Full Penetration PFC to PFC Web

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I work in the manufacturing industry as a project engineer and an issue has been brought up from the workshop floor regarding getting full penetration between a PFC and PFC web. http://i.imgur.com/smjhxs8.pngA fillet weld was done on the inside and a buttweld on top. Radiographic testing was conducted on this weld and has failed. Lack of fusion was seen towards the corner where the buttweld and fillet weld meets up. The welder and my manager have said that this is not avoidable and as such I am at a loss on how to fix up this issue. Is there merit to what they are saying? How would you guys fix up this problem?(MIG welding was used)
Reply:Your drawing is a little small for me to see what is going on. What is a PFC? Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Originally Posted by CEPYour drawing is a little small for me to see what is going on. What is a PFC?
Reply:Looks like an easy enough weld to make. They are beveling the C-channel correct? I like 37 1/2 degree bevels for my joint prep on thinner material. 45-degrees on thick material.If there is any doubt on getting 100% penetration, I would bevel all the way around, with no land, make a knife edge.Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Here is how I like my joint prep for full penetration welds. Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:PFC- probably from china...Couldn't resist.. I think to get full penetration your cost is going to go way up. All the factors involved would slow things down. What is this structure for that it involves radiograph? It might be better to just "Live With It" . More info and more pictures will help us help you!Nothing Ever Got Done By Quitting, Never Give Up.
Reply:Originally Posted by Doug247PFC- probably from china...Couldn't resist.. I think to get full penetration your cost is going to go way up. All the factors involved would slow things down. What is this structure for that it involves radiograph? It might be better to just "Live With It" . More info and more pictures will help us help you!
Reply:eluuDitto - Doug247.If such critical specs [radiograph] are required in such a mundane sectional configuration - a more accommodating joint should have been specified - or;Have i.imgur.com change their napkin drawing to represent how;a joint so configured - turns out exercising good trade-practice.Opus
Reply:to eluu: out of curiosity(clarity), what's the thickness of the web and/or flange?