Bad weld photos

   / Bad weld photos #11  
Welding schools are only as good as the instructors. Lot of times the old saying is true, THOSE WHO CAN, DO; THOSE WHO CANT, TEACH. Many "teachers" are never coulds and only know what they read in a book. Kinda like an inspector with a AWS QC1 cert but never welded or worked in construction, just book study and dont know sheet. Might be able to tell a good weld from a bad one but no idea on how to fix it or what caused the problem in the first place.
 
   / Bad weld photos #12  
Well I goated up my first weld test. Guy called me to weld braces on cell tower base. He said I needed aws cert., okay I'll get it and see you next week. I call and closest test was 5 hours and money I didnt have. I borrowed money from my parents drove down that morning thinking I just make weld and drive back. Guy asks what company I with, I say me and I have done this before what do you want? He says make a good weld and hurry up I shutting this place in few hours.
Nervous, hot, rain dripping in this tiny stall, inspection light burning down my neck, and broke. Welded vert first and weaved a tight neat cap to save time. Tacked overhead and when they came in to inspect my bead... Inspector says: never ever never weave a cap in my shop. I'm terrified he gonna fail me on it. I told him sorry ill put stringers in but I was just trying to speed it up . He says if the weld passes he will allow it but no more weave.
Okay now I'm relived and very nervous. Shirt is sticking to me, I take a deep breath, put in a new rod, settle my feet, raise my arm to get slack in sleeve and lead- 14" 7018 extending from the stinger from my outstretched arm goes right between two fluorescent light bulbs to the metal fixture screwed to the grounded metal booth. Whhoomm was the sound, lights flickered, rod burns through fixture and sticks, I snatched it out, flung out that rod, and welded that coupon out faster than you could say I gotta get the heck outta here. The whole booth shook as I worked. I did pass both test, and instructor asked if I heard any commotion back there while I tested. So if your ever testing in the south I gotta a ugly weld in light fixture somewhere.??
 
   / Bad weld photos #13  
I remember taking an x-ray Innershield test for a Navy shipyard project one time. When I walked into the booth there was a water cooled gun on the wire feeder. The cup must have been a 1 1/2-inch in dia. Wasn't much of a problem for horizontal, and vertical. But with the overhead the splatter liked to fill the cup up. Every pass I had to clean the cup out. About half way through the last cap pass some splatter was going up and down on the wire as it was coming out of the contact tip. Then all of a sudden the little glob of splatter stuck to the wire, and right into the puddle! Never being allowed to use a grinder on a structural welding test I knew I was in big trouble! Took the test plate to the inspector and explained to him what happened, told him I knew I wasn't allowed to use a grinder. He looked at me and said that's right, you can't use a grinder, but I can. :D
 
   / Bad weld photos #14  
Well I goated up my first weld test. Guy called me to weld braces on cell tower base. He said I needed aws cert., okay I'll get it and see you next week. I call and closest test was 5 hours and money I didnt have. I borrowed money from my parents drove down that morning thinking I just make weld and drive back. Guy asks what company I with, I say me and I have done this before what do you want? He says make a good weld and hurry up I shutting this place in few hours.
Nervous, hot, rain dripping in this tiny stall, inspection light burning down my neck, and broke. Welded vert first and weaved a tight neat cap to save time. Tacked overhead and when they came in to inspect my bead... Inspector says: never ever never weave a cap in my shop. I'm terrified he gonna fail me on it. I told him sorry ill put stringers in but I was just trying to speed it up . He says if the weld passes he will allow it but no more weave.
Okay now I'm relived and very nervous. Shirt is sticking to me, I take a deep breath, put in a new rod, settle my feet, raise my arm to get slack in sleeve and lead- 14" 7018 extending from the stinger from my outstretched arm goes right between two fluorescent light bulbs to the metal fixture screwed to the grounded metal booth. Whhoomm was the sound, lights flickered, rod burns through fixture and sticks, I snatched it out, flung out that rod, and welded that coupon out faster than you could say I gotta get the heck outta here. The whole booth shook as I worked. I did pass both test, and instructor asked if I heard any commotion back there while I tested. So if your ever testing in the south I gotta a ugly weld in light fixture somewhere.??

LOL, I have known that feeling before! :0
 
   / Bad weld photos
  • Thread Starter
#15  
Reminds me of the time in school when a wiseacre kid was getting ready for a welding test. Went to flip his hood down and his arm went sideways and caught a metal post support for the building. It didn't stick for a millisecond so we had a shower of sparking and then it stuck and stuck good. Surprisingly, his attitude failed to clear up. Probably welding farm gates these days...
 
   / Bad weld photos #16  
A big round of applause for cool inspectors and other ones that keep us humble. I failed a test for a cap that was too flat. Guy was super nice, I said dang can you a least be a jerk about do I can leave with some dignity!!;)
 
   / Bad weld photos #17  
Danggit boy! It's all fun and games till somebody gets hurt :) I have one on my other phone of a stringer on a staircase at a plant. Weight of the hammer or bred of the dog is the only ify part. I'll try to find it and some others.


View attachment 293423

Mount for pneumatic cylinder, when they hired me they asked "are you sure you can weld" when I showed up I knew why.

WOW. That looks like my welds when I started welding.

Thankfully I can do better now.

Below's A weld I did on a ball attached to a lawn tractor. I'll admit part of it isn't very good looking. But at least it's strong.

I was gonna go over it again on the bad side but it was getting really cold outside so I said the heck with it for now.

I might go over it again and redo the weld just for the fun of it once it warms up. Although I'm sure that the ball ain't gonna come off.

If it was on a hitch that was gonna be pulling a trailer down the highway then I would've fixed it before I put it to use. But since I'm just pulling a trailer around with a slow speed lawn tractor if the ball breaks it won't be that bad. But I doubt it will.

It's actually got good penetration on that bad looking side and it actually looked great but the second time I went over it to build up the weld I didn't get a pretty bead. lol

View attachment 361860 View attachment 361861
 
   / Bad weld photos #19  
Well, I would show a pic of some of my Ugly weld, but I dont have enough film in the camera for all of them.
 
   / Bad weld photos #20  
behind schedule should never trump safety!!
Where I worked for 45 years before retiring, we had a saying, IF YOU DONT HAVE TIME TO DO IT RIGHT, WHEN WILL YOU HAVE TIME TO DO IT OVER. And another one SAFETY AND QUALITY BEFORE PRODUCTION. One of the things I liked about that company was that we all lived those slogans, and anyone that didn't, didn't last long on the payroll. Even now working on old farm equipment, I over weld everything and make sure it is all good quality welds just as if I were taking an Xray test. I spent the money getting a quality Phoenix 350# dry rod oven that stays on 300F all the time for my low hydrogen rods so they make as good a weld as possible, grind off ALL old paint/rust /etc prior to welding if at all possible. Sometimes one just cant get grinders or brushes into corners to remove everything, and that is when the 6010 comes out for the first pass. Not as good as cleaning first but it sure helps.

I think maybe Shieldarc learned from his mistake, a crushed truck was cheap remembrance of why one should never let shoddy work pass regardless of how far behind schedule one is.
 

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