ODonnell Consulting

Weld Troubleshooting/ Consulting

Weld Testing and Troubleshooting

We perform a spectrum of weld consulting services – from weld testing and analysis, to weld overlay design and joint analysis, to weld procedure development and qualification, to (distortion/ cracking /corrosion/ fatigue/ failure) troubleshooting and repair of Code compliant issues.

To see a more comprehensive list of equipment we have worked on, see Industries Served.

Our services also include Certified Weld Inspection Services (CWI) as well as engineering analysis – presenting effective repair solutions to challenging weld issues, often through the use of three-dimensional finite element analysis to quantify residual welding stresses, fatigue strength reduction due to lack of fusion, underpenetration, inclusions and other imperfections.

Our experience covers AWS D1.1, AWS D1.5 and the numerous ASME codes, resolving issues including:

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

We investigated the cause of a fractured axle bracket. Shown here is a high magnification where a small portion of the weld metal adhered to the bracket. Slag is observed under the initial weld pass and the frame surface, indicating that the weld failed due to lack of fusion.

To see more of our projects, see Portfolio.

Contact Us for a free quote.

Axle Bracket Weld Failure under High Magnification

Recent Projects

Durable welding is what holds every plant together. Often, equipment design life is often 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.

A few examples include:

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

For a comprehensive list of components we have worked on, see Industries Served. Resume summaries of our engineers are described in Our Team.

We are experienced, 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 welding 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 our article about managing risk specific to weld failures in Fugitive Emissions Journal. (PDF)

Related Links:
>> Materials/ Metallurgical Consulting
>> Engineering Troubleshooting
>> Stress Corrosion Mitigation
>> Introduction to Fatigue
>> Publications

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