Weld Testing and Troubleshooting

Performing weld troubleshooting/ consulting services, providing repair solutions to manufacturing and field issues – keeping you compliant to AWS, API, ASME and other relevant Codes.

Our services include weld testing & analysis, resolving (weld distortion/ cracking /corrosion/ fatigue/ failure) issues – as well as joint analysis and stress analysis.

See Portfolio to read about additional projects.

Our services also include Certified Weld Inspection Services (CWI). From the inspection results, we provide engineering analysis and effective weld repair solutions, often through the use of three-dimensional finite element analysis (FEA) to quantify residual welding stresses, fatigue strength reduction due to lack of fusion, underpenetration, inclusions and other imperfections.

Using various AWS welding codes including AWS D1.1, AWS D1.5 and other codes – we resolve issues including:

  • Weld Defects/ Porosity
  • Distortion/ Cracking
  • Weld Failures
  • Fatigue of Welded Joints
  • PWHT/ Heat Treatment Issues
  • Weld Corrosion/ SCC Issues
  • Welding Metallurgy
  • Weld Non-conformance

Weld troubleshooting and subsequent redesign on a heater that had a limited structural life. The heater was constructed of .025 inch thick stainless steel. The configuration includes an edge weld joint type, where two .025 sheets are placed side-by-side and the top surfaces are welded. When this is connected to the header, a three point T weld joint configuration is created. Many fatigue cracks initiated in this area.

To see more of our projects, see Portfolio.

Welded Junction on Heater
  • Recent Projects

  • Engineering Support – Resolving Weld Issues

    Durable welding is what holds every plant together. Often, equipment design life is  compromised through inadequate manufacturing processes such as welding, thermal/ transient conditions, and high temperature conditions. At elevated temperatures, creep, and component strains occur, especially in welded connections.

    Defects often occur in welded, cast and forged parts. Parts with complex geometries often include crack starters such as metallurgical notch effects. We provide Certified Weld Inspections (CWI) and Nondestructive Testing (NDT) including radiographic (RT) and ultrasonic (UT) to determine quality and serviceability. Read about the various types of NDT.

    Often, local post-weld heat treatment (PWHT) operations are performed on welded assemblies and weld repairs to minimize weld residual stress and mitigate various damage mechanisms. Engineering support is required to minimize potential non-compliances. We provide such support (including FEA) to optimize PWHT arrangements and thermal gradients to prevent detrimental distortion, cracking, excessive residual stress effects or fatigue failure.

    Examples Include:

    • Manufacturing
    • Petrochemical
    • Mining
    • Oil/ Gas
    • Power Generation
    • Assemblies
    • Machinery
    • Presses
    • Supports
    • Cranes
    • Pressure Vessels
    • Heat Exchangers
    • Ductwork
    • Condensors
    • Reactors


    We are a team of multi-disciplined engineers providing clients with support across the spectrum of welding and joining challenges – including troubleshooting, code compliance, weld and joint inspection, mechanical testing, and evaluation of weld procedure specifications (WPS), procedure qualification records (PQR), and welder performance qualifications (WPQ).

    Several of our senior engineers have developed patents, published technical reports, and have been active in Codes and Standards Committees including the American Society of Mechanical Engineers (ASME), the National Association for Corrosion Engineers (NACE), the American Nuclear Society (ANS) and the American Welding Society (AWS).

    Read article “Weld Defects and Failures: Quantifying Fitness for Service” in Fugitive Emissions Journal. (PDF)
    Give us a call – Let’s talk about your needs.

    Weld Consulting Related Links

    >> Tom O’Donnell, PE
    >> Materials/ Metallurgical Consulting
    >> Engineering Troubleshooting
    >> Stress Corrosion Cracking Mitigation
    >> Portfolio of Projects
    >> Our Team of Engineers
    >> Links to Engineering Resources

    Learn from the experience of others. Especially when one such “other” is Dr. William O’Donnell, PhD, PE, Founder and President of O’Donnell Consulting Engineers, Inc., and ASME “Engineer of the Year” – his 50 years of experience in analysis of components including fatigue and fracture safety evaluations and failure analyses are now comprised in this volume.

    If you are interested learning more in Engineering Design, Manufacturing and Construction, as well as Failure Analysis, then this book is a must have!


    * Does not include shipping, handling or tax

    Handbook of Lessons Learned

    (412) 835-5007

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