How weld defect acceptance limits work
Surface discontinuities are judged against different limits depending on type. This calculator applies a simplified reading of the AWS D1.1 visual inspection acceptance criteria for statically loaded connections and compares the accumulated discontinuity length against the allowance for the length of weld inspected.
Undercut up to 1/32 in is acceptable with no length limit; between 1/32 and 1/16 in it is limited to 2 inches accumulated in any 12 inches; deeper than 1/16 in it must be repaired. Visible piping porosity is limited by the sum of the pore diameters, 3/8 in in any linear inch and 3/4 in in any 12 inches. An undersize fillet leg is acceptable up to 1/16 in undersize provided the undersize portion covers no more than 10% of the weld length. Cracks and incomplete fusion are never acceptable at any length.
Treat the output as a reference result. Cyclically loaded members, pressure vessels and piping are governed by other codes with tighter limits, and internal discontinuities require radiographic or ultrasonic testing that visual criteria do not cover. Final acceptance must come from a Certified Welding Inspector working from the published tables and the project specification.
Frequently Asked Questions
The tool applies a simplified version of the AWS D1.1 visual inspection acceptance criteria for statically loaded nontubular connections. Cyclically loaded members, pressure vessels and piping fall under different codes whose limits can be stricter.
Cracks are not acceptable at any length or location because they propagate under load and can lead to fracture. A crack must be completely removed, the joint rewelded and the area reinspected.
Visual inspection covers surface discontinuities only. Internal flaws need radiographic or ultrasonic testing, and the required method and coverage are set by the project specification. Final acceptance rests with a qualified welding inspector.