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In the case of horizontal weld, the slag covers the fresh molten melt because it has a lower density and forms a protective layer which prevents molten metal to come in contact with atmospheric gases. But, In Overhead welding as the slag has a lower density, it should move inside the molten metal and form a layer. this layer should cause defects and weakening of the weld. Is this what actually happens?

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No, overheads welds can be completed without inclusions and blowholes. Just needs learning and experience.

Check out the various methods of welding as some don't produce much or any slag.

Solar Mike
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