Connections

Weld

Welding
It is a process of joining parts by means of heat &
pressure, causing fusion of parts (Resistance Welding) OR
heating metal to fusion temperature with or without
addition of weld metals (Fusion Welding).
Code & specification AWS (American Welding Society)
Fusion welding employs either
Electric arc (used for most structural welding) OR
Oxyacetylene flame
Welding is categorized according to the type of weld and
also how welding is done.
Type : Groove, Fillet, Plug and Slot
How: Flat, Horizontal, Vertical and Overhead

Types of Welding
Groove weld is made in opening between two parts being
joined.

Fillet weld, triangular in shape, joins surfaces which are at

an angle with one another.

Fillet Welds
Welds fail in shear at 45o through the throat
So Shear strength = Allowable shearing stress x Theoretical
throat area of weld
Theoretical throat area of weld = Theoretical throat x weld length
Figs:

Fillet Welds
Effective throat thickness = te = 0.707 x leg size
Electrodes are from E 70 to E 90
Shear Lap = te x 0.3 x 70

Types of Welding
Plug weld is made by depositing weld metal in a circular
hole in one of two lapped places.

Slot weld similar to plug but the hole is elongated.

Welding Process
Forge Welding: It consists of simply heating the pieces
above certain temperature and hammering them together.
Resistance Welding: Heat is generated by electrical
resistance to a current of high amperage & low voltage
passing through small area of contact between parts to be
connected.

Welding Process
Fusion Welding: Method of connecting pieces by molten
metal
In Metal-arc welding, arc is a sustained spark between a
metallic electrode and work to be welded.
At the instant arc is formed the temperature of work and
tip of electrode are brought to melting point.
As the tip of electrode melts, tiny globules of molten
metal form.
The molten metal, when exposed to air combines
chemically with oxygen & nitrogen forming oxides &
nitrides, which tend to make it less corrosive resistant.
Ductile welds are produced if molten pool is shielded by
an inert gas, which envelops molten metal & tip of
electrode.

Welding Process
Fusion Welding: Method of connecting pieces by molten
metal
In Metal-arc welding, arc is a sustained spark between a
metallic electrode and work to be welded.
At the instant arc is formed the temperature of work and
tip of electrode are brought to melting point.
As the tip of electrode melts, tiny globules of molten
metal form.
The molten metal, when exposed to air combines
chemically with oxygen & nitrogen forming oxides &
nitrides, which tend to embrittle it & less corrosive
resistant.
Tough, ductile weld are produced if molten pool is
shielded by an inert gas, which envelops molten metal &
tip of electrode.

Welding Process
Shielded Metal Arc Welding
When an arc is struck between the metal rod (electrode)
and the work piece, both the rod and work piece surface
melt to form a weld pool.
Effective throat thickness = te = 0.707 x Size of leg

Welding Process
Shielded Metal Arc Welding
Simultaneous melting of the flux coating on the rod will
form gas and slag which protects the weld pool from the
surrounding atmosphere.
Effective throat thickness = te = 0.707 x Size of leg
If leg size < 3/8
If leg size > 3/8
(then add 0.11 to leg size)

Welding Process
Submerged Arc Welding
A bare wire is fed through welding head at a rate to
maintain constant arc length.
Welding is shielded by blanket of granular fusible material
fed onto the work area by gravity, in an amount sufficient
to submerge the arc completely.
In addition to protecting weld from atmosphere, the
covering aids in controlling rate of cooling of weld.

Welding Process
Flux Cored Arc Welding
The process utilizes the heat of an arc between a
continuously fed consumable flux cored electrode and the
work. The heat of the arc melts the surface of the base
metal and the end of the electrode. The metal melted off the
electrode is transferred across the arc to the work piece,
where it becomes the deposited weld metal. Shielding is
obtained from the disintegration of ingredients contained
within the flux cored electrode.

Welding Process
Metal Arc Inert Gas (MIG) Welding
The "Metal-arc Inert Gas" (MIG) Welding refers to the wire
that is used to start the arc. It is shielded by inert gas and
the feeding wire also acts as the filler rod.

Welding Process
Tungsten Arc Inert Gas (TIG) Welding
The arc is started with a tungsten electrode shielded by
inert gas and filler rod is fed into the weld puddle
separately. The gas shielding that is required to protect the
molten metal from contamination is supplied through the
torch.

Stresses in Welds
Groove weld may be stressed in tension, compression,
shear, or a combination of tension, compression and shear,
depending upon the direction and position of load relative
to weld.
The load P in Fig is resisted by shearing force P/2, on the
throat of each fillet weld.

f = (P /2) / (LTe)

Stresses in Welds
It is customary to take the force on a fillet weld as a shear
on the throat irrespective of the direction of load relative to
throat.
Tests have shown that a fillet weld transverse to the load is
much stronger than a fillet weld of same size parallel to the
load.

Stresses in Welds
Load sharing of P, between two longitudinal fillet & one
transverse fillet weld depends either on:
Proportional to their length if welds are of same size.
Proportional to the area for different size weld.

Shear

Tension

Shear

Stresses in Welds
Any abrupt discontinuity or change in section of member
such as notch or a sharp reentrant corner, interrupts the
transmission of stress along smooth lines.
These concentrations are of no consequence for static
loads, but they are significant where fatigue is involved.
Joint is elongated in direction of load to produce a more
uniform transfer of stress

Specifications for Welded Connections

Welding electrodes are classified on the basis of
mechanical properties of weld metal, Welding position,
type of coating, and type of Current required.
Each electrode is identified by code number EXXXXX,
E stands for Electrode and each X represents number.
First two or three Nos. indicate tensile strength (Ksi)
Next No. position in which electrode can be used. (e.g. 1 -all positions, 2 -- flat & horizontal fillet welds, 3 flat
welding only)
Last No.denotes type of covering, type of current, polarity.
E7018 means
Tensile strength 70 Ksi
1 means can be used in all positions
8 means it is iron-powder, low-hydrogen electrode used
with A.C or D.C but only in reverse polarity.

Code Requirements
AISC/ASD
Allowable stress in welded connection is given in Table 2-21
AISC/LRFD
Design strengths of welds are given in Table 2-22 with
resistance factor .
AASHTO
Allowable stress are more conservative than AISC e.g. 0.27Fu
for fillet weld, Fu is tensile strength of electrode but not less
than tensile strength of connected part.
AREA
Allowable shear stress on fillet welds are given as function of
base material and strength of weld metal e.g.
A36. Electrode or electrode-flux combinations with:
60,000 psi tensile strength 16,500 psi
70,000 psi tensile strength 19,500 psi

Code Requirements
The min length of fillet weld may not be less than 4 times the
nominal leg size of weld.
Max size of fillet weld for in thick material is in. For thicker
material it may be 1/16 in less than the material thickness.
Smallest weld size is 1/8 in and most economical is 5/16 in.
Manually one pass weld is 5/16 in
End returns should be made and min length of end return is
twice the nominal size of weld
When longitudinal fillet welds are used alone for the connection
of plates or bars, their length may not be less than the
perpendicular distance between them. The distance between
fillet welds may not be greater than 8 in for end connections
unless transverse bending is otherwise prevented.

Example No 1
Data
Weld size = 5/16
Length of weld = 1
E 70 electrode
Shielded Metal Arc Welding (SMAW) process
Submerged Arc Welding (SAW) process
Find the allowable shear capacity

Example No 1
SMAW Process
Effective throat thickness = te = cos 45o x leg size

= 0.707 x 5/16 = 0.221 in

Shear capacity per in of length

= te x 0.3 x Electrode x weld length

= 0.221 x 0.3 x 70 x 1 = 4.641 kips

SAW Process
Effective throat thickness = te = leg size < 3/8

= 5/16 < 3/8 so take 5/16

Shear capacity per in of length

= te x 0.3 x Electrode x weld length

= 5/16 x 0.3 x 70 x 1 = 6.56 kips

Example No 2
Data
Fillet Weld size = 7/16
Length of weld = 1
E 70 electrode
Shielded Metal Arc Welding (SMAW) process
Submerged Arc Welding (SAW) process
Find the allowable capacity of connection

Example No 2
SMAW Process
Shear capacity of weld per in of length

= te x 0.3 x Electrode x weld length

= 0.707 x 7/16 x 0.3 x 70 x 1

= 6.495 kips / in
Shear capacity of plates = 0.4 Fy tp

= 0.4 x 36 x = 10.8 kips / in

So shear capacity is the lesser of two
Tensile capacity of weld = 6.5 ( 6 + 8 + 6 ) = 130 kips
Tensile capacity of plate = 0.6 Fy Ag

= 0.6 x 36 x x 8 = 129.6 kips

So tensile capacity is the lesser of two

Example No 2
SAW Process
Eff throat thickness = te = 7/16 > 3/8 so

= cos 45 x leg size x 0.11

= 0.707 x 7/16 x 0.11 = 0.419

Shear capacity of weld per in of length

= te x 0.3 x Electrode x weld length

= 0.419 x 0.3 x 70 x 1 = 8.81 kips

Shear capacity of plates = 0.4 Fy tp

= 0.4 x 36 x = 10.8 kips / in

So shear capacity is the lesser of two
Tensile capacity of weld = 8.81 ( 6 + 8 + 6 ) = 176.2 kips
Tensile capacity of plate = 0.6 Fy Ag

= 0.6 x 36 x x 8 = 129.6 kips

So tensile capacity is the lesser of two

Example No 3
Data
Plate size is 3/8 (Thick) x 6 (Wide)
E 70 electrode
A36 steel
Shielded Metal Arc Welding (SMAW) process
Design the welded connection

Example No 3

Max weld size = 3/8 1/16 = 5 / 16

Min weld size = 3 / 16
Try 4/16 =
Shear capacity of weld = te x0.3x Electrode x weld length
= 0.707 x x 0.3 x 70 x 1 = 3.71 k/in
Shear capacity of plates = 0.4 Fy tp
= 0.4 x 36 x 3/8 = 5.4 kips / in
So shear capacity is the lesser of two
Tensile capacity of plate = 0.6 Fy Ag
= 0.6 x 36 x 3/8 x 6 = 48.6 kips
Length of weld = 48.6 / 3.71 = 13.1
End return = 2 x 4 / 16 = say 1
= 13.1 (1+1) = 11.1 / 2 = 5.55 say 6

Example No 3

Example No 4
Data
Shielded Metal Arc Welding (SMAW) process
E 70 Electrodes
A 36 steel
AISC Specs
No welding allowed on reverse side
Max overlap is 6
C 15 x 40
Tensile load 250 kips

Example No 4
C 15 x 40
d=15 tw =
Weld size
Max weld size = - 1/16 = 7/16 (page 5-67)
Min weld size = 3/16 (AISC Table J2-4)
Select 7/16 weld
Shear Str of weld = 0.707 x 7/16 x 0.3 x 70 (J 3.3)

= 6.5 k / in
Shear capacity of Channel = 0.4 Fy tw

= 0.4 x 36 x = 7.2 k
Since 6.5 k < 7.2 k so OK
Now Tensile load 250 kips

Example No 4
Width of slot may not be less than member
thickness + 5/16 in (rounded of to the nearest
greater 1/16 in) and may not be greater than 2
times the weld thickness.
Max length of slot weld is 10 times the weld
thickness.

Example No 4

Length of weld = 250 / 6.5 = 38.5 in

Available length = 15 + 6 + 6 = 27 < 38.5
We resort to slot welding
Min width of slot = + 5/16 = 13/16
Max width of slot = 2.25 x (leg size) = 18/16
Selected slot width is = 15/16
Max length = 10 x thickness of weld = 10x =5
Shear capacity of weld/in = 15/16 x 0.3 x 70
= 19.69 k /in
Weld Capacity = (7/16) x 0.707 x 0.3 x 70 x (6+6+15- (15/16))
= 169 k < 250 k by 81 k
For balance force of 75 k the length of slot weld is
= 81 / 19.6 = 4.13 < 5 so 4 1/8

Example No 4
Provide 7/16 fillet weld for 26 1/16 and slot weld 15/16 x
x 4 1/8

Truss Member Welded Connection

For static loading the centroid of weld may not coincide
with the centriod of member but for repeated loading
conditions the centroid of weld should coincide with
centroid of member.
Symmetrical Member

Asymmetrical member

Truss Member Welded Connection

Data
L 5 x 3 x (A = 3.75 in2 )

Example no 5
Tensile capacity of angle = 22 x 3.75 = 81 k
Taking moment about L1 to determine P2

81 x 1.75 5 x P2 = 0

P2 = 28.35 k

P1 = 81 28.35 = 52.65 k
Max weld size = - 1/16 = 7/16
Capacity of 7/16 = (7/16) x 0.707 x 0.3 x 70

= 3.9 k / in
L2 = P2 / cap = 28.35 / 3.9 = 7.27
L1 = P1 / cap = 52.65 / 3.9 = 13.5
End return = 2 x 7/16 = 14/16 say 1
So L2 = 6.27 and L1 = 12.5

Welds In Combined Shear & Torsion

Assumption is the connected pieces are
completely rigid and all deformations will occur in
weld.

f=Td/J

Where

T = Torsion

d = distance of C.G. from point considered

J = Polar moment of inertia

Welds In Combined Shear & Torsion

Welds In Combined Shear & Torsion

fh = (P x e ) v / J

fv = (P x e ) h / J
Where J = Ix + Iy
So fresultant = ((fshear + fvertical)2 + fhorizontal2) 0.5

Example No 6

AISC Specs
A 36 Steel
E 70 Electrodes
Assume thickness of weld = 1

Example No 6
C.G of weld
ax = ax1 +ax2
(10+4+4) x = ((1 x 1 ) x 2) x 2

x = 0.89
Ix = bd3 / 12 + A d2

= 2x(4 x 13 / 12 +4x1 x 52)+1x 103 / 12 +10x0

= 284 in4
Iy = 2x(1x43/12+4(2 0.89)2) +10x13/12+10x0.892

= 29.28 in4

I = Ix + Iy = 313.3 in4

Example No 6
Shear stress fs = P / Area = 15 /18 = 0.83 ksi
Torsional Stress (10+4+4) x = ((1 x 1 ) x 2) x 2
fh = ( P e v ) / J = (15 x 11.11 x 5)/313.3

= 2.66 ksi
fv = ( P e h ) / J = (15 x 11.11 x (4-0.89))/313.3

= 1.65 ksi
fr = ( (1.65 +0.83)2 + 2.662 )0.5

= 3.64 ksi
Capacity of 1 weld = 1 x 0.707 x 0.3 x 70

= 14.84 k / in
Weld size = 3.64 / 14.84 = 0.26 say 5/16

Example No 7 (Shear and Bending)

Shear and moment at two different locations

Example No 7 (Shear and Bending)

Capacity of 1 weld = 1 x 0.707 x 0.3 x 70

= 14.84 k / in
Shear stress fs = P / Area = 30 /(2x8) = 1.875 k/in
f=Mc/I
where in this case c = 4 and I = 85.33 in4
f = (30 x 2.5) x 4 / 85.33
= 3.52 ksi
fr = (1.8752 + 3.522 ) 0.5 = 3.99 ksi
Weld size = 3.99 / 14.84 = 0.269 say 5/16

Practice Question

Thanks