WeldedJoints

VedatTemiz Assistant Professor ofMachine Design

Introduction
Aweldedjointisapermanentjointwhichisobtainedbythe fusionoftheedgesofthetwopartstobejoinedtogether,withor withouttheapplicationofpressureandafillermaterial.Theheat req iredforthef required fusion sionofthematerialma maybeobtainedby b burningofgas (incaseofgaswelding)orbyanelectricarc(in caseofelectricarcwelding).Thelattermethodisextensively usedbecauseofgreater speed ofwelding. Welding gisextensively yusedinfabricationasanalternative methodforcastingorforgingandasareplacementforboltedand rivetedjoints.Itisalsousedasarepairmediume.g.toreunite metal latacrack, k tobuild b ldupasmall llpartthat h has h broken b k off ffsuch h asgeartoothortorepairawornsurfacesuchasabearing surface. surface

AdvantagesandDisadvantagesof WeldedJointsoverRivetedJoints
1) Theweldedstructuresareusuallylighter thanrivetedstructures.Thisisduetothe reason thatinwelding, reason, welding gussetsorotherconnectingcomponentsarenotused used. 2) Theweldedjointsprovidemaximumefficiency(maybe100%)whichisnotpossible incase ofriveted joints. 3) Alterationsandadditionscanbeeasilymadeintheexistingstructures. 4) Astheweldedstructureissmoothinappearance,thereforeitlookspleasing. ) Inweldedconnections,thetensionmembersarenotweakenedasinthecaseof 5) rivetedjoints. 6) Aweldedjointhasagreatstrength.Oftenaweldedjointhasthestrengthofthe parentmetalitself. p 7) Sometimes,themembersareofsuchashape(i.e.circularsteelpipes)thatthey afforddifficultyforriveting.Buttheycanbeeasilywelded. 8) Theweldingprovidesveryrigid joints. joints Thisisinlinewiththemoderntrendof providingrigid frames. 9) Itispossibletoweldanypartofastructureatanypoint.Butrivetingrequires enoughclearance. clearance 10) Theprocessofweldingtakeslesstime thantheriveting.

DisadvantagesandDisadvantagesof WeldedJointsoverRivetedJoints
1) Sincethereisanunevenheatingandcoolingduring fabrication,thereforethemembersmaygetdistortedor additionalstressesmaydevelop. develop 2) Itrequiresahighlyskilledlabour andsupervision. 3) Sincenoprovisioniskeptforexpansionandcontractionin theframe,thereforethereisapossibilityofcracks developinginit. 4) Theinspectionofweldingworkismoredifficultthanriveting work.

Welding g Processes
Theweldingprocessesmaybebroadly classifiedintothefollowingtwogroups: groups 1) Weldingprocessesthatuseheatalone e.g. fusion welding. 2) Weldingprocessesthatuseacombinationof heatandpressuree.g.forge welding.

Fusion Welding g
Incaseoffusionwelding welding,thepartstobejointedareheldinpositionwhile themoltenmetalissuppliedtothejoint.Themoltenmetalmaycome fromthepartsthemselves(i.e.parentmetal)orfillermetalwhichnormally havethecompositionoftheparentmetal. metal Thejointsurfacebecome plasticorevenmoltenbecauseoftheheatfromthemoltenfillermetalor othersource. Thus,whenthemoltenmetalsolidifiesorfuses,thejointisformed. Thefusionwelding,accordingtothemethodofheatgenerated,maybe classifiedas: 1.Thermit welding, 2.Gaswelding,and 3.Electricarcwelding.

Thermit Welding g
Inthermit welding, welding amixtureofironoxideandaluminium calledthermit is ignitedandtheiron oxideisreducedtomolteniron.Themoltenironis pouredintoamouldmadearoundthejointandfuseswiththepartstobe welded Amajoradvantageofthethermit weldingisthatallpartsofweld welded. sectionaremoltenatthesametimeandtheweldcoolsalmostuniformly. Thisresultsinaminimumproblemwithresidualstresses.Itis f d fundamentally ll amelting l and dcastingprocess. Thethermit weldingisoftenusedinjoiningironandsteelpartsthatare toolarge g tobemanufacturedinonep piece, ,suchasrails, ,truckframes, , locomotiveframes,otherlargesectionsusedonsteamandrailroads,for sternframes,rudderframesetc.Insteelmills,thermit electricweldingis employedtoreplacebrokengearteeth teeth,toweldnewnecksonrollsand pinions,andtorepairbrokenshears.

Gas Welding g
Agasweldingismadebyapplyingtheflameofanoxy acetyleneorhydrogengasfromaweldingtorchuponthe surfacesofthep prepared p j joint.Theintenseheatatthewhite coneoftheflameheatsupthelocalsurfacestofusionpoint whiletheoperatormanipulatesaweldingrodtosupplythe metalfortheweld. Afluxisbeingusedtoremovetheslag.Sincetheheatingrate i gaswelding in ldi is i slow, l therefore th f itcanb beused donthinner thi materials.

Electric Arc Welding g

Inelectricarcwelding welding,theworkispreparedinthesamemannerasforgas welding.Inthiscasethefillermetalissuppliedbymetalweldingelectrode. Thebasemetalinthepathofthearcstreamismelted,formingapoolof moltenmetal metal,whichseemstobeforcedoutofthepoolbytheblastfrom thearc,asshowninFig.Asmalldepressionisformedinthebasemetal andthemoltenmetalisdepositedaroundtheedgeofthisdepression, which h hiscalled ll dthe h arccrater.The h slag l isbrushed b h doff ffafter f the h jointh has cooled.

Thearcweldingdoesnotrequirethe metaltobepreheatedandsincethe temperatureofthearcisquitehigh, thereforethefusionofthemetal isalmost instantaneous.

Electric Arc Welding g

Therearetwokindsofarcweldings dependinguponthetypeofelectrode. electrode 1.Unshieldedarcwelding,and 2.Shielded arc welding. Whenalargeelectrodeorfillerrodisusedforwelding,itisthensaidtobe unshieldedarcwelding.Inthiscase,thedepositedweldmetalwhileitis hotwillabsorboxygenandnitrogenfromtheatmosphere atmosphere.Thisdecreases thestrengthofweldmetalandloweritsductilityandresistanceto corrosion.

Inshieldedarcwelding,theweldingrods coatedwithsolidmaterialareused,as showninFig. Theresultingprojectionof coatingfocusesaconcentratedarc stream,whichprotectstheglobulesof metal lfrom f the h airandpreventsthe h absorptionoflargeamountsofharmful oxygenandnitrogen.

Arc Welding g
Electriccurrentflowingthroughahighresistanceairgap generatesanintensearcwithtemperaturesrangingfrom o C. 3,000 , to5,500 ,

Arc welding isthe most common method used with structural steel welding.

Forge g Welding g
Inforgewelding welding,thepartstobejointedarefirstheatedtoa propertemperatureinafurnaceorforgeandthen hammered.Thismethodofwelding gisrarely yusednowadays. y Anelectricresistanceweldingisanexampleofforgewelding. Inthiscase, ,thep partstobej joinedarep pressedtogether g andan electriccurrentispassedfromoneparttotheotheruntilthe metalisheatedtothefusiontemperatureofthejoint. Theprincipleofapplyingheatandpressure,either sequentiallyorsimultaneously,iswidelyusedintheprocesses k known asspot,seam,projection, j i upsetand dfl flash hwelding. ldi

Types yp ofWelded Joints

LapJoint
Thelapjointorthefilletjointisobtainedbyoverlappingtheplatesand thenweldingtheedgesoftheplates.Thecrosssectionofthefilletis approximatelytriangular.Thefilletjointsmaybe 1.Single transverse fillet, 2.Double transverse fillet,and 3.Parallel fillet joints.

Types yp ofWelded Joints

Butt Joint
Thebuttj jointisobtainedby yp placing gthep platesedge g toedge. g Inbuttwelds, , theplateedgesdonotrequirebevelling ifthethicknessofplateisless than5mm.Ontheotherhand,iftheplatethicknessis5mmto12.5mm, theedgesshouldbebevelled toVorUgrooveonbothsides. Thebutt jointsmaybe 1.Squarebuttjoint, 2.SingleVbuttjoint 3.SingleUbuttjoint, 4. 4 Double D bl Vbutt b tt joint, j i t and d 5.Double Ubutt joint

Types yp ofWelded Joints

Other Joints
Theothertypeofweldedjointsarecornerjoint,edgejointandTjointas showninFig.below.

Themainconsiderationsinvolvedintheselectionof weld ldtypeare: 1.Theshapeoftheweldedcomponentrequired, 2.Thethicknessoftheplatestobewelded,and 3.Thedirectionoftheforcesapplied.

Basic Weld Symbols y

Supplementary pp y Weld Symbols y

ElementsofaWelding gSymbol y
Aweldingsymbolconsistsofthefollowingeightelements: 1.Referenceline, 1 line 2 Arrow, 2. Arrow 3.Basicweldsymbols, 4.Dimensionsandotherdata, 5 Supplementarysymbols, 5. symbols 6. 6 Finishsymbols, symbols 7.Tail,and8.Specification,processorotherreferences.

StandardLocationofElements of faWelding W ldi Symbol S b l

Thearrowpointstothelocationofweld, weld thebasicsymbolswith dimensionsarelocatedononeorbothsidesofreferenceline.The specificationifanyisplacedinthetailofarrow.Fig.belowshowsthe standardlocationsofweldingsymbolsrepresentedondrawing. drawing

Representation ofwelding p g symbols y

StrengthofTransverseFillet W ld dJ Welded Joints i t

Thetransversefilletweldsaredesignedfortensilestrength. Letusconsiderasingleanddoubletransversefilletweldsas showninFig.(a)and(b)respectively.

StrengthofTransverseFillet W ld dJ Welded Joints i t

Inordertodeterminethestrength g ofthefilletjoint, j ,itisassumedthatthe sectionoffilletisarightangledtriangleABCwithhypotenuseACmaking equalangleswithothertwosidesABandBC. TheenlargedviewofthefilletisshowninFig Fig.belowThelengthofeach sideisknownaslegorsizeoftheweldandtheperpendiculardistanceof thehypotenusefromtheintersectionoflegs(i.e.BD)isknownasthroat thickness. hi k The Th minimum i i areaof fthe h weld ldi isobtained b i datthe h throat h BD BD, whichisgivenbytheproductofthethroatthicknessandlengthofweld.

t =Throat thickness (BD), s =Legorsizeofweld, =Thickness ofplate,and g of fweld, , l =Length

StrengthofTransverseFillet W ld dJ Welded Joints i t

F From Fi Fig.b below, l wefi find dth that tth theth throat tthi thickness, k

Minimumareaoftheweldorthroatarea, A=Throat thickness Length ofweld =t l=0.707s l Ift istheallowabletensilestressfortheweldmetal,thenthetensilestrengthof thejointforsinglefilletweld, tarea Allowable All bl t il stress t F=Th Throat tensile = 0.707s l t
andtensilestrengthofthejointfordouble filletweld,

F =2 0.707 0 707s l t =1 1.414 414s l t

StrengthofParallelFillet W ld dJ Welded Joints i t

Theparallelfilletweldedjointsaredesignedforshearstrength.Considera d bl parallel double ll lfill fillet twelded ld dj joint i tasshown h in i Fig. Fi (a). ) The Th minimum i i areaof f weldorthethroatarea,A=0.707s l If istheallowableshearstressfortheweldmetal,thentheshearstrength g ofthejointforsingleparallel fillet weld, F=Throatarea Allowableshearstress=0.707s l
and dshear h strength t thof fthe th j joint i tf ford double bl parallel ll lfill fillet tweld, ld

F =2 0.707 s l =1.414s l

Notes
1. Ifthereisacombinationofsingletransverseanddoubleparallelfillet weldsasshowninFig.,thenthestrengthofthejointisgivenbythesumof strengthsofsingletransverseanddoubleparallelfilletwelds. Mathematically, F =0.707s l1 t +1.414s l2 2. Inordertoallowforstarting gandstopping pp gofthebead, ,12.5mmshould beaddedtothelengthofeachweldobtainedbytheaboveexpression.

3. Forreinforcedfilletwelds,thethroat dimensionmaybetakenas0.85t.

Special CasesofFilletWeldedJoints p
Circularfilletweldsubjectedtotorsion. torsion
Weknowthatshearstressforthematerial,

Thisshear Thi h stress t occursi inah horizontal i t lplane l along l a l legof fth thefill fillet t weld.Themaximumshearoccursonthethroatofweldwhichis inclinedat45 tothehorizontalplane. Lengthofthroat,t=ssin45 =0.707s Maximum shear stress d =Diameter ofrod, r =Radius ofrod, T =Torqueactingontherod, s=Size(orleg)ofweld, t =Throat thickness, J=Polarmomentofinertiaofthe weldsection

Special CasesofFilletWeldedJoints p
Circularfilletweldsubjectedtobendingmoment..
Weknowthatthebendingstress,

Thisbending Thi b di stress t occursi inah horizontal i t lplane l along l a l legof fth the filletweld.Themaximumbendingstressoccursonthethroatofthe weldwhichisinclinedat45 tothehorizontalplane. Lengthofthroat,t=ssin45 =0.707s g stress Maximum bending d=Diameter ofrod, M =Bendingmomentactingon therod, s =Size(orleg)ofweld, t =Throat thickness, Z =Section S i modulus d l of fthe h weld ld section

Strength g ofButt Joints

Thebuttjointsaredesignedfortensionorcompression. compression Considerasingle VbuttjointasshowninFig.(a). Incaseofbuttjoint,thelengthoflegorsizeofweldisequaltothethroat thickness h k which h hisequal ltothickness h k of fplates. l Tensilestrengthofthebuttjoint(singleVorsquarebuttjoint),

F =t l t
andtensilestrengthfordoubleV buttjointasshowninFig Fig.(b)

P=(t1 +t2)l t
t1 = Throatthicknessatthetop,and t2 = Throatthicknessatthebottom. l= Lengthofweld. weld Itisgenerallyequal tothewidthofplate.

Stresses for Welded Joints

Thestressesinweldedjointsaredifficulttodeterminebecauseofthe variableandunpredictableparameterslikehomogenuity oftheweldmetal, thermalstressesinthewelds,changesofphysicalpropertiesduetohighrate ofcoolingetc. etc Thestressesareobtained, obtained onthefollowingassumptions: 1. Theloadisdistributeduniformlyalongtheentirelengthoftheweld,and 2. Thestressisspread p uniformly yoveritseffectivesection. Thefollowingtableshowsthestressesforweldedjointsforjoiningferrous metalswithmildsteelelectrodeundersteadyandfatigueorreversedload.

StressConcentrationFactorfor W ld dJ Welded Joints i t

Th Thereinforcement i f tprovided id dto t the th weld ldproduces d stress t concentrationatthejunctionoftheweldandtheparentmetal. Whenthepartsaresubjectedtofatigueloading, loading thestress concentrationfactorasgiveninthefollowingtableshouldbe takenintoaccount.

Note:Forstaticloadingandanytypeofjoint,stress concentrationfactoris1.0.

Axially Loaded Unsymmetrical W ld d Sections Welded S ti

Sometimesunsymmetricalsectionssuchasangles,channels,Tsections etc weldedontheflangeedgesareloadedaxiallyasshowninbelow. etc., below In suchcases,thelengthsofweldshouldbeproportionedinsuchawaythat thesumofresistingmomentsoftheweldsaboutthegravityaxisiszero. C id anangle Consider l section ti asshown h i inFi Fig.
Momentofthetopweldaboutgravityaxis momentofthebottomweldaboutg gravity yaxis Sincethesumofthemomentsoftheweldabout thegravityaxismustbezero,therefore Weknowthatl=la +lb

f=Resistanceofferedbytheweld perunitlength.

Eccentrically y Loaded Welded Joints

Aneccentric A t i load l dmaybe b i imposed donwelded ld dj joints i t i inmanyways.Th Thestresses t inducedonthejointmaybeofdifferentnatureorofthesamenature.The inducedstressesarecombineddependinguponthenatureofstresses.Whenthe shearandbendingstressesaresimultaneouslypresentinajoint(seecase1), thenmaximumstressesareasfollows:
Maximum normalstress,

Maximum shear stress

Whenthestressesareofthesamenature,thesemaybecombined vectorially (see case 2).

Eccentrically y Loaded Welded Joints

ConsideraTjointfixedatoneendand subjected bj t dto t aneccentric t i load l dPat ta distanceeasshowninFig.
Thej jointwillbesubjected j tothefollowing gtwotypes yp ofstresses: 1.DirectshearstressduetotheshearforcePactingatthewelds, 2.BendingstressduetothebendingmomentP e. Weknowthatareaatthethroat throat,A=t l 2=2t l =2 0.707s l=1.414s l Shearstressintheweld(assuminguniformlydistributed),

Sectionmodulusoftheweldmetalthroughthethroat Bending moment,M=F e g stress Bending Weknowthatthemaximumnormalstress, ,

Eccentrically y Loaded Welded Joints

Whenaweldedjointis loadedeccentricallyas showninFig. thefollowingtwotypesof thestressesareinduced: 1. Directorprimaryshear stress, 2. 2.Shearstressdueto turningmoment. LettwoloadsF1 andF2 (eachequaltoF)areintroducedatthecentreofgravityG'oftheweld system. t The Th effect ff tof fload l dF1 =Fis i to t produce d di direct tshear h stress t which hi hi isassumed dt tob be uniformovertheentireweldlength.TheeffectofloadF2 =Fistoproduceaturningmomentof magnitudeF ewhichtendsofrotatethejointaboutthecentreofgravityG'oftheweld system Duetotheturningmoment, moment secondaryshearstressisinduced. induced system. Weknowthatthedirectorprimaryshearstress