Weld Testing and Troubleshooting

Performing weld failure analysis – investigating weld distortions, cracking, corrosion and fatigue, providing repair solutions to ensure structural integrity and keeping you compliant to American Welding (AWS), API, ASME and other relevant Codes.

See Portfolio to read about more projects.

From inspection results, we provide engineering analysis and effective weld repair solutions – often through the use of finite element analysis (FEA) to quantify residual welding stresses, fatigue strength reduction due to lack of fusion, underpenetration, inclusions and other imperfections.

We develop repair solutions according to American Welding Society Codes – including  AWS D1.1, and AWS D1.5. 

  • Weld Failure
  • Distortion / Cracking
  • Defects/ Porosity
  • Fatigue of Welded Joints
  • PWHT/ Heat Treatment Issues
  • Corrosion/ SCC Issues
  • Weld Metallurgical Issues
  • Weld Non-conformance
Axle Bracket Weld Failure under High Magnification

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.

See Portfolio to read more of our projects.

  • Recent Projects

  • Durable welding is what holds every plant together. Often, equipment design life is often compromised through fatigue, 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 welds/ 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 to optimize PWHT arrangements and thermal gradients to prevent detrimental distortion, cracking, or excessive residual stress.

    A Few Examples Include:

    • Assemblies
    • Machinery
    • Presses
    • Supports
    • Cranes
    • Pressure Vessels
    • Heat Exchangers
    • Ductwork
    • Condensors
    • Reactors

    Read our article “Weld Defects and Failures: Quantifying Fitness for Service” in Fugitive Emissions Journal. (PDF)

    Several other codes we work with include:

    • ASME Section III Class 1, 2 and 3
    • ASME Section VIII Div. 1, 2 and 3
    • ASME (B31.1 Power & B31.3 Process Piping)
    • ASME Section XI

    See Industries Served to see a list of the components we’ve worked on.
    Give us a call – Let’s talk about your needs.

    Related Links:

    >> Materials/ Metallurgical Consulting
    >> Engineering Troubleshooting
    >> Our Team of Engineers
    >> Stress Corrosion Cracking Mitigation
    >> Introduction to Fatigue Analysis
    >> Publications – Heat Exchangers, Pressure Vessels, Fatigue, Weld Applications
    >> 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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