07/02/2022

Lecture outline
Joining and Assembly
Why Welding is Important?
Welded Joints Limitations and Drawbacks of Welding
Types of Welding Processes

Prof. Nirosh Jayaweera, PhD, CEng Basic Welded Joints

07th February, 2022 Welding Symbols
Strength calculation of Welded joints
Weld Defects

Learning Outcomes Joining and Assembly

After this lesson students should be able to:
Joining - welding, brazing, soldering, and
1. Describe different method of welding and adhesive bonding
types of welded joints
• These processes form a permanent joint
2. Perform strength calculation of fillet and butt between parts
welded joints
Assembly - mechanical methods (usually) of
fastening parts together
• Some of these methods allow for easy
disassembly, while others do not

Welding Structural Welding

Joining process in which two (or more) parts

are combined at their contacting surfaces
by application of heat and/or pressure
– Many welding processes are accomplished by
heat alone, with no pressure applied
– Others by a combination of heat and pressure
 Common method for connecting structural steel
– Still others by pressure alone with no external
 Many fabrication shops prefer to weld rather than bolt
heat
 There are several welding processes, types, and
• In some welding processes a filler material positions to be considered in building construction
is added to facilitate joining

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Structural Welding Why Welding is Important?

 Provides a permanent joint
Welded components become a single entity
 Usually the most economical way to join
components in terms of material usage and
fabrication costs
Mechanical fastening usually requires additional
hardware components (e.g., screws and nuts)
and geometric alterations of the parts assembled
 Welding is the process of fusing multiple pieces of
metal together by heating the filler metal to a liquid state
 Not restricted to a factory environment
 A properly welded joint is stronger than the base metal Welding can be accomplished "in the field"

Limitations and Drawbacks of

Types of Welding Processes
Welding

Most welding operations are performed • Some 50 different types of welding processes
manually and are expensive in terms of have been catalogued by the American
labor cost Welding Society (AWS)

Most welding processes utilize high energy

• Welding processes can be divided into two
and are inherently dangerous
major categories:
Welded joints do not allow for convenient
disassembly – Fusion welding
Welded joints can have quality defects that – Solid state welding
are difficult to detect

Fusion Welding Some Fusion Welding Processes

Arc welding (AW) – melting of the metals is

Joining processes that melt the base metals
accomplished by an electric arc
 In many fusion welding operations, a filler metal
is added to the molten pool to facilitate the Resistance welding (RW) - melting is
process and provide bulk and added strength to accomplished by heat from resistance to an
the welded joint electrical current between faying surfaces
 A fusion welding operation in which no filler held together under pressure
metal is added is called an autogenous weld. Oxyfuel gas welding (OFW) - melting is
(A fusion welding process using heat without the addition of filler accomplished by an oxyfuel gas such as
metal to join two pieces of the same metal)
acetylene

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Solid State Welding Some Solid State Welding Processes

Diffusion welding (DFW) –coalescence is by

Joining processes in which coalescence solid state fusion between two surfaces held
results from application of pressure together under pressure at elevated
alone or a combination of heat and temperature
pressure
Friction welding (FRW) - coalescence by
If heat is used, temperature is below heat of friction between two surfaces
melting point of metals being welded Ultrasonic welding (USW) - coalescence by
No filler metal is added in solid state ultrasonic oscillating motion in a direction
welding parallel to contacting surfaces of two parts
held together under pressure

Applications of Welding The Welded Joint

Construction - buildings and bridges There are Three distinct zone

Piping, pressure vessels, boilers, and
 Base metal
storage tanks
Shipbuilding  Heat – affected zone
Aircraft and aerospace  Weld metal
Automotive
Railroad

The Welded Joint Parts of a Weld

Heat-affected zone Weld metal

(HAZ) (Fusion zone)

Unaffected
parent material

Fusion and heat-affected zones

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Types of Welds Types of Weld

 groove,
Many welds can be made by various types of  fillet,
joints  plug,
Factors to be consider in choosing joint  slot,
geometry and weld types:  stud,
 spot,
 accessibility to the joint for welding
 projection,
 type of welding process being used  seam,
 suitability to the structural design  back or backing weld,
 surfacing and
 cost of welding  flange.

Types of joints Five Basic Welded Joints

Butt Joint
A joint between two
members aligned
approximately in
the same plane
and are joined at
their edges

Different Edge Shapes and Symbols

Five Basic Welded Joints
for some Butt-Joints

Corner Joint
A joint between two
members located at
right angles to each
other and are joined
at the corner of the
angle

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Some Different Edge Shapes and

Five Basic Welded Joints
Symbols for Corner Joints

T-Joint
A joint between two
members located
approximately at right
angles to each other in
the form of a T

Some Different Edge Shapes and Five Basic Welded Joints

Symbols for T-Joint
Lap Joint

A joint between
two overlapping
members

Some Different Edge Shapes and

Five Basic Welded Joints
Symbols for Lap Joints
Edge Joint
A joint between the
edges of two or more
parallel or nearly
parallel members and
the joint is made at
the common edge(s)

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Some Different Edge Shapes and

Fillet Weld
Symbols for Edge Joints

• Used to fill in the edges of plates created by

corner, lap, and tee joints
• Filler metal used to provide cross-section in
approximate shape of a right triangle
• Most common weld type in arc and oxyfuel
welding
• Requires minimum edge preparation

Fillet Weld Groove Welds

Usually requires part edges to be shaped

into a groove to facilitate weld penetration
Edge preparation increases cost of parts
fabrication
Various forms of fillet welds: The grooved shapes include square, bevel,
(a) inside single fillet corner joint
V, U, and J, in single or double sides
(b) outside single fillet corner joint
(c) double fillet lap joint and Most closely associated with butt joints
(d) double fillet tee joint
Dashed lines show the original part edges

Groove Welds Groove Welds

Seven types of groove welds and symbols to
represent them
– Square
–V
– Bevel Symbols take the shape
–U of the groove the weld
–J is to be placed in. Some groove welds
– Flare-V (a) square groove weld, one side (b) single bevel groove weld
(c) single V-groove weld (d) single U-groove weld
– Flare-bevel
(e) single J-groove weld (f) double V-groove weld for thicker
sections.
Dashed lines show original part edges

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Spot Weld What are Welding Symbols?

A small fused section between surfaces of • Welding symbols give • Welding symbols are
two sheets or plates the welder specific – Universally used
Used for lap joints instructions about the – Governed by the AWS
weld including: – Found on engineering
Most closely associated with resistance
welding – Placement drawings
– Size
– Length
– Process
– Any other special notes
Spot weld
“How to Read Shop Drawings”
available at www.jflf.org

Examples:
Welding Symbols
Fillet Welds on T-Joints

Examples:
Welding Symbol Examples
Fillet Welds on T-Joints
 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

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Example: Fillet Weld Length and Pitch

Weld Reinforcement
Indications

Usually weld may be weaker than the base plates

due to slag blow holes.

Therefore, weld is reinforced to equalise the strength

of the weld and the base plates.

The reinforcement may be taken as 10% of the plate

thickness.

Strength of Transverse Fillet Welded Strength of Transverse Fillet Welded

joints joints

From the Figure, throat thickness,

Minimum area of the weld or throat area:

Enlarge view of a fillet weld

Strength of Transverse Fillet Welded Strength of Parallel fillet welded

joints Joints
The parallel fillet welded joints are designed for shear
If σt is the allowable tensile stress for the weld metal, strength. Consider a double parallel fillet welded joint.
the tensile strength of the joint for single fillet weld,
Minimum area of weld or the throat
area,
A = 0.707 s x ɩ
Tensile strength of the joint for double fillet weld If Ʈ is the allowable shear stress for
the weld metal, then the shear
strength of the joint for single parallel
fillet weld.

Shear strength of the joint for double parallel fillet weld:

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Strength of Parallel fillet welded

Question
Joints
Note:
1. If there is a combination of A plate 100 mm wide and 10 mm thick is to be
transverse and parallel fillet weld,
The strength of the joint is given by
welded to another plate by means of double
the sum of strengths of single parallel fillets. The plates are subjected to a
transverse and double parallel fillet static load of 80 kN. Find the length of weld if
welds:
the permissible shear stress in the weld does
not exceed 55 MPa.

Answer Special Cases of Fillet Welded joints

Given: Circular fillet weld subjected to torsion
Consider a circular rod connected to a rigid plate by a fillet weld:
Width = 100 mm
Thickness = 10 mm
P = 80 kN = 80 x 103 N
Ʈ = 55 MPa = 55 N/mm2
Let ɩ = length of weld
s = size of weld = Plate thickness = 10 mm (Given)

Maximum load which the plate can carry for double parallel fillet weld :

80 x 103 = 1.414 x s x ɩ x Ʈ = 1.414 x 10 x ɩ x 55 = 778 ɩ

Shear stress for the material
ɩ = 80 x 103 / 778 = 103 mm
Adding 12.5 mm for starting and stopping of weld run,
ɩ = 103 + 12.5 = 115.5 mm

Special Cases of Fillet Welded joints Questions

This shear stress occurs in a horizontal plane along a leg
of the fillet weld. A 50 mm diameter solid shaft is welded to a flat plate by 10
mm fillet weld as shown in figure. Find the maximum
The maximum shear occurs on the throat of weld which torque that the welded joint can sustain if the maximum
is inclined at 450 to the horizontal plane. shear stress intensity in the weld material is not to exceed
80 MPa.

Maximum shear stress:

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Circular fillet weld subject to bending

Answer
moment
Given: Consider a circular rod connected to a rigid plate by a fillet weld:

Maximum shear stress:

Bending Stress

Circular fillet weld subject to bending

moment
This bending stress occurs in a horizontal plane along a
leg of the fillet weld. The maximum bending stress
occurs on the throat of the weld which is inclined at 450

Any Questions?
to the horizontal plane.

Maximum bending stress:

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