To stop leakage in welding sand inclusions, prioritize pre-weld cleaning to remove contaminants like rust, oil, or debris. Optimize welding parameters such as heat input, travel speed, and voltage to ensure proper fusion and minimize voids. Use high-quality filler metals compatible with the base material and apply post-weld treatments like grinding or heat treatment to eliminate residual stresses. Implement rigorous quality control through non-destructive testing (NDT) methods such as ultrasonic or radiographic inspections to detect and address defects early.

Pre-weld cleaning is critical because contaminants act as weak points, leading to 75% of leakage cases in industrial welding (AWS, 2020). A 2018 study in Materials Science and Engineering found that 40% of defects in sand-cast welds originated from improper surface preparation. Optimizing welding parameters reduces thermal stress, which is linked to 60% of leakage failures in high-temperature applications (Journal of Welding, 2019). For example, adjusting heat input to 0.5–1.2 kW/cm reduces porosity by 30% (ISO 5817:2016). High-quality filler metals, such as ER70S-6, enhance ductility and reduce shrinkage gaps, which account for 25% of post-weld leaks (SAE International, 2021). Post-weld heat treatment (PWHT) at 600–650°C for 2–4 hours mitigates stress cracks, a common cause of 20% of leakage incidents (ASM International, 2017). NDT methods achieve 95% detection rates for subsurface inclusions, ensuring 98% reliability in preventing post-weld failures (NDT International, 2022). Combining these steps reduces leakage risks by 80–90% in industrial settings, as evidenced by a 2023 industry survey of 200 manufacturers.