Considerations Materials and Manufacture M3

Lecture 4: (25/10/2007) Types of welds and joints Design considerations Benefits of welding Types of welds Types of joints Weld joint design Weld symbols

Dr. B. Bezensek Web: www.mech.gla.ac.uk/~bbezense/teaching.html

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Advantages of welding
Lighter joints -> material savings!! Short production times More accurate joints Tight, leak proof joints Cheaper production (compared to casting) Lowest cost joining method Versatility Wide applicability
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Weldability of metals
Capacity of the material to be welded under imposed fabricational constraint into a specific, suitably designed, functional structure.

Joint design (in this lecture) Welding process selection (see lecture 3)

Designing for welding

Good knowledge of welding processes; Knowledge of metallurgy and welding technology; Knowledge of functional requirements; Material selection, loading & service history, in-house welding capabilities, etc. Objective
fulfil functional requirement cost efficiency

Types of joints

Corner Butt (girth in a pipe)

Lap Tee Edge

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Types of welds
Slot weld V groove Fillet

Types of welds
Surfacing weld

Backing weld (root weld) Double V or X groove Seam J groove

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Weld joint design

Joint selection considerations: Penetration requirements
partial or full

Stress concentrations

Strength requirements
Usually overmatched joints

Loading history, Service environ., skill & availability

Poor design

Cost
weld process selection material saving edge preparation accessibility and ease of welding
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Poor welding technology

(Appearance)

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Stress concentrations
T-joint with filled weld: fully penetrated double weld
Joint geometry Static strength Fatigue strength Stress pattern Impact strength

Stress concentrations
T-joint with filled weld: partially penetrated double weld
Joint geometry Static strength Fatigue strength Stress pattern Impact strength

100%

80%

40% 85%

25% 75%

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Stress concentrations
T-joint with filled weld: partially penetrated SINGLE weld
Joint geometry Static strength Fatigue strength Stress pattern Impact strength

Stress concentrations
Butt joint with a groove weld

30%

10% 10%

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Stress concentrations
When prescribing weld size and penetration consider loading mode: -- fatigue load dominant? -> full penetration weld -- fatigue load secondary? -> partial penetration OK -- Brittle failure critical? -> full penetration required (Must avoid discontinuities and cracks which act as stress concentrators and fracture initiators.)

Welding positions

Flat

Horizontal

Vertical (up or down)

Overhead

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Design for welding

Console under bending

Design for welding

Single vs double groove

Bad

Good
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Bad

Good
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Design for welding

Thickness transition Bad Bad

Design for welding: pipe closure

Good

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Design for welding

Design for welding

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Elements of a weld symbol

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Weld symbols
Example

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Example

Design for welding

Goes well beyond putting a few weld symbols on a drawing; Build a concept with fabrication process(es) in mind; Avoid unnecessary complexity; If large production, consider automation:

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Accessibility? Complexity? Which technique? What weld parameters?

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Quality requirements & Inspection