I am currently involved in work where we are experiencing a high failure rate with welder qualification tests on FCAW fillet welds. The macro etch test and fillet weld break tests are carried out as per AWS D1.1 Table 4.10 Option 1. The marco etch results are acceptable by code as there is complete penetration at the root. The fillet weld break tests show complete root penetration, however some lack of side wall fusion.

The contention is that whilst complete root penetration is achieved, there is lack of side wall penetration.

As per AWS D1.1 2004 Para 4.30.4.1 - Acceptance Criteria for fillet weld break test" states
The broken specimen shall pass if
(2) "The fillet weld, if fractured, has a fracture surface showing complete fusion to the root of the joint...."
It doesn't say anything about side wall

Para 4.30.2.3 - Macroetch Test Acceptance Criteria part 1 says (for visual acceptance of the test specimen) states
"Fillet welds shall have fusion to the root of the joint but not necessarily beyond"

What does the word "to" mean in the above statements?
1.  Does it mean that fusion is only required at the root of the joint (i.e. the intersection of the vertical and horizontal members)
2.  Or does it mean that fusion is required to (as in towards) the root, hence inferring that side wall penetration is also required

Can anyone shed any light?

Thanks
Damien