5.10 Solidification Cracking
Consider that the weld puddle solidifies like a small casting. The process of solidification starts with
the formation of several crystals (or dentrites) at the unmelted heat affected zone and continues as
these crystals grow towards the center of the puddle. Where two crystals meet, they form a grain
boundary and a sound weld should result (Figure 5.28).
However, in the presence of such elements as carbon, sulfur and phosphorous in the weld metal, small
amounts of liquid metal enriched in sulfur and phosphorous are trapped between the crystals before
the solidification is completed. As the weld metal shrinks further during cooling, a crack may form in
the region where the liquid was trapped. The liquid that solidifies last, near the grain boundaries, has a
lower melting point because of the impurities such as sulfur and phosphorous.