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Thread: Weld Quality
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7th Apr 2014, 10:19 AM #1Member
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Weld Quality
I'm seeking your opinions on the quality of these welds. These are on some brakets for airbag suspension. I think the welds are disgusting, highly in-effective and lack any substantial penetration thus doomed to fail.
Experienced in removing the tree from the furniture
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7th Apr 2014, 01:24 PM #2Tool addict
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I'd send it back, or at the very least complain. It's a little thing, but leaving a length of MIG wire still hanging off where it shorted just screams out how poor the rest of it will be.
I wouldn't trust anything on it.
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7th Apr 2014, 03:32 PM #3Member
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I emailed (with pictures) the mob in Melbourne whom I brought them from, they contacted the maker, I had a phone call from the maker appoligising and dosen't know how the faults occured but will be sending replacements. So far so good... we'll see.
Experienced in removing the tree from the furniture
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7th Apr 2014, 03:54 PM #4Tool addict
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Really good to hear that sort of reaction from the seller and subsequently the maker.
Probably a trainee effort, or a Friday knockoff job.
Last time I saw a weld that impressive was at my old job, when a fitter welded up some cracks on the deck of a RC drill rig. The cracks weren't structurally compromising, but I cringed when I saw them, and the boily laughed himself silly.
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7th Apr 2014, 04:26 PM #5Member
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You would think that quality control would have picked it up, but obviously not, if that was done manually then that employee should not be welding.
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7th Apr 2014, 09:07 PM #6
You would be amazed at the number of welded joints similar to the quality shown are actually missed by the quality control departments.
It will also probably not surprise you to find out that some of these defects are found in products of companies that are huge multinational companies such as car makers.
Mind you, it doesn't happen too often,but when it does some of the fails are doozies.
I suspect the problem may stem from from engineers/department heads who do not understand basic welding equipment settings.
Grahame
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7th Apr 2014, 09:11 PM #7Most Valued Member
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Scary what may be approaching you at 100Kmh isn't it.
I wonder how many more substandard units are out there? I would imagine they would be made as a production run.
Worth a phone call to the certifying body and hopefully a public alert or recall.
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8th Apr 2014, 02:15 PM #8Golden Member
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It makes me think I must be an expert by comparison.
You would think that it must have passed through the plating department as well, and they would surely have noticed and pointed it out. And even the packaging department.
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8th Apr 2014, 05:45 PM #9Most Valued Member
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In a previous job, I worked next to a truck dealership, therefore completing all of their welding repairs as required. This dealership sold a well known brand of American born prime mover considered to be the ultimate by many a Truckie. No, it wasn't Kenworth or Mack.
Anyway, the list of warranty work that we carried out via the dealership included, repairing a front crossmember originally suspected of cracking, but closer inspection revealed the weld had missed the joint by a good 10-12mm. Rectification of loose radiator support brackets that also held the entire bonnet assembly - UNF nuts rattled onto UNC bolts the cause there. Numerous rear cab support crossmembers cracking through mounting plates. A change from flame cut to very roughly punched mounting plates were the cause of those. Oh and my favourite for last. An entire steering column that dropped out in the drivers lap at 100Kmh, due to the plates on the mounting stays only being tacked on. That's without listing the suspension seats that failed due to no lubrication in the bushes, or the multiple rear axle housing failures, (only on air bag suspended trucks as I recall) and several spectacular gearbox failures caused by a 1600Ft/Lb rated gearbox being mounted behind a 2050Ft/Lb engine.
Can't say I've ever seen anything similar on a Japanese or European truck.
Quality workmanship and quality control it would seem died some time ago.
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14th Apr 2014, 09:35 AM #10Member
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Have now recieved the replacement brackets with the welds being varstly improved.
Experienced in removing the tree from the furniture
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15th Apr 2014, 05:01 PM #11
The replacement parts are no better than your first set. It has gone from a very poor cold and non penetrated full length weld to a ever so slightly improved approx 20mm runs at either end. Not too sure what the welds above look like but I would reject and return these parts. People wonder why we are losing manufacturing to overseas and this is one of the reasons why. I can only assume these parts are made here. To allow these parts to be the replacement ones for you is extremely careless and should reflect badly on the company and the people directly involved. I would not allow fit sub standard parts like those pictured to be fitted to any vehicle. The potential down time and cost to remove after you have fitted them is not worth it should they start to show signs of failure. I would strongly recommend sourcing another brand.
Part of the possible problem with these welds are.,,
Under powered machine as these parts are around 10mm - 15mm thick
Incorrect settings and no pre test on some similar size scrap
Power supply issue within the factory or where the welding machine is plugged in to.
Operator with very little experience,knowledge or care.
QC have no idea or dont care or if they do care management dont.
There is no QC
Bottom line here is return the second set and ask for refund and look else where.
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