What is the maximum defect size allowed per porosity, skip, or void in open butt joint?

What is the maximum defect size allowed per porosity, skip, or void in open butt joint?

• A. 2 mm
• B. 3 mm
• C. 1.5 mm
• D. 4 mm

Answer: (B)

In open butt joints, the question tests how large a single flaw—porosity, skip, or void—can be and still be considered acceptable. A defect reduces the cross‑section of the weld and can become a weak point under load, so inspectors specify a maximum size per defect to ensure the joint remains structurally sound. The standard acceptance is 3 millimeters per defect. That means any individual porosity, skip, or void up to 3 mm can be tolerated, while defects larger than 3 mm should be removed (grind out) and the area rewelded to restore the weld’s integrity. This size strikes a practical balance for collision repair welding—large enough to accommodate common process variations, but small enough to maintain strength. If multiple defects are present, they still must conform to the per-defect limit, and larger or clustered defects would require repair.

In open butt joints, the question tests how large a single flaw—porosity, skip, or void—can be and still be considered acceptable. A defect reduces the cross‑section of the weld and can become a weak point under load, so inspectors specify a maximum size per defect to ensure the joint remains structurally sound. The standard acceptance is 3 millimeters per defect. That means any individual porosity, skip, or void up to 3 mm can be tolerated, while defects larger than 3 mm should be removed (grind out) and the area rewelded to restore the weld’s integrity. This size strikes a practical balance for collision repair welding—large enough to accommodate common process variations, but small enough to maintain strength. If multiple defects are present, they still must conform to the per-defect limit, and larger or clustered defects would require repair.