ODonnell Consulting

Weld Troubleshooting/ Consulting

Weld Testing and Troubleshooting

We provide design and inspection/ analysis of welded structures – as well as weld troubleshooting services, providing solutions to manufacturing and field welding issues.

These services include weld testing and analysis, weld overlay design and joint analysis, weld procedure development and qualification, as well as (weld distortion/ cracking /corrosion/ fatigue/ failure) troubleshooting and repair of Code compliant issues.

See our Portfolio page to read more about our projects.

Our services also include Certified Weld Inspection Services (CWI). From the inspection results, we provide engineering analysis and effective 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.

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

  • Weld Distortion
  • Weld Cracking
  • Weld Defects/ Porosity
  • Fatigue/ Failure of Welded Joints
  • PWHT/ Heat Treatment Issues
  • Weld 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.

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

A few examples include:

  • Manufacturing
  • Petrochemical
  • Mining
  • Oil/ Gas
  • Power Generation
  • Assemblies
  • Machinery
  • Presses
  • Supports
  • Cranes
  • 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 “Weld Defects and Failures: Quantifying Fitness for Service” in Fugitive Emissions Journal. (PDF)

Related Links:
>> Materials/ Metallurgical Consulting
>> Engineering Troubleshooting
>> Stress Corrosion Cracking Mitigation
>> Introduction to Fatigue
>> Publications – Heat Exchangers, Pressure Vessels, Fatigue, Weld Applications

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!


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Handbook of Lessons Learned