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Six cracked A36 steel gusset plates that formed part of the roof trusses of a large manufacturing facility were discovered during a routine final inspection of a new building construction. Two different-size plates from different locations in the building were removed and tested. It was determined that the gusset plates failed in the heat-affected zone via an intergranular microcracking mode due to hydrogen-assisted underbead and toe-weld cracking. Proper nondestructive testing techniques for magnetic particle and radiographic inspection of the plate-weld gusset areas were recommended.

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William F. Jones, III, Hydrogen-Induced Cracking of Welded Truss Gusset Plates, Handbook of Case Histories in Failure Analysis, Vol 1, Edited By Khlefa A. Esaklul, ASM International, 1992, p 382–384,

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