What is the recommended action if a weld shows holes and projecting globules?

• A. Remove all of the old weld, and reweld the joint
• B. Patch the holes with filler only
• C. Grind down the protrusions and leave
• D. Apply heat to re-melt only the surface

Answer: (A)

Weld defects like holes (porosity) and projecting globules show the weld didn’t fuse properly and has surface and possibly internal flaws that can weaken the joint. The best fix is to remove the entire weld and redo the joint on clean base metal with proper fit-up, shielding, and heat control. This gives you a fresh, sound fusion and correct bead geometry, reducing the risk of cracks or corrosion later on. Patching with filler would leave internal porosity, grinding down the protrusions only hides surface issues and can create stress risers, and heating the surface alone won’t remove subsurface flaws or ensure full penetration.