SIMPLE WELDED CONNECTION

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 Welding
Welding is a process of joining metal pieces by the application of heat
(i.e. fusion) with or without pressure
 Types of Welding Process
Forge Welding
Thermit Welding
Gas Welding
Resistance Welding
Electric Arc Welding – Most popular and preferred
Arc welding is a welding process that is used to join metal to
metal by using electricity to create enough heat to melt metal,
and the melted metals, when cool, result in a binding of the
metals.
Electric Arc Welding
 Reasons for using Welded Connections
1. As no hole is required for welding, no reduction of area,
so structural members are more effective in transferring
the loads
2. Filler plates, Gusseted plates, Connecting angles etc. are
not used, which leads to reduced overall weight of the
structure
3. More economical as less material is required
4. Efficiency of welded joints is more (i.e. 100%) than
rivetted or bolted joints (Formula of efficiency)
 Reasons for using Welded Connections
5. Looks better than the bulky riveted or bolted joints
6. Faster Speed of construction in comparison with riveted
or bolted joints
7. Complete rigid joints (role of fixity, indeterminate strs)
8. Alteration and addition to existing structure is easy as
compared to riveted or bolted joints
9. No noise as compared to riveted joints
10. Welding process required less space
11. Any shape of joint is easily possible
 Disadvantages of Welded Connections

1. Welded joints are brittle & therefore their fatigue strength

is less than the members joined.
2. Due to uneven heating and cooling during the welding,
the members may distort resulting in additional stresses
3. Skilled labour and electricity is required for welding
4. No provision for expansion and contraction is kept in
welded connection and therefore there is possibility of
cracks
 Disadvantages of Welded Connections

5. Inspection of welding work is more difficult and

expensive than riveting or bolting work
6. Defects like an internal air pocket, slag inclusion, and
incomplete penetration are difficult to detect
 Types of Welds

Classification based on their formation:

• Fillet weld
• Butt weld
• Intermittent weld
• Plug weld
• Slot Weld
 Fillet Welds

1. When two members are overlapped

2. When two members are joined in

different planes
(use of additional cleat
not required)
 Butt Welds

When two members are joined in the same plane

(Important: the penetration of weld material may be complete
or incomplete based on the type of butt weld)
 Intermittent Welds

To reduce weld length

 Plug and Slot Welds

Plug and slot welds are used for the transfer of shear force only.

Used to transmit shear in lap joints.

Used to join components of built-up members

Used to prevent buckling of lapped parts.

 WELD DEFECTS

Incomplete Fusion is the failure of the base metal to get

completely fused with the weld metal.
Incomplete Penetration is the failure of the weld metal to
penetrate the complete depth of joint.
Porosity occurs due to voids or gas pockets entrapped in the
weld while cooling. It results in stress concentration and reduced
ductility of the metal.
Slag Inclusions are metallic oxides and other solid compounds
which are sometimes found as elongated or globular inclusions.
Cracks are divided as hot and cold. Hot cracks occur due to the
presence of sulphur, carbon, silicon and hydrogen in phosphorus
and hydrogen trapped in the hollow spaces of the metal structure
give rise to the formation of cold cracks.
Undercutting is the local decrease of the thickness of the parent
metal at the weld toe.
Weld Symbols
 FILLET WELDS

These welds are done for the members which overlap. The
welds are subjected to shear stresses. They are also subjected
to axial stress but is not of much importance.
Convex shape is better for static loads, whereas concave shape
for fatigue loading.
FILLET WELDS
Design Specifications for Fillet Welds

The size of fillet weld is specified as the minimum leg length of the weld.
Maximum Size of Weld
The maximum size of a fillet weld is obtained by subtracting 1.5 mm from the
thickness of the thinner member to be jointed. In case of welds applied to the round
toe of steel sections the maximum size of the weld should not exceed ¾ of the
thickness of the section at the toe.
Minimum Size of Weld (Table 21. Cl. 10.5.2.1 Pg. 78)

Table Minimum size of first run of fillet weld or of a single run fillet weld
Effective Throat Thickness Specifications continued
(Cl. 10.5.3 Pg. 78)
It is the shortest distance from the root of fillet weld to the face
of diagramatic weld.
Throat in no case should be less than 3 mm.
 Specifications continued
• Effective length: It is the length of the fillet weld for which the specified
size and throat thickness of weld exist.
• In practice the actual length of weld is made of the effective length shown
in the drawing plus two times the weld size.
• End returns (Cl. 10.5.1.1 Pg. 78) as shown in the figure are made equal to
twice the size of the weld to relieve the weld length from high stress
concentrations at their ends.

If the length of the welded joint exceeds 150

times the throat size of the weld, a reduction in
weld strength is done by a factor (Cl. 10.5.4.4
Pg. 79)
Specifications continued

• Effective Area (Cl. 10.5.4 Pg. 78) The effective area of a fillet
weld is equal to effective length of the weld multiplied by effective
throat thickness.
• Overlap (Cl. 10.5.1.2 Pg. 78) the overlap of the plates to be fillet
welded should not be less than four times the thickness of thinner
part jointed or 40 mm whichever is more.
• Transverse spacing (Cl. 10.5.1.2 Pg. 78) Length of fillet weld
should not be less than the transverse spacing between them.
 Design Strength
( Cl. 10.5.3.2 Pg. 78, Cl. 10.5.7.1.1 & Cl. 10.5.9 Pg. 79)

The design strength of a fillet weld is based on its throat area and is
given by
FILLET WELD FOR TRUSS MEMBERS
 Butt Welds
Usually designed for axial/bending tension or compression but if
shear is also there then due provision should be made
Involves no abrupt change in section at the joint, it is the most
suitable form of the weld for transmitting alternating stresses
The groove welds may be of partial penetration or of complete
penetration; the former being not preferred. It is difficult to
achieve complete penetration for single-U, V, J or bevel welds.
However, this can be achieved by using back-up strips.
 Butt Weld
Double-U, V, J or bevel welds are examples of complete
penetration groove welds.
In case of complete penetration of the groove weld the effective
throat thickness is taken as the thickness of the thinner member
jointed.
 Butt Weld
In case the full penetration of groove weld cannot be achieved,
an effective throat thickness of 7/8th of the thickness of the
thinner member should be used. But for calculating the strength,
the effective throat thickness is assumed to be 5/8th of thickness
of the thinner member.
Design Specifications of Butt/Groove Welds (Cl. 10.5.7.1.2 Pg. 79)
Reinforcement
It makes the throat dimension at least 10% greater than the
thickness of the welded material. In any case, the reinforcement
should not exceed 3 mm.
Throat Thickness
In case of complete penetration of the groove weld the effective throat
thickness is taken as the thickness of the thinner member jointed.
In case the full penetration of groove weld cannot be achieved,
an effective throat thickness of 7/8th of the thickness of the
thinner member should be used. But for calculating the
strength, the effective throat thickness is assumed to be 5/8th of
thickness of the thinner member.
Effective Area
It is the product of the effective throat thickness and the
effective length.
 Design Strength of Butt/Groove Welds
(Cl. 10.5.7.1.1, Cl. 10.5.7.1.2 and 10.5.9 Pg. 79)
The design strength of the groove weld in tension or compression is given by

where fy = smaller of yield stress of the weld (fyw) and the parent metal (fy) in MPa
lw = effective length of the weld in mm
te = effective throat thickness of the weld in mm
= partial safety factor
= 1.25 for shop welding
= 1.5 for site welding
The design strength of the groove weld in shear is given by

where fyw1 = smaller of shear stress of weld and the parent metal
= partial safety factor as defined above
fyw = yield stress of weld (MPa)
 INTERMITTENT WELDS
• Intermittent fillet weld section should have a]minimum effective length of four
times the size of the weld with a minimum of 40 mm. (Cl. 10.5.5.1 Pg. 79)

• Clear spacing between an intermittent fillet weld should not exceed 12t for
compression and 16t for tension and be more than 200mm (Cl. 10.5..7.1.2 Pg.
79)

• At the ends, the longitudinal intermittent fillet weld should be of a length not less
than the width of the member or else transverse welds should also be provided. If
transverse welds are provided along with longitudinal intermittent fillet welds, the
total weld length at the ends should not be less than twice the width of the
member.
 PLUG (Cl. 10.5.4.3 Pg. 79) AND SLOT WELDS (Cl. 10.5..7.1.3 Pg. 79)

Plug and slot welds

These are used most often to tie two parts together, and in particular to reduce the
unsupported dimensions of cover plates in compression which increase the critical
stress.

Specifications
1. Width or diameter should be ≥ 3t and also ≥ 25 mm.
2. Corner radius in slotted hole should be ≥ 1.5t and also ≥ 12 mm.
3. Clear distance between holes should be ≥ 2t and also ≥ 25 mm
where t is the
thickness of plate having a hole or slot.
Stresses due to Individual Forces (Cl. 10.5..9 Pg. 79)

subjected to either compressive or tensile or shear force alone, the stress in the weld is
given by
 COMBINATION OF STRESSES (Cl. 10.5.10 Pg. 80)

Fillet Welds (Cl. 10.5.10.1 Pg. 80) Butt Welds (Cl. 10.5.10.2 Pg. 80)

For fillet welds check for the combination of For butt welds check for the combination of stresses need
stresses need not be done in the following not be done if butt welds are axially loaded, and in single
situations. and double bevel welds the sum of normal and shear
For side fillet welds joining of cover plates and stresses does not exceed the design normal stress, and
flanges plates. fillet welds where sum of normal and the shear stress does not exceed 50 per cent of the
shear stresses does not exceed 𝑓 determined. design shear stress.

Combined Bearing, Bending and Shear

Thank You!

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