What is a common cause of weld failure?

A common cause of weld failure can indeed be attributed to incorrect joint design. The joint design is critical as it dictates how well the weld will perform under load and how effectively the welded parts fit together. Poor joint design may lead to stress concentrations, difficulty in achieving proper penetration, and insufficient fusion between the base materials. Each of these can significantly reduce the weld's strength and integrity, ultimately leading to failure.

Welds are required to bear loads and resist various forces in real-world applications, and if the joint design doesn't accommodate those dynamic conditions, the likelihood of failure increases greatly. Therefore, ensuring that the joint design meets the appropriate standards for the specific application is essential for achieving a durable and reliable weld.

Other factors like excessive heat input, improper shielding gas, and inadequate weld preparation also contribute to weld failures but often stem from poor execution rather than a fundamental flaw in the design itself. This highlights the importance of careful planning and design in the welding process to prevent issues down the line.