What can lead to incomplete fusion in a weld?

Incomplete fusion in a weld occurs when the filler material does not fully bond with the base metal, which can compromise the strength of the weld. The scenario described involves an incorrect angle of the electrode or inadequate heat.

When the electrode is not angled properly during the welding process, it may not adequately direct heat onto the base metal. This improper angle can prevent the heat from effectively melting both the base metal and filler, leading to insufficient fusion between the two materials. Additionally, if there is inadequate heat overall, it may not generate enough energy to melt the filler or base metals sufficiently, which further leads to incomplete fusion. In both these circumstances, the result is a weak joint that may fail under stress or load.

This understanding highlights the importance of proper technique and settings in the welding process. Factors like electrode angle and heat intensity are critical to ensure fusion occurs properly, thereby reinforcing the integrity of the weld joint.