232 S T E E L D E S I G N E R S ’ H A N D B O O K

(c) From the point of view of resistance to fatigue, fillet welds are inferior to butt welds.
This is because there exists both an abrupt change in the direction of the stress
trajectory and a notch-like effect at the root of the fillet weld. This results in stress
concentrations and a triaxial stress state, and can lead to brittle fracture when the
weldment is subjected to a large number of load cycles (fatigue failure).
The main uses of fillet welds are:
(a) For lap splices. The transfer of force from one plate to another is through shear in the
weld. Fillet welds can be arranged to be parallel with the member axial force
(longitudinal welds) or at right angles to it (transverse welds), or a combination of
both.
(b) For T-joints. The two modes of transfer of forces are: compression or tension and
shear through weld.
(c) For corner joints similar to T-joints.
(d) For structural plug and slot welds. Non-structural plug welds are permitted to be
filled in flush with the surface of the plate, but such welds are rarely sound and they
contain many cracks. Fillet welds run around the periphery of the hole can reliably
be used to transmit the forces.
Where the forces transmitted by fillet welds are relatively small and the structure is not
exposed to weather, it may be advantageous to use intermittent welds. Their benefits
include using less filler metal and causing less distortion during welding. They may not
show cost savings, however, because of frequent stop–start operations.
The inspection of fillet welds can usually be specified to include inspection during the
preparation of material, fit-up and actual welding. Typical weld defects found in fillet
welds are shown in Figure 8.15 as well as design concepts and terminology. Inspection
must, of course, ascertain that the leg size and weld length specified in the design have
been achieved.

T heoret i ca l w eld sh a p e
W eld ( i sosceles t r i a ngle)
p enet ra t ion

T heoret i ca l Id e a l w e ld
E x ce ssi v e U nder cut cont our
fa i lur e
conca v i t y Ex cessi v e p la ne
conv ex i t y W eld
Ov e rla p E ffect i v e leg t oe Ap p a rent leg

R oot ga p
D esi gn
(a) T h roa t
W eld r oot (b)
Leg lengt h T hi ckne ss t 1
E x ce ssi v e La ck of
r oot ga p fusi on Dep t h of p enet r a t i on

Figure 8.15 Fillet welds: (a) typical defects, and; (b) concepts and terminology.

The fact that the strength of fillet welds has a direct relationship to the nominal tensile
strength of the weld consumable used leads to the necessity of specifying on the drawings