Porosity

Porosity is when pockets of air become trapped in the weld nugget.

Probable Causes:
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Concave surface on weld tips.
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Incorrect Machining of weld tips.
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Weld tips with ridge around the diameter of the tip surface.

Detecting this condition with Ultrasonic Inspection:
Ultrasonic inspection allows you to non-destructively identify acceptable and defective Weld Nuggets. During ultrasonic inspection, a transducer probe sends sound waves through a weld nugget and the results are displayed graphically. The three conditions that are analyzed from the graph are Attenuation, Spacing, and Interface Echoes.

What a good weld ultrasonic inspection graph looks like:
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Good Weld Attenuation Graph
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Good Weld Spacing Graph
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Good Weld Interface Echoes Graph

What a porosity ultrasonic inspection graph looks like:
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Porosity Attenuation Graph
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Porosity Spacing Graph
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Porosity Interface Echoes Graph