is seriously compromised and surface smoothing won’t fix the underlying porosity or improper fusion. The safest, most reliable repair is to remove all of the old weld and reweld the joint, ensuring clean base metal, proper fit-up, and correct technique to produce a sound weld. Grinding it down or leaving it as is would not remove internal defects that can lead to failure. Epoxy filler isn’t appropriate for structural weld repairs, and applying primer doesn’t address weld integrity.