weld failed

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Any guess why?(fillet welded with 7018, one pass. Material 3/8X4", welded to 2.5" thick plate) Attached Images
Reply:From the looks of it, there didn't appear to be any penetration or fusion.  The edge that you welded still looks like a straightedge.  It looks like the filler just melted on top of the base metal.  What kind of metal is the plate...it looks suspiciously like cast.  2.5 inches is pretty thick...you dont mention amperage used.Smithboy...if it ain't broke, you ain't tryin'.
Reply:Uh, lack of fusion? Or maybe just a wee bit on the cold side?   enlpck: where is the "armpit of NJ"? I can think of a number of areas in Jersey that match that description!
Reply:Failure was from start to finish:Mill scale not removedpoor fusion with partShould have had several passes run... not for this piece, but due to the heavy section it was welded to. Gotta get the heat in.Was done blind and with restricted accessShould have been rooted with a rod that burns in well, like 6010Original welder is very good, but doesnt do this type of weld much. Probably should have been good enough (low load part) if he had a little more burn-in.I had the rework. Cleaned the scale off and beveled the edges for full pen. Rooted with 6010... the top side (uphill at 45degrees) burned in good, bottom I won't talk about. A second pass on top with 6010, then two fast, hot, heavy passes with 7018, to get heat into the heavy section. The bottom (overhead) side is good enough without the covers. Ugly, but suitable.Got about 2" off the end of each stick due to restricted access. All done blind. I'm not real good with 6010 blind (<-- understatement) but the 7018 is fine. DetailerDave: I used to live on the little pimple sticking out right by Sandy Hook, which is the scraggly armpit hair pointing back to New York Harbor. I live in a better (read as less crime, cleaner) area now.