What does it indicate if a weld has so many flaws that it will fail inspection?

When a weld has numerous flaws that lead to its failure during inspection, it signifies a condition known as severe discontinuity. This term refers to significant imperfections that disrupt the integrity and continuity of the weld metal or joint. Such discontinuities can include cracks, porosity, incomplete fusion, or other forms of material discontinuities that compromise the weld's strength and performance.

Severe discontinuities not only affect the mechanical properties of the weld but can also lead to premature failure of the welded assembly under service conditions. Standards set by the Structural Welding Code emphasize the importance of achieving weld quality that minimizes these defects, ensuring that the joined components can safely sustain the intended loads and stresses throughout their service life.

In contrast, undercut, excessive reinforcement, and weld failure are related concepts but do not encapsulate the broader idea of a multitude of flaws leading to inspection failure in the same comprehensive way as severe discontinuity. Each of these terms refers to specific types of shortcomings or results, whereas severe discontinuity indicates a larger, more critical problem with a weld.