2009/01/14

Weld Joints

Weld Types

ME 538 Welding Design, Fabrication & Quality Control

[Cary: Modern Welding Technology, 1998]

Fillet Welds

correction

ME 538 Welding Design, Fabrication & Quality Control

Groove Welds
Directing electrode at side wall of the joint will help ensure good sidewall fusion in deep welds

Provide base metal for root and prevent blow through Ensure full penetration
ME 538 Welding Design, Fabrication & Quality Control 3

Examples of Groove Welds

Edge Weld
ME 538 Welding Design, Fabrication & Quality Control
CWA W59 Appendix E

Butt Joint & Applicable Weld Types

[AWS Handbook, 9th ed., Vol.1, Chap.5, and CSA W59-M1989 Standard]
ME 538 Welding Design, Fabrication & Quality Control 5

Corner Joint & Applicable Weld Types

[AWS Handbook, 9th ed., Vol.1, Chap.5, and CSA W59-M1989 Standard]
ME 538 Welding Design, Fabrication & Quality Control 6

T Joint & Applicable Weld Types

[AWS Handbook, 9th ed., Vol.1, Chap.5, and CSA W59-M1989 Standard]
ME 538 Welding Design, Fabrication & Quality Control 7

Lap Joint & Applicable Weld Types

[AWS Handbook, 9th ed., Vol.1, Chap.5, and CSA W59-M1989 Standard]
ME 538 Welding Design, Fabrication & Quality Control 8

Edge Joint & Applicable Weld Types

[AWS Handbook, 9th ed., Vol.1, Chap.5, and CSA W59-M1989 Standard]
ME 538 Welding Design, Fabrication & Quality Control 9

2009/01/15

Standard Locations of Elements of a Welding Symbol

ME 538 Welding Design, Fabrication & Quality Control

[AWS Handbook, Vol. 1, also ANSI/AWS Standard A2.4-98]

10

The Weld Joint & Reference Line

ME 538 Welding Design, Fabrication & Quality Control

[Cary: Modern Welding Technology, 1998]

11

Groove Weld Symbols

ME 538 Welding Design, Fabrication & Quality Control

[AWS Handbook, Vol. 1, also ANSI/AWS Standard A2.4-98] 12

Fillet and Other Weld Symbols

ME 538 Welding Design, Fabrication & Quality Control

[AWS Handbook, Vol. 1, also ANSI/AWS Standard A2.4-98]

13

Supplementary Symbols

Finishing Codes
ME 538 Welding Design, Fabrication & Quality Control

[AWS Handbook, Vol. 1, also ANSI/AWS Standard A2.4-98]

14

Welding, Brazing & Soldering Process Designations

ME 538 Welding Design, Fabrication & Quality Control

[AWS Handbook, Vol. 1, Chap. 8]

15

Example: Welding Symbols with Multiple Reference Lines

ME 538 Welding Design, Fabrication & Quality Control

[AWS Handbook, Vol. 1, Chap. 8]

16

Example: Welding Symbols for Intermittent Fillet Welds

1/4 1/4

1/4 1/4

All units are Inches

ME 538 Welding Design, Fabrication & Quality Control

[AWS Handbook, Vol. 1, Chap. 8]

17

Example: Brazing & Soldering Symbols

FS

ME 538 Welding Design, Fabrication & Quality Control

[AWS Handbook, Vol. 1, Chap. 8]

18

2009/01/19

Selection of the Joint Type

The most appropriate joint type for an application will depend on:
The required part geometry The ability of the joint to transfer the load The welding position Accessibility of the joint for welding and inspection 5. Joint preparation and welding costs 6. Governing code and qualification requirements (Fabrication)
ME 538 Welding Design, Fabrication & Quality Control 19

1. 2. 3. 4.

Selection of Weld Types

Selection of the most appropriate weld type for a joint is based on the ability of the weld to safely transfer the load in service and on the cost of making the weld. The designer can choose:
1. Plug or slot welds 2. Fillet welds for joints subject to lower stress j j or less demanding service conditions 3. Full penetration groove welds for joints in critical service conditions, e.g., high stress or cyclic loading
ME 538 Welding Design, Fabrication & Quality Control 20

10

Prohibited Applications of One-sided Fillet Welds One-

ME 538 Welding Design, Fabrication & Quality Control

[AWS Handbook, Vol. 1, Chap. 8]

21

Example: CSA W59 Required Fillet Lap Joints in Tension

F F

ME 538 Welding Design, Fabrication & Quality Control

22

11

Welding Positions

More Favored
Easier, Faster, Higher Deposition Rates, Less L Cost

Less Favored
Harder, Slower, Lower Deposition Rates, More Cost

ME 538 Welding Design, Fabrication & Quality Control

[Cary: Modern Welding Technology, 1998]

23

Groove & Fillet Welds Positions

ME 538 Welding Design, Fabrication & Quality Control

[CSA W59-M1989 Standard]

24

12

Pipe Welding Positions

ME 538 Welding Design, Fabrication & Quality Control

[Cary: Modern Welding Technology, 1998]

25

Examples of Poor Weld Accessibility

POOR

POOR

POOR

BETTER

POOR BETTER

POOR
ME 538 Welding Design, Fabrication & Quality Control

[J. Hicks, A Guide to Designing Welds, 1989]

26

13

More Examples of Weld Accessibility

ME 538 Welding Design, Fabrication & Quality Control

[J. Hicks, A Guide to Designing Welds, 1989]

27

Economics of Groove Welds

Square groove welds: Lowest Cost but thickness is limited
From one side 1/4 to 3/8 (6 to 10 mm) max. From both sides 1/4 to 1/2 (6 to 12 1/4 1/2 mm) max.

Single V or single bevel welds:

Thickness is equal or less than 3/4 (18 mm)

Double V or double bevel welds:

Up to 40 mm gives lowest distortion

Single and double J groove welds:

Less weld metal is required, but requires machining operation

Single and double U groove welds:

Less weld metal is required, but requires machining operation
ME 538 Welding Design, Fabrication & Quality Control

Welding & Metal Fabrication, Mar. 1977, pp. 85-91

28

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Rule of Thumb for Fillet Welds

Weld strength is proportional to the weld throat area Throat Area = 0.707 S x L To double the strength: 1) Double the size, S, but the volume of weld metal required increases in proportion to S2, i.e., the volume of weld metal required increases by 4 times! 2) Double the length and the volume only doubles

Weld Throat

Rule of Thumb for Fillet Welds: Always make a fillet weld small and long
Note: there are usually minimum allowed fillet weld sizes in codes due to metallurgical limitations
ME 538 Welding Design, Fabrication & Quality Control

[Cary: Modern Welding Technology, 1998]

29

Minimum weld sizes in steel welding codes are to avoid formation of martensite at the fusion boundary due to high cooling rates in small welds on large plates.

2009/01/21

Volume of Weld Metal for T-Joints T-

ME 538 Welding Design, Fabrication & Quality Control

[AWS Welding Handbook, Vol. 1 (9th Ed.)]

30

15

Equal Throat/Strength T-Joint Welds T-

ME 538 Welding Design, Fabrication & Quality Control

[AWS Welding Handbook, Vol. 1 (9th Ed.)]

31

Typical Corner Joint Designs

ME 538 Welding Design, Fabrication & Quality Control

32

Corner Welds => D&E groove welds used for larger plates *E can be a problem with structural steel due to lamilar tearing

16

Deposition Rates

ME 538 Welding Design, Fabrication & Quality Control

[AWS Welding Handbook, Vol. 1 (9th Ed.)]

33

Deposition Rates
SMAW

GMAW

FCAW

SAW

ME 538 Welding Design, Fabrication & Quality Control

[AWS Welding Handbook, Vol. 1 (9th Ed.)]

34

EXXXX

UTS

Additives

Position

17

Operator Factor

ME 538 Welding Design, Fabrication & Quality Control

[AWS Welding Handbook, Vol. 1 (9th Ed.)]

35

2009/01/22

Some General Weld Joint Design Guidelines

1. Designed weld strength must be greater than or equal to the required joint strength 2. Use standardized joints whenever p j possible 3. Use complete penetration welds for joints in tension or fatigue (CP) 4. Always choose a joint preparation that minimizes machining costs and the amount of weld metal and welding time required 5. Always use the smallest fillet or partial penetration weld size allowed ld i ll d 6. Use intermittent fillet welds whenever possible, but be aware of minimum length & pitch requirements 7. Always try to reduce the number of welds required 8. Avoid overwelding
ME 538 Welding Design, Fabrication & Quality Control

[Cary & Helzer: Modern Welding Technology, 2005]

36

18

Some General Weld Joint Design Guidelines

9. Remove material in butt joints between different thicknesses for better transition (dont add material) 10. Try to avoid using double T or cruciform joints 11. Always bevel the thinner member of corner joints 12. Avoid plug or slot welds in highly stressed members 13. Use flat welding position whenever possible 14. 14 Welding in an enclosed area must be well ventilated 15. Always ensure accessibility 16. Weld symbols must be clear and unambiguous

ME 538 Welding Design, Fabrication & Quality Control

[Cary & Helzer: Modern Welding Technology, 2005]

37

Practical Welding Design Principles

1. Secondary Member: There is no secondary member in a welded structure 2. Transverse Forces: Always provide a path so that a transverse load can enter part/parts of the weldment that lie parallel to the load 3. Force Redirection: Always provide a component when a force changes direction p g 4. Weld Details vs. Welders skill: Always avoid a joint design where the skills of the welder determine the welds integrity
ME 538 Welding Design, Fabrication & Quality Control

[Cary & Helzer: Modern Welding Technology, 2005]

38

19

Examples: CSA W59 Minimum Allowed Weld Sizes for Welded Steel Construction

ME 538 Welding Design, Fabrication & Quality Control

[CSA W59-M1989 Welded Steel Construction]

39

Examples: Secondary Members

Backing bars butted together => Incipient crack
Discontinuous Backing Bar

Solution: Weld backing bars together or use continuous length

ME 538 Welding Design, Fabrication & Quality Control

Keep weld away from joint

40

20

Examples: Transverse Forces

A force applied transverse to a member will ultimately enter a portion of the section that lies p p parallel to the applied force

ME 538 Welding Design, Fabrication & Quality Control

[AWS Welding Handbook, Vol. 1 (9th Ed.)]

41

Provision for Transverse Force

Poor Design Better Design

ME 538 Welding Design, Fabrication & Quality Control

[AWS Welding Handbook, Vol. 1 (9th Ed.)]

42

21

Example: Attachments with Transverse Loads

ME 538 Welding Design, Fabrication & Quality Control

[AWS Welding Handbook, Vol. 1 (9th Ed.)]

43

Example: Attachments with Transverse Loads

ME 538 Welding Design, Fabrication & Quality Control

[AWS Welding Handbook, Vol. 1 (9th Ed.)]

44

22

Example: Attachments with Transverse Loads

ME 538 Welding Design, Fabrication & Quality Control

[AWS Welding Handbook, Vol. 1 (9th Ed.)]

45

Example: Designing for Transverse Forces

Poor Design

Better: Add External Gusset Plates

ME 538 Welding Design, Fabrication & Quality Control

Best: Add Internal Stiffener Plates

[Blodgett, Eng. J. - AISC, 1980, 17(4), pp. 106-119]
46

23

Force Redirection

ME 538 Welding Design, Fabrication & Quality Control

47

Weld Details vs. Welders Skill

Poor Design
ME 538 Welding Design, Fabrication & Quality Control

Better Design
O.W. Blodgett, Eng. J.-AISC, 17(4),1980,106-119
48

24

Weld Details vs. Welders Skill

A weld must start and stop so no crater is left at points of high stress
(AWS Standard D1.1 and CSA W59 Welded Steel Construction)

ME 538 Welding Design, Fabrication & Quality Control

O.W. Blodgett, Eng. J.-AISC, 17(4),1980,106-119

49

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