Weld Penetration Problems

Ken P...

Our problem, we get linear porosity at the furthest point of penetration (heavy plate). The size of porosity is 0.3mm dia. but occurs regularly in every weld sectioned so far. Please suggest any steps, which should be checked.
Weld Info: Semi-Automatic process, Spray Transfer, Blasted Material, Electrode: 0.045" ER70S-6, Gas: 91Ar / 5Co2 / 4O2 @ 35cfh, WFS: 485ipm, Travel Speed: 13ipm, Amps: 335A, Voltage: 29.3, Finished weld size is 12mm

Ken,
I would suspect that your weld penetration profile is showing “finger penetration” (Not sure if that is a real term but), a real deep area of penetration at the weld root. The profile is much deeper (at this location) than it is wide. This will cause this area to open up during solidification.
Grab your copy of AWS D1.1 and check out the Commentary section at C3.7.2 “Width/Depth Pass Limitations” also, Figure C-3.2 “Examples of Centerline Cracking”.
I was asked to troubleshoot a similar condition during a job interview for a former employer. To save money, they had changed a process from an 0.045 dia. electrode to an 0.052 dia. When they made the change they did not change any other parameters. The high wire feed with the larger diameter electrode created a considerable increase in current which equates to a considerable increase in root penetration. Like you, everywhere they sectioned, they had this pore, which I believe was more of a linear void. A reduction in WFS, although not popular, eliminated the problem. P.S. I got the job!
Typically, a reduction in current (WFS) will reduce this finger penetration and this should remedy your issue. One other thing; yours is a weird shielding gas mixture. Not sure why you would go with so much Oxygen but I don’t know your whole story. If you can, replace the Oxygen with more Co2. Perhaps that will change your weld profile as well.

Good Luck! PWC

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