Insufficient weld cross-section
Insufficient weld cross-section means there is too little filler material to achieve the required weld thickness or width. This leads to weak points and reduced mechanical properties.
Physical-Chemical Mechanism of Action
An undersized weld cross-section happens when less metal goes into the weld than planned. That can be caused by too short a welding time or too low a feed rate.
Metallurgical Relevance & Welding Risks
An undersized weld cross-section leaves weak spots in the weld that can crack easily under mechanical load. Mechanical properties like strength and fatigue life drop, which gets risky, especially with hardness issues and hot cracking.
Shop Practice & Action Points
To avoid an undersized weld cross-section, you have to stick to the exact filler metal deposition. That means using enough welding time and the right feed rate. If needed, you can also build up the workpiece before welding by adding thickness or width to make sure the weld cross-section meets the requirements.