What Is Distortion In Welding?

Distortion can significantly affect the outcome of welding projects, making it one of the key elements in successful welding. In fact, according to the American Welding Society, the amount of distortion is estimated to be up to 19% of the time and materials costs.

Understanding how distortion occurs and how it can be minimized is critical for welders and manufacturers. In this article, we will cover what distortion is in welding, the various causes of distortion and how to minimize it. With some of the tips and tricks in this article, we hope to help you understand how distortion in welding works so that you can complete your projects more efficiently and with better results.

What is distortion in welding?

Welding is a joining process which uses intense heat or pressure to form permanent bonds between two objects.

It is an essential part of manufacturing. Despite its usefulness, welding also carries with it certain drawbacks. One of the most significant drawbacks is distortion.

In this article, we’ll discuss what distortion is, what causes it, and how to control it.

What is Distortion in Welding?

Distortion is the warping or misalignment of the two parts that were joined together.

In welding, components can become distorted from the heat or pressure that is applied during the welding process. This distortion can lead to out-of-tolerance dimensions and misalignment of the components, which can affect the fit and function of the final product.

What Causes Distortion in Welding?

There are several factors that contribute to distortion in welding.

The most common causes are:

  • Restrained assembly
  • Unbalanced or uneven welding
  • Heat dissipation
Restrained assembly occurs when the components are secured together in the welding jig before the welding process begins. This causes unequal stress to be placed on the components when they are welded, which can lead to distortion. Unbalanced or uneven welding is another common cause of distortion.

If one side of the weld is applied too quickly or with too much heat, this can cause the weldment to warp. Heat dissipation is the process of heat moving from the weldment to the surrounding material, which can also cause the weldment to warp.

How to Control Distortion in Welding

There are several measures that can be taken to control distortion in welding. These include:
  • Proper fit-up of the components
  • Optimized weld sequencing
  • The use of tacks or a weld jig
  • Weld backstepping
  • Cross-welding
Proper fit-up of the components ensures that there is minimal space between the components when they are secured together. This can help to reduce the effects of restrained assembly. Optimized weld sequencing is the process of controlling the order and direction in which welding is applied to the components. This can help to keep the welds balanced, thus reducing the chances of warping or distortion. The use of tacks or a weld jig can also help to control distortion. Tacks or a weld jig can be used to secure the components together during the welding process. This helps to keep the components from moving due to heat dissipation or other movement. Weld backstepping is the process of junction welding from the sides of the joint in order to control the heat input. Finally, cross-welding is the process of welding from one side of the joint and then the other in order to keep the distribution of heat even.


Distortion is a common problem in welding and can be caused by several factors. Fortunately, there are measures that can be taken to help minimize and control distortion. Proper fit-up of the components, optimized weld sequencing, the use of tacks or a weld jig, weld backstepping, and cross-welding are all ways that distortion can be controlled. Citation URL: https://www. aronsonmfg. com/what-is-distortion-in-welding/https://www. tulsaworld. com/enginuity/what-is-distortion-caused-by-in-welding/article_82e8c905-aefb-5245-ab39-f6847f6086ff. htmlhttps://www. discoverwelding. com/how-to-prevent-distortion-when-welding/

Leave a Comment