What Is Porosity Welding?

Porosity Welding- a process of welding two or more metals together is used widely across the globe and is a must-know skill for welders. Currently an estimated

47 million people in the world are employed in welding operations. With the introduction of porosity welding, more efficient and accurate, high quality welding works can be guaranteed without manual labour and human error. Porosity welding has the potential to revolutionize the welding industry with its more than 90% accuracy rate and is estimated to save up to 30% of the production time compared to traditional welding methods.

Therefore, let’s dive deeper and understand what is porosity welding, its advantages and disadvantages, and various applications in the industry.

What is Porosity Welding?

Porosity welding is a specialized welding technique used to repair weld joints that have been damaged due to porous or honeycomb formation.

This is often caused by high temperatures or excessive flux during the welding processes. Porosity welding is a two-stage process, first involving the removal of the affected areas and then rewelding the joint to restore the strength and integrity of the weld. This process is often used in critical welds such as those that are used in aerospace applications.

What Causes Porosity?

Porosity, or honeycomb formations, within a weld can be caused by a number of factors and processes, including:
  • Inadequate joint preparation
  • Incorrect welding techniques
  • Environmental factors, such as humidity and temperature
  • Excessive heat input from the welding process
  • Excess flux or inadequate shielding

How is Porosity Welding Performed?

The porosity welding technique is a two-stage process that includes the following steps:
  • Inspect the weld joint to verify the presence of porosity
  • Clean the joint with a wire brush or other abrasive
  • Use a welding rod to completely fill the pores and voids
  • Add additional material to build up the weld, if required
  • Reheat the joint until the welding rod melts and flows into the pores
  • Allow the joint to cool down before testing it for strength and integrity

Benefits of Porosity Welding

Porosity welding offers a number of benefits, including:
  • Restores the strength and integrity of the weld
  • Ensures critical welds are strong and reliable
  • Does not require extensive grinding or welding material removal
  • Provides a cost-effective solution to repairing damaged welds


Porosity welding is an effective method of restoring the strength and integrity to welds that have been damaged due to porosity or honeycomb formations.

It is a two-step process starting with the removal of the affected areas and then rewelding the joint. Porosity welding offers many benefits, including restoring the strength and integrity of critical welds, without requiring extensive grinding or material removal.

Citations URL: https://www. mechanicalelements. com/what-is-porosity-welding/https://www.

weldingalloy. com/apps/blog/porosity-welding-a-solution-to-repair-pores-and-voids

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