If a fillet weld is rejected for excessive porosity, what must be done?

When a fillet weld is rejected for excessive porosity, the appropriate action is to remove the defective areas and replace them with sound weld. Porosity indicates that there are voids or gas pockets formed in the weld metal, which can significantly weaken the weld and compromise its integrity.

To rectify this issue, the affected portion of the weld must be removed to eliminate the pores. Then, the area can be properly cleaned to prepare for rewelding. By replacing the porosity with sound weld metal, you ensure that the structural requirements and integrity of the weld are restored. This process not only addresses the quality concerns of the weld but also aligns with industry standards for weld repair and soundness, making it the necessary corrective action in such cases.