CollegeofEngineeringandComputerScience

MEC430 Machine Design

WELDED JOINTS

CollegeofEngineering&ComputerScience CECS

MEC 430 Machine Design

Chapter Objectives

Welding and types of welding joints

American Welding Society (AWS)

Examples of intensively welded products

Welding symbols

Tensile stresses in welded joints

Shear stresses in welded joints

Weld strength

Fatigue loading of welded joints

Examples
CollegeofEngineering&ComputerScience CECS

MEC 430 Machine Design

Welding
Welding
Parts are joined together by Fusion. Fusion is
brought about by a combination of heat and
pressure between parts being joined. In normal
welding processes very high temperatures and
little or no pressure is used.

Welding conditions
Smooth joint surfaces that match each other
Surfaces clean and free from oxides, grease and dirt.
Metals to be joined have same microstructure

Welding (Cont.)
Why Welding is Important
Provides a permanent joint
Welded components become a single entity
One of the most economical ways to join parts in
terms of material usage and fabrication costs
Mechanical fastening usually requires additional
hardware (e.g., screws) and geometric alterations
of the assembled parts (e.g., holes)
Not restricted to a factory environment
Welding can be accomplished "in the field"

Welding (Cont.)
Limitations and Drawbacks of Welding
Most welding operations are performed manually and
are expensive in terms of labor cost
Most welding processes utilize high energy and are
inherently dangerous
Welded joints do not allow for convenient
disassembly
Welded joints can have quality defects that are
difficult to detect
Welded joints can have significant residual stresses

Welded Joints Parameters & Types

Joint Root
is that portion of a joint to be welded where the members
are closest to each other
The joint root may be
either a point, line, or an
area
The joint roots are shown
as shaded areas in (A)-(D)
and lines in (E) (F)

Welded Joints Parameters & Types (Cont.)

Groove face, Root face and Root edge
Groove face is that
surface of a member
included in the
groove
Root face (land) is
that portion of the
groove face within
the joint root
Root edge is a root
face of zero width

Welded Joints Parameters & Types (Cont.)

More parameters of welded joints
1

6
2

1
4

1 - groove angle
2 - bevel angle
3 - root face (land)
4 - root opening (root gap)
5 - groove face

1 - throat
2 - weld face
3 - depth of fusion
4 - root
5 - fillet leg length
6 - weld toe

Welded Joints Parameters & Types (Cont.)

More parameters of welded joints
Bevel angle, Groove angle and Groove Radius

Welded Joints Parameters & Types (Cont.)

More parameters of welded joints

Welded Joints Types (Cont.)

Butt Joint
A joint between two
members aligned
approximately in the
same plane

Welded Joints Types (Cont.)

Lap Joint
A joint between two
overlapping members

Welded Joints Types (Cont.)

T Joint
A joint between two
members located
approximately at right
angles to each other

Welded Joints Types (Cont.)

Corner Joint
A joint between two
members located at right
angles to each other

Welded Joints Types (Cont.)

Core Pipe Disc Filter

Example of Intensive
Welding Products

Weld optimization
Minimizing cost and time
Minimizing amount of weld
Improving reliability

Central Rings

Example of Intensive
Welding Products

Weld procedure
optimization

Minimizing cost and time

Minimizing amount of weld

Improving reliability

Screw Pump

Core Pipe
Disc Filter

Example of Intensive
Welding Products

Weld procedure
optimization

Minimizing cost
and time

Minimizing
amount of weld

Improving
reliability

Example of Intensive
Welding Products

Weld procedure
optimization

Minimizing cost and

time

Minimizing amount of
weld

Improving reliability

Pulp Screw

Various cracks initiating

from weld site

Example of
Intensive Welding
Products

FE model with
added crack

Global Model of
Existing Design

Weld procedure
optimization

Minimizing cost and time

Minimizing amount of weld

Improving reliability

American Welding Society (AWS)

The American Welding Society (AWS) was founded in 1919 as a
multifaceted, nonprofit organization with a goal to advance the science,
technology and application of welding and related joining disciplines
The Engineering Societies Building (left) in New
York City was the home of AWS until 1961 when
the Society moved to the United Engineering
Center, also in New York City.

The Society moved its headquarters to

Miami in 1971 (above).

American Welding Society (AWS) (Cont.)

Technical Publications
American Welding Society AWS offers over hundreds
of books, charts, videos, replicas, proceedings, and
software. AWS-developed codes, recommended
practices, and guides are produced under strict
American National Standards Institute (ANSI)
procedures, including one of the most consulted codes
in the world, D1.1 Structural Welding Code - Steel.

American Welding Society (AWS)

AWS D1.1 Structural Welding Code - Steel
Guidelines for design of welded joints, prequalified
joint geometries
Statically loaded structures
Dynamically loaded structures
Tubular sections

Details the processes used with particular joints

How to qualify welding procedures and personnel
Outlines quality and inspection in welded
construction

Welding Symbols

Welding symbol standardized by American Welding Society

Specifies details of weld on machine drawings

Figure W1

Welding Symbols
(Cont.)

Welding Symbols (Cont.)

Weld Symbol Terminology
OtherSide
ArrowSide

Fillet Weld (Arrow

Side Only)

Figure W2

Fillet Weld
(Both sides)

Welding Symbols Examples

Weld leg size of 5 mm

Fillet weld
Both sides

Intermittent and
staggered 60 mm along
on 200 mm centers

Leg size of 5 mm
On one side only
(outside)
Circle indicates all the
way around

Figure W3

Welding Symbols Examples (Cont.)

Figure W4

Welding Symbols Examples (Cont.)

Figure W4

Welding Symbols Examples (Cont.)

Welding Symbols Examples (Cont.)

Welding Symbols Rules (Cont.)

When only one member is to be edge prepared to make the joint,
the arrow should point at the plate
Dimensions of size are indicated in mm without writing the unit
mm.
If unequal legs of fillet are to be used, they should also be given
on the left hand side.
If a weld is to be made all around a joint, a circle should also be
placed at the elbow, connecting the arrow and the reference line.
If a weld is to have a flush or flat finish, a straight line should be
added above the symbol.
The welding process is to be indicated or required, it is to be
placed at the end of the arrow.

Tensile-Stressed Butt Joint

Simple butt joint loaded in tension or compression

Stress is normal stress
W-1

Throat h does not include extra reinforcement

Reinforcement adds some strength for static loaded joints
Reinforcement adds stress concentration and should be ground
off for fatigue loaded joints

Figure W5

Shear-Stressed Butt Joint

Simple butt joint loaded in shear

Average shear stress
W-2

Fig. W6

Stresses in Transverse Fillet Joints

Joint loaded in tension

Weld loading is complex

Figure W7

Figure W8

Stresses in Transverse Fillet Joints (Cont.)

Summation of forces

Law of sines

Solving for throat thickness t

Figure W9

Stresses in Transverse Fillet Joints (Cont.)

Nominal stresses at angle

Von Mises Stress at angle

Figure W9

Stresses in Transverse Fillet Joints (Cont.)

Largest von Mises stress occurs at = 62.5 with value of

' = 2.16F/(hl)
Maximum shear stress occurs at = 67.5 with value of
max = 1.207F/(hl)

Figure W9

Stresses in Transverse Fillet Joints (Cont.)

Experimental results are more complex

Figure W10

Stresses in Transverse Fillet Joints (Cont.)

Figure W9a
Throat area is an assumed minimum area for carrying the
load, either normal or shear components.

Simplified Stresses in Transverse Fillet Joints

No analytical approach accurately predicts the experimentally

measured stresses.
Standard practice is to use a simple and conservative model
Assume the external load is carried entirely by shear forces on
the minimum throat area.
W3

By ignoring normal stress on throat, the shearing stresses are

inflated sufficiently to render the model conservative.
By comparison with previous maximum shear stress model, this
inflates estimated shear stress by factor of 1.414/1.207 = 1.17.

Stresses in Parallel Fillet Joints

Same equation also applies for simpler case of simple shear

loading in fillet weld
W3

Figure W11

Stresses in Fillet Joints Loaded in Torsion

Fillet welds carrying both

direct shear V and moment M
Primary shear

Secondary shear

A is the throat area of all

welds
r is distance from centroid of
weld group to point of
interest
J is second polar moment of
area of weld group about
centroid of group

Figure W12

Torsional Loading: Finding A and J

Rectangles represent
throat areas. t = 0.707 h

Fig. 913

Torsional Loading: Finding A and J

Note that t3 terms will be

very small compared to
b3 and d3
Usually neglected
Leaves JG1 and JG2 linear
in weld width
Can normalize by
treating each weld as a
line with unit thickness t
Results in unit second
polar moment of area, Ju
Since t = 0.707h,
J = 0.707hJu

Fig. 913

Table W-1: Torsional Loading: A and J Values

Table W-1: Torsional Loading: A and J Values

Example W1
Fig. W14

Figure W14

Example W1 (Cont.)
Fig. W15

Figure W15

Example W1 (Cont.)
Fig. W14
Figure W15
Table W15

Fig. W15

Example W1 (Cont.)

Fig. W15

Example W1 (Cont.)

Example W1 (Cont.)

Fig. W16

Example W1 (Cont.)

Fig. W16

Stresses in Fillet Joints Loaded in Bending

Fillet welds carry both shear V and moment M

Fig. W17

Table W-2: Fillet Joints Bending Properties

Table W-2: Fillet Joints Bending Properties (Cont.)

Table W-3a: Combined Bending & Torsion Properties

Table W-3a: Combined Bending & Torsion Properties (Cont.)

Table W-3a: Combined Bending & Torsion Properties (Cont.)

Strength of Welded Joints

Must check for failure in parent material and in weld

Weld strength is dependent on choice of electrode material
Weld material is often stronger than parent material
Parent material experiences heat treatment near weld
Cold drawn parent material may become more like hot rolled in
vicinity of weld
Often welded joints are designed by following codes rather than
designing by the conventional factor of safety method

Strength of Welded Joints (Cont.)

Minimum Weld-Metal Properties (Table W3)

Strength of Welded Joints (Cont.)

Stresses Permitted by the AISC Code for Weld Metal
(Table W-4)

Strength of Welded Joints (Cont.)

Fatigue Stress-Concentration Factors

Kfs appropriate for application to shear stresses

Use for parent metal and for weld metal

Strength of Welded Joints (Cont.)

Allowable Load or
Various Sizes of Fillet
Welds (Table 96)

Strength of Welded Joints (Cont.)

Minimum Fillet Weld Size, h (Table 96)

Example W2

Fig. 918

Example W2

Example W2

Example W3

Fig. 919

Example W3

Example W3

Example W3

Example W3

Example W3

Example W4

Fig. 920

Example W4

Example W4

Example W4

Example W5

Fig. 921

Example W5

Example W5

Example W6

Fig. 922

Example W6

Example W6

College of Engineering & Computer Science - CECS

MEC 430 Machine Design