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IIW/EWF Diploma -
Design and Construction (Foundation)
Contents
Section Subject
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Contents
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Section 1
The present course is the first of these levels and is intended to cover the
scope appropriate for a European Welding Specialist. Two subsequent
courses address the scope of the higher level qualifications.
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Introduction - Designing Things
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Section 2
2.2 Welds
A weld is a permanent union between materials caused by the application of
heat or pressure or both. A weld made between two faces that are
approximately parallel is known as a butt weld.
A weld made between two faces that are approximately at right angles to
each other is known as a fillet weld.
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For simplicity these diagrams show an arc welding process that deposits
filler weld metal in a single weld pass. Typical features of a butt weld are
shown in Figure 2.3. Typical features of a fillet weld are shown in Figure 2.4.
The weld or weld metal refers to all the material that has melted and re-
solidified. The heat-affected zone is material that has not melted, but whose
microstructure has been changed as a result of the welding. The fusion line
is the interface between the weld metal and the heat affected zone. The root
is the bottom of the weld, or the narrowest part and the face is the top, or
the widest part. At the corners of the weld cross section where the weld
metal joins the parent metal are the weld toes. Weld toes are at each corner
of both the weld face and the weld root in a butt weld, but only on the weld
face in a fillet weld.
a)
b)
Figure 2.3 Typical features of a butt weld, shown schematically in a) and in b) for a
double-sided butt weld.
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The distance between the weld toes is called the weld width. When the
distance is between the toes at the weld cap, it is the weld cap width; the
distance between the toes at the root is the weld root width. The height of
the additional weld metal in the weld cap is called the excess weld metal.
This used to be called reinforcement which wrongly gives the impression
that increasing this dimension will strengthen the weld. If the excess weld
metal is too great it old serves to increase the stress concentration at the
weld toe. This extra weld metal at the weld root is called the excess root
penetration.
Figure 2.6 Definitions of excess weld metal, root penetration and weld width on a
butt weld.
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An alternative to a conventional lap joint is to weld the joint using plug or slot
welding. Slot and plug welds are shown in Figure 2.12 we can drastically
alter the typical lap joint. The hole for a slot weld should have a width at
least three times the plate thickness and not less than 25mm. In plate less
than 10mm thickness, a hole of equal width to the plate thickness can be
welded as a plug weld.
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a) b)
Figure 2.12
a) Slot welded lap joint;
b) Plug welded lap joint.
Corner joints can be fitted and welded in a number of ways. The unwelded
pieces can be assembled either with an open corner or closed together. The
weld can be placed on the external corner, the internal corner or both in a
double-sided weld.
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Figure 2.14 Leg length (z) and throat size (a) in a fillet weld.
This is only valid for mitre fillet welds having similar leg lengths (see Figure
2.15), but is not valid for concave, convex or asymmetric welds. In concave
fillet welds the throat thickness will be much less than 0.7 times the length.
The leg length of a fillet weld is often approximately equal to the material
thickness. The actual throat size is the width between the fused weld root
and the segment linking the two weld toes, shown as the red line in
Figure 16. Thanks to root penetration, the actual throat size of a fillet weld is
often larger than its design size, but because of the unpredictability of the
root penetration area, the design throat size must always be taken as the
stress parameters in design calculations.
Figure 2.15 Mitre fillet weld Figure 2.16 Design throat of a fillet weld.
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Figure 2.18 Definition of design and actual throat in concave and convex fillet
welds.
The choice between mitre weld, concave and convex fillet weld needs to
take into account the weld toe blend. A concave fillet weld gives a smooth
blend profile and a low stress concentration at the fillet weld toe. Convex
fillet welds can have a higher stress concentration at the weld toe. If the
fluidity of the weld pool is not controlled, it is possible to obtain an
asymmetrical fillet weld where the weld pool has sagged into the joint
preparation and there is also a risk of undercut on the bottom weld toe (see
Figure 2.19). Having a smooth toe blend is important to give better fatigue
performance for fillet welds.
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Figure 2.20 Design throat (t1) and the actual throat (t2) for butt welds.
The weld toe blend is important for butt welds as well as fillet welds. Most
codes state that the weld toes shall blend smoothly. This statement is open
to individual interpretation however. The higher the toe blend angle the
greater the amount of stress concentration. The toe blend angle ideally
should be between 20-30o (Figure 2.21).
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2.6 Dilution
When filler and parent material do not have the same composition, the
resulting composition of the weld depends largely on the weld preparation
before welding. The degree of dilution results from the edge preparation and
process used; the percentage of dilution (D) is particularly important when
welding dissimilar materials and is expressed as the ratio between the
weight of parent material melted and the total weight of fused material
(multiplied by 100 to be expressed as a percentage), as shown by the
equation below.
Low dilutions are obtained with fillet welds and with butt welds with multiple
runs. However, considering a single pass, better dilution is obtained with
grooved welds; see Figure 2.22.
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Figure 2.22 Effect of weld preparation on dilution and weld metal composition
(for a single pass only).
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However, symbolic representation can only be used for common joints and it
requires training to understand the symbols properly. Symbolic
representation of a welded joint contains an arrow line, a reference line and
an elementary symbol. The elementary symbol can be complemented by a
supplementary symbol. The arrow line can be at any angle (except 180
degrees) and can point up or down. The arrow head must touch the
surfaces of the components to be joined and the location of the weld. Any
intended edge preparation or weldment is not shown as an actual cross
sectional representation, but is replaced by a line. The arrow also points to
the component to be prepared with single prepared components
ISO 2553 and AWS A2.4 list all the main elementary symbols, some
examples are shown in Table 1. The symbols for arc welding are often
shown as cross sectional representations of either a joint design or a
completed weld. Simple, single edge preparations are shown in Figure 2.25.
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Figure 2.25 Welding symbols for the most common joint types shown on a
reference line.
These simple symbols can be interpreted as either the joint details alone or
the completed weld, however, for a finished weld it is normal to find that an
appropriate weld shape is specified. There are a number of options and
methods to specify an appropriate weld shape or finish. Butt welded
configurations would normally be shown as a convex profile (Figure 2.26 'a',
'd' and 'f') or as a dressed-off weld as shown in 'b' and 'c'. Fillet weld
symbols are always shown as a mitre fillet weld and a convex or concave
profile can be superimposed over the original symbol's mitre shape.
Figure 2.26 Welding symbols showing the weld profile for the most common joint
types.
In order that the correct size of weld can be applied, it is common to find
numbers to either the left or to the right of the symbol. For fillet welds,
numbers to the left of the symbol indicate the design throat thickness, leg
length, or both design throat thickness and leg length requirements
(Figure 2.27).
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Figure 2.27 Throat and leg length dimensions given on the weld symbol for a fillet
weld.
For butt joints and welds, an S with a number to the left of a symbol refers to
the depth of penetration. When there are no specific dimensional
requirements specified for butt welds on a drawing using weld symbols, it
would normally be assumed that the requirement is for a full penetration butt
weld. Numbers to the right of a symbol or symbols relate to the longitudinal
dimension of welds, eg for fillets, the number of welds, weld length and weld
spacing for non-continuous welds.
Figure 2.28 Weld symbols showing the weld length dimensions to the right of the
weld joint symbols for an intermittent fillet weld.
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Flat PA
Welding
Symbol Abbreviation
position
Horizontal PB
Horizontal
PC
vertical
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Vertical up,
vertical PG/PF
down
Overhead PE
Horizontal
PD
overhead
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The design of the edge prep includes not only the bevel angle (or included
angle is both sides are bevelled), but also the square edges root face and
root gap. In a joint where both sides are bevelled, the prep is called a V or
vee preparation (Figure 31). V preps are usually used for plate of thickness
between 3-20mm. An alternative is a U prep (or J prep if only one side has
the edge prep) in which the edge is machined into the shape of a U. This
type of edge preparation is used in thicker plate, over 20mm thick, where it
uses less filler metal than a V prep joint. J or U edge preparations also
requires a bevel angle and root face and gap to be defined, but also needs a
root radius and land to be specified (Figure 2.32). Single sided edge
preparations are often used for thinner materials or when there is no access
to the root of the weld (such as pipelines). If there is access to both sides of
the material then a double-sided edge preparation is used, especially for
thicker materials. Single and double edge preps are shown in Figure 2.33.
Included angle
Bevel angle
Root face
Gap
Included angle
Root radius
Bevel
angle
Root
face
Gap
Land
Figure 32 U bevel.
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Figure 2.33 Range of single and double sided bevel, vee, J and U preps.
Figure 2.34 Bevel angle to allow electrode manipulation for sidewall fusion.
The root gap and root face are selected to ensure good root fusion
(Figure 2.35). This will depend on the welding process and the heat input. If
the root gap is too wide or the root face is too narrow then there is a risk of
burn through. If the root gap is too narrow or the root face is too deep the
there is a risk of lack of root penetration. A balance must be found and
designed for and this difference in weld root size is shown in Figure 2.36.
High heat input process require a larger root face, but less weld metal is
required, which reduces distortions and increases productivity. Typical
values for the root face are around 1.5-2.5mm and the root gap around
2-4mm.
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Figure 2.35 The importance of selecting the correct root face and root gap.
a) b)
Figure 2.36 Root size for welding processes with different heat inputs;
a) Low heat input;
b) High heat input.
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a) b)
a) b)
Backing bar or backing strip is used to ensure consistent root fusion and
avoid burn through. However, if you choose to use permanent backing strip
(rather than a backing bar which is removed after welding), be aware that it
gives a built-in crevice which can make the joints susceptible to corrosion
(Figure 39). When using backing for aluminium welds, make sure any
chemical cleaning reagents have been removed before assembling the joint.
A backing strip will also give a lower fatigue life.
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Outside of the design of the joint and weld, access to weld locations and the
order in which welds are made are just as important. Figure 2.40 shows
examples of the limitations of access in designing welded joints and gives
improved designs. It is important to ensure that it is indeed possible to make
welds as required by the drawing.
Figure 2.40 Examples of improved weld designs where there is limited access.
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2.12 Summary
At the end of this module you should be able to label the parts of a butt and
fillet weld and to label the parts of a vee and U edge preparation. You
should be able to recognise welding symbols and know what they mean.
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Revision questions
2 Draw and label the significant features of a single sided vee preparation butt joint.
3 Sketch the weld that would be fabricated from the weld symbols shown in this
design drawing:
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Section 3
Industrial structural elements for carrying loads include cables, bars, beams,
plates, slabs and shells. Some of these can be seen on the bridge
structures in Figure 3.1.
a b c
Figure 3.1 Bridge and crane structures showing cables, bars and beams as
examples of load carrying components.
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Individual load carrying members are joined together to fabricate the entire
structure, such as the complete bridge, crane, offshore structure, or building.
A simple arrangement of structural components can form a frame, which is
an assembly of bars arranged to support the loads. These are relatively
easy to design and an example of a truss frame is shown in the bridge
verticals in Figure 3.1a, or the crane arm in Figure 3.1c. Joining the
components together is where the importance of welding comes in; although
many structures are joined using rivets or bolts as well as or instead of
welds (Figure 3.2).
3.2 Forces
Now lets consider the loads, or forces, that act on structural components in
more detail. A force has a size (magnitude) and a direction. Two or more
forces may be added together to give a single equivalent force, as shown in
Figure 3. Instead of simply adding the magnitudes of the forces together,
their directions must be taken into account as well. The forces are
represented as arrows with a length equal to their magnitude and pointing in
the direction of the force. The two (or more) force arrows are added point to
tail and the single equivalent force is the arrow which points from the origin
to the final arrow point. The combination of five different forces is shown in
Figure 3.4.
Figure 3.3 Combination of two forces (Fx and Fy) into a single force, F.
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Figure 3.4 Combination of five forces (F1 to F5) into a single force, FR.
Figure 3.5 Resolution of a single force, F, into two forces at right angles (Fx and
Fy).
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Given that the structure does not itself move, there is no resultant force and
all the loads acting on it must be in equilibrium, iethe sum of all the forces
added together must equal zero. That means that any applied force is
reacted by an internal reaction force inside the components. This is
illustrated in Figure 7 by a free body diagram of the truss members of a
bridge. All the loading on the bridge is carried as forces inside the truss
members. The overall force on the bridge is reacted by the bearings at
either end of the bridge too.
Step 1 - find out if frame can be statically calculated. If the design will be
dominated by fatigue then an alternative design approach will be needed.
Step 2 - find reactive forces in bearings, based on the loads the structure is
designed to carry.
Step 4 - calculate weld sizes for the connections, based on the forces they
are required to carry (plus a safety factor)
Figure 3.8 The method to determine whether this bridge design is appropriate and
the required welds.
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Figure 3.10 Load-displacement curves for thick and thin specimens of the same
material.
Stress (Figure 3.11) is defined as load (or force) divided by the cross
sectional area,. If the force, F, is in newtons (N) and the cross sectional area
is in millimetres squared (mm2), then the tensile stress, given the symbol ,
is in newtons per millimetre squared (N/mm2), which is also the same as
megapascals (MPa).
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Stress
Youngs modulus E
Strain
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Where there is no obvious yield point, such as a yield plateau and the stress
strain curve rises smoothly into the plastic region, it is necessary to define
an arbitrary yield point. In such cases, the 0.2% proof strength (Rp0.2) is
used as a design parameter. Rp0.2 describes the stress obtained for an
elongation of 0.2% and is determined by plotting a line parallel to the elastic
part of the stress-strain curve, at an offset of 0.2% along the strain axis.
Where this line intersects the stress-strain curve is the 0.2% proof strength
(Figure 3.14).
Figure 3.14 Definition of the 0.2% proof strength for stress-strain curves without an
obvious yield point.
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The design assumption of load bearing assumes that the cross-section area
remains the same and this is how the Engineering stress-strain curve is
produced, as shown in the stress-strain curves above. BUT necking of the
material reduces the REAL cross-section area. In reality, the stress does not
decrease with increasing applied loading but flattens out around the
maximum stress while the cross sectional area decreases. Allowing for this
reduction in cross sectional area gives the real or true stress-strain curve.
After the UTS and necking, fracture occurs at the fracture stress. The strain
at fracture is usually defined as a percentage elongation. In some materials
fracture occurs before the stress-strain curve reaches a maximum. The
ability of a material to deform plastically before fracture is known as ductility.
Some examples of stress-strain curves for real materials are given in Figure
3.16.
A b
Figure 3.16 Examples of stress strain curves in a) for 1-low carbon steel; 2-
medium carbon steel; 3-high carbon steel; 4-bronze; and in b) for aluminium and
Duralmin.
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As the test progresses and necking and final failure occur, measurements of
the original and final gauge length are taken and of the original and final
diameters at the neck location. The reduction of area and the elongation are
reported as percentages. The yield strength (or 0.2% proof strength) is
reported along with the value of UTS. Often the data points from logging the
whole stress strain curve are recorded, so the stress-strain curve can be
plotted.
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Tension and compression act perpendicular to the cross sectional area and
give rise to direct axial stress, as has been discussed in Section 3.3. When
the load is applied parallel but offset to the cross sectional area then a shear
stress results.
a b.
Shear stresses are particularly significant for calculating stresses in fillet and
lap welds. The shear stress is given the Greek symbol tau, and is also
calculated as the shear force, Q, over the cross sectional area, but in this
case it is the force that acts parallel to the cross sectional area, A.
Likewise the shear strain, , is also the change in dimensions over the
original dimensions, but it is the shear strain, , (acting parallel to the
applied, Q) over the offset between the two opposite shear forces, h. These
dimensions are shown in Figure 3.22.
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Figure 3.22 Dimensions for the definition of shear stress and strain.
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The amount of axial stress in the beam caused by the applied moment
depends on how stiff the design of the beam is. This stiffness is
characterised by the beams second moment of area (also called its moment
of inertia) and given the symbol, I. A stiff beam with a large second moment
of area tends to be tall and thin, with most of the beams mass at a vertical
distance from the neutral axis (such as a tube section or an I-beam). Beams
with low stiffness (low second moment of area) are wide flat beams. You
can demonstrate this by bending your ruler while its flat and then turning it
on its edge and trying to bend it that way its much harder! A range of
beam cross sections are shown in Figure 3.25 in order of their stiffness for
the same cross sectional area.
Figure 3.25 Beam cross sections ranked in order of stiffness by their 2nd moment
of area, for an equivalent cross section area.
= My / I
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This means that for the same applied bending moment (ie the same length
of cantilever beam with the same load on the end), a beam with a larger 2nd
moment of area will result in a much lower maximum stress at the tension
surface. This is why structures are designed with square or round hollow
section beams and I-beams, because they allow greater loads to be carried
without redundant extra weight being required.
Start by assuming the beam is square section (10mm by 10mm) and then
well calculate the bending stress if we use a rectangular section beam of
the same cross sectional area, but 5mm by 20mm.
Assume the beam is 300mm long with a load of 200N on its free end. First,
calculate the bending moment, M.
Lets calculate the second moment of area of the beam. For square and
rectangular beams the formula for a beam with a breadth, b and depth, d is
I = bd3/12
This means that the second moment of area for the square section beam is
833mm4, whereas the rectangular beam has a second moment of area of
3333mm4. The rectangular beam is four times stiffer than the square beam.
The distance from the neutral axis, y, is basically half the depth of each
beam, ie 5mm for the square beam and 10mm for the rectangular beam.
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The engineers bending formula, = MY/I can now be used to work out the
bending stress in each beam. The square section beam has a stress equal
to 60,000 x 5 / 833 which equals 360MPa. The rectangular section beam
has stress equal to 60,000 x 10 / 3333 which equals 180MPa. Therefore by
changing the square section beam to a rectangular beam the stress in the
beam is halved!
3.9 Summary
At the end of this module you should understand how structures carry loads
and forces and that reaction forces are set up to give equilibrium conditions.
You should understand how to calculate the stress that a force will impose
on a structure and how to draw and interpret a stress-strain curve for a
given material. You ought to know how to calculate a bending moment and
to recognise the Engineers bending formula.
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Revision questions
1 Describe how to add two forces together.
6 How can you define the yield point where there is no yield plateau?
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Section 4
Fatigue
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Fatigue
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4 Fatigue
4.1 Introduction
Fatigue loading is the repeated application of a load. A simplified fatigue
loading cycle is shown in Figure 4.1.
Fatigue failures have been occurring for many years; a train returning to
Paris from Versailles crashed in May 1842 at Meudon after the leading
locomotive broke an axle (Figure 3). The carriages behind piled into the
wrecked engines and caught fire, killing at least 55 passengers. The
accident was widely reported in Britain and discussed extensively by
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If the minimum stress is zero then the fatigue cycle is known as a pulsating
cycle. If the maximum stress is equal and opposite to the minimum stress
then the fatigue spectrum is known as alternating cycles. If the minimum
stress is half the maximum stress then the cycling is known as half tensile
cycles.
a b
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The most important parameters are the stress range, Sr (the difference
between the maximum and minimum stress) and the stress cycle, ie the
interval between equivalent points in the stress history. Other fatigue
parameters include the stress ratio, R (the minimum stress divided by the
maximum stress) and the stress amplitude, which is half the stress range.
Figure 4.7 Graph of stress range against number of cycles to failure - the S-N
curve.
Increasing the stress range increases the fatigue damage. Increasing the
number of cycles also increases (Figure 8).
Figure 4.8 Effect of increasing the stress range or number of cycles on the fatigue
damage.
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Figure 4.13 Stress raisers at weld toes provide easy fatigue crack initiation sites.
Figure 4.14 High magnification image of a weld toe intrusion, which extends as far
as A, initiating the rest of the fatigue cracking from that location.
The effect of these fatigue initiation sites on the S-N curve is shown in
Figure 4.15, which shows fatigue data for one specific steel in three
conditions - unwelded, unwelded but with a stress raiser (a hole) and
welded with two plates attached to the surface. It is clear that the fatigue
performance of the welded material is very much inferior to that of the
unwelded material.
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Figure 4.15 Fatigue data for one type of steel in the unwelded condition, unwelded
but with a stress raiser and the welded conditions.
One of the most serious consequences of the fact that the fatigue lives of
welded joints are dominated by crack growth concerns the influence of
material strength. Although the fatigue strength of un-notched material
usually increases with tensile strength, the level of increase decreases if the
material contains a notch until there is no increase at all for welded material.
This is because rate of fatigue crack growth is not dependent on material
strength and hence welded low and high strength materials give the same
fatigue life. The benefit of material strength comes in the crack initiation
stage, which is effectively absent in the welded material. Fatigue data from
unwelded and welded steels of different tensile strengths are shown in
Figure 4.16.
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A large number of fatigue tests have been carried out on many different joint
geometries, Fatigue tests can be carried out on full-scale structures (Figure
4.17a), or on smaller-scale specimens. A common specimen is a flat strip
with fillet welded attachments on either side (Figure 4.17b). A series of
these specimens have been tested at a variety of stress ranges and the
fatigue lives plotted on an S-N curve, shown in Figure 4.18. As is often the
case with fatigue data, these results exhibit some scatter. For design
purposes, the lower limit S-N curve is used.
A b
Figure 4.17 Fatigue testing, a) full-scale beam and b) fatigue test specimen after
test.
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When the appropriate design curves obtained from fatigue tests on different
geometries are compared, it is clear that fatigue performance is strongly
dependent on joint geometry, shown in Figure 4.19. Fillet welds have a
shorter fatigue life than butt welds under equivalent stress cycles. Welded
joints that exhibit similar fatigue strengths can then be grouped into classes
and this approach is used in fatigue design rules. Welds in the same fatigue
class have similar stress concentration effects. The fatigue joint
classifications range from A (plain material with the best fatigue resistance
and longest fatigue life) down the alphabet as the fatigue resistance
decreases to F, F2, G and then W, these latter few being used only for
special types of weld joints.
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Stress
R=0
Effective stress range
R = -1
Time
0
R = 0 (compression)
Figure 4.20 Effective stress range in the presence of high tensile residual stresses.
Figure 4.21 Fatigue improvement technique, showing grinding of the weld toes.
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4.7 Summary
At the end of this module you should understand an S-N diagram and
describe the influence of notches and weld defects of fatigue performance.
You need to recognise which welded joints are most susceptible to fatigue.
You should also be able to describe modifications for fatigue improvement.
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Revision questions
1 What types of structures and applications are at most risk of fatigue cracking?
2 Sketch an alternating fatigue cycle and label the fatigue parameter on the
diagram.
4 What effect does increasing the strength of the steel have on its fatigue
performance?
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Section 5
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Shell
Main body of the vessel, most often cylindrical but some pressure vessels
use conical or spherical shells.
Head
At each end to complete the basic shape and produce a closed container,
are most often dished but can be flat.
Nozzles
A number of openings for filling, inspection or drainage.
Saddle supports
Hold the pressure vessel in place.
Nameplate
Indicates the main working parameters of the pressure vessel including
work pressure and temperature. Details may include the manufacturing
company, year of manufacture, the code to which the pressure vessel has
been designed and manufactured and the inspection body stamp.
Offset
The shell of a pressure vessel can range in thickness from a few millimetres
for a BBQ propane gas bottle to several hundred millimetres for industrial
pressure vessels. The minimum design thickness is dependant on the
shape of vessel, internal pressure, diameter of the vessel and material
strength. A spherical shell requires a much smaller wall thickness than a
cylindrical shell for the same diameter, internal pressure and construction
material.
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A b c
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Ellipsoidal dished head the longitudinal section of this type of dished head
(ie a section along its longitudinal axis) is half an ellipse. Since the stress
developed in the dished head in this case is equal to the hoop stress, the
required thickness for an ellipsoidal dished head is equal to that of the
cylindrical shell. Advantages are there is no need to supply different plate
thickness to manufacture a pressure vessel with ellipsoidal dished heads
nor for a transition between two different thicknesses, making manufacture
easier.
Knuckle
radius, r
Crown
radius, R
The junction of the torus with a cylinder gives rise to bending stresses as the
greater the deviation from a sphere, the higher these stresses would be.
Torispherical dished heads are often preferred to ellipsoidal ones since the
depth of drawing is less so they are cheaper to manufacture. The small axial
dimension is an advantage when the longitudinal size of the pressure vessel
is a critical factor, but their higher stress concentration and lower allowable
pressure for a given material size may outweigh this as a result, the
thickness required for a torispherical dished head is larger than that for a
cylindrical shell.
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The force which acts on each closed end of the cylinder due to the internal
pressure is dependent on the cross section area on which this pressure is
acting. Cylinders with larger ends but the same internal pressure have a
smaller force pushing against them.
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pr
x
2t
The hoop stress y is twice the axial stress and is calculated by:
pr
y
t
Since the hoop stress is twice the value of the axial stress, failure of a
cylindrical pressure vessel will preferentially occur along the longitudinal
welds, also true for other similar pressure components such as pipelines.
Consequently longitudinal welds are subjected to more stringent acceptance
standards than the circular girth welds (welds around the circumference of
the vessel or pipe).
For a spherical pressure vessel the stress in the vessel wall is symmetric
about all planes therefore there is only one membrane stress calculated:
pr
2t
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Offset
In the ASME Boiler & Vessel Code, Section VIII, Division 1, vessels made of
two or more courses shall have the centres of the welded longitudinal joints
of adjacent courses staggered or separated by a distance of at least five
times the thickness of the thicker plate.
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Various weld joint designs exist to join the heads to the shell and the choice
of joint will depend on the welding process to be used, access conditions
and the material to be welded. Some examples are shown below.
a b
C d
The weld preparations shown in Figures 5.10a and b are the simplest joint
designs and assume that access for welding can be made from the inside of
the vessel and so would not be used for small pressure vessels. Figure
5.10c shows a self-jigging joint design with an integrated backing strip which
can be welded entirely from the outside. This joint would be appropriate for
thick section material, whereas Figure 5.10d shows a self-jigging joint that
could be formed in thinner material.
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A b
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5.6.3 Reinforcement
A hole or opening in the shell of a pressure vessel for nozzles can have a
detrimental effect on the structural integrity of the shell. The hole can act like
a local stress concentration. The shell thickness is a function of the
operating stresses within the shell, if the shell experiences greater stress in
a region due to stress concentration the shell thickness needs to be greater
in this region to withstand the stresses. Welded plates of additional
thickness around openings in the pressure vessel are called reinforcement
plates or compensation plates.
Autoclaves
Sterilise medical equipment by heating them to a high temperature inside
a sealed container. An autoclave is a pressurised device designed to
heat aqueous solutions above their boiling point without evaporation.
Heating is by feeding hot steam into the outer envelope. During
sterilisation, medical equipment must be protected from contamination
by being in a hermetic container, ie the inner container.
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Dewar vessels
For storing low temperature fluids like liquefied gases. To avoid heat
transfer from the outside to the contents in the inner vessel, the jacket
space between the two walls is evacuated.
5.9 Summary
At the end of this section you should understand the weld design details for
pressure vessel construction, of the vessel shell and head, as well as
attachments. You should also be able to outline how to calculate hoop
stress and axial stress in a pressure vessel shell.
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Revision questions
1 Sketch a pressure vessel and label the shell, head and a nozzle connection.
Show the weld joints on your sketch.
2 When welding a thicker plate dished head onto a thinner plate shell wall, what
gradient of taper should be used?
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Section 6
Stresses in Welds
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Stresses in Welds
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6 Stresses in Welds
6.1 Making things Simple
In the majority of situations it is very difficult, if not impossible to take into
consideration all the factors that might influence the load carrying capacity
of a welded joint. This is why designers use assumptions to simplify the
approach and reach a practical result without over-complicated calculations.
a b
Figure 6.1 Excess weld metal in a butt weld a and fillet weld b.
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a b
Figure 6.2 The design throat in a butt weld a and fillet weld b.
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1MPa = 1N/mm2
Joint factors are sometimes used to reduce this initial design stress to reflect
a reduced level of NDT and the risk of weld flaws being present. For
example. if only 10% of welds will be inspected, the value of 2/3 yield
strength is multiplied by a joint factor of 0.8, thus reducing the value of the
design stress.
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The concept of hot spot stress was developed in the 1970s for determining
the strength of tubular joints in offshore platforms. The approach is now
used to assess the resistance of fillet welds and its concept extrapolates the
structural stress profile measured close to the weld toe. The hot spot stress
can be experimentally determined using strain gauges positioned at very
specific locations or using finite element calculations.
A particular advantage of using the hot spot stress approach is that it is far
easier to extract the hot spot stresses from finite element analysis, instead
of trying to determine the equivalent nominal stress. When much of the
current design of welded joints is done using finite element modelling, this
makes it easier to extract the stresses to compare to the design stress limit.
Stress
Notch stress
Structural stress
Nominal stress
Figure 6.4 Stress terminology close to the weld toe of a fillet weld.
The notch stress design approach uses the peak stress by capturing the
increase in stress intensity due to the presence of the weld. It takes into
account the radius of the weld toe and geometry of the joint. This calculation
requires more parameters than the hot spot stress approach so is more
complex.
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Figure 6.5 Full penetration butt weld under uniaxial tension load.
The cross section area is in millimetre squared (mm2) if the thickness and
length are both expressed in millimetres (mm).
For a flat plate in uniaxial tension with a butt weld (Figure 6.5), the stress is
calculated in the same way as the stress in a flat plate under uniaxial
tension with no weld (Figure 3). In a full penetration butt weld the stress is
given by the following equation:
For the stress to be calculated in MPa (equivalent to N/mm2), the load must
be converted into Newtons (N) and the length and thickness of the weld are
both in millimetres. Be careful because often loads are given in kiloNewtons
and will need to be multiplied by 1000 to get the equivalent number of
Newtons.
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The tensile stress which occurs in the weld is therefore calculated by:
Again, if the stress is to be in MPa, the load must be converted into Newtons
(N) and the length and thicknesses of the welds are all in millimetres.
Figure 6.6 Partial penetration, double sided butt weld under uniaxial load.
Another feature to consider in this type of weld is the crack-like gap left
between the two welds. Since defects are more likely close to the weld root,
adding a sharp corner in this area is not good practice. Therefore, it is
strongly advised to avoid partial penetration butt welds and to opt for fully
penetrated butt welds with a prepared edge to obtain a reliable joint.
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The CSA of the weld under loading (ie the shaded area) is therefore equal
to: CSA = length, L x thickness, t = x ID x t.
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Simplest design. All that has to be done is to stand one piece against the
other and run the welding electrode/gun where the parent metals touch.
Can be made with any number of passes. The welder can either
increase productivity and reduce distortion by reducing the number of
passes or avoid a wide HAZ in a sensitive material (eg fine grained
structural steel) by reducing the heat input and increasing the number of
passes.
6.4.2 Disadvantages
If not performed correctly, lack of penetration can occur. This means that
even if the leg size is achieved, the weld throat which carries the load is
reduced. Visual examination or other NDT techniques cannot reveal this
defect, the only way is by macro examination, but since this is a
destructive test it cannot be applied to a welded assembly.
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The throat is the shortest distance from the root to the face of the weld. Fillet
weld sizes should be specified by referring to the throat thickness, a,
although leg length, z, is often used and can be easier to measure during
weld inspection. Conventionally, leg lengths are regarded as being of equal
dimension, the weld forming an isosceles triangle in cross-section. Convex,
concave and deep penetration welds are illustrated in Figure 6.9 below.
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Figure 6.11 Design versus actual throat thickness for fillet welds.
The convex fillet is generally undesirable for two main reasons. The junction
of the weld metal with the parent metal at the weld toe can form a significant
stress raiser and will adversely affect both fatigue life and brittle fracture
resistance. Excess weld metal in the cap costs time and money to deposit
without contributing to joint strength.
The concave fillet weld can be beneficial with respect to fatigue strength but
the minimum specified throat thickness MUST be achieved.
Deep penetration fillet welding can give a stronger joint, but it is not possible
to allow for this during design as the actual penetration depth cannot be
verified by inspection techniques during production.
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In a simplified way, the stress in the weld throat can be calculated by the
following equation:
Stress = load P
length, L x throat, a
Similarly, this equation also holds for fillet welds under shear such as in
Figure 6.13 below.
Often when fillet weld sizes are calculated, they are mainly subjected to
shear. The allowable, or design, shear stresses on the weld throat area are
applied. Some codes specify these values depending on the welding
electrode but in the absence of such information yield stress of the parent
material is assumed as the design shear stress (compared to 2/3 yield for
the design axial tensile stress). This value of design shear stress takes into
consideration the higher sensitivity towards cold cracking shown by fillet
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welds due to the increased combined thickness (see MAB module) as well
as the effect of the natural lack of penetration present at the root of the joint.
Figure 6.12 Weld throat and leg length in a mitre fillet weld.
For a fillet weld with equal leg lengths, the cross section triangle is a right-
angle triangle with angles of 45 in each corner. The relationship between
weld throat, a and leg length, z, is given by the following equation.
6.5 References
IIW Guidelines; Niemi E, Fricke W, Maddox S J: Fatigue analysis of welded
components: Designer's guide to the structural hot-spot stress approach,
Woodhead Publishing, 2009.
6.6 Summary
At the end of this section you should be able to understand the cross section
areas of different welds and how forces act on them. You should also know
the differences between design stress, nominal stress, hot-spot stress and
notch stress.
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Revision questions
1 Calculate the stress in this butt weld
Answer: 64MPa
2 What size fillet weld is needed in this joint? Steel has a yield strength of 350MPa.
8mm
Answer: 5.8mm
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Section 7
Specimen 1
Specimen 2
The load-extension curves from the two specimens are shown in Figure 2
and it can be seen that specimen 2 can withstand the greater load.
However, tensile strength is what is a material specific property and these
specimens are of the same material so should have the same strength
regardless of size. Therefore we take the size of the specimen into account,
when determining the stress (as opposed to the load) and the units of stress
are N/mm2.
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Stress takes into account the cross section area (CSA) of a specimen so is
the true indicator of strength, not the maximum load applied. The CSA of the
specimen in Figure 7.3 is the area being tested perpendicular to the tensile
direction of loading and is often a circle in a round tensile specimen, but
square or rectangular section specimens are also possible. The tensile
specimen is thicker at the ends where the specimen is gripped, but the
material being tested is in the central parallel section, called the gauge of
the specimen. It is the CSA within the gauge length that is used to calculate
stress.
Figure 7.4 Different sized specimens of the same material give the same stress-
strain curve.
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We can use the stressstrain curves for different materials to help design
structures. To ensure there is no plastic deformation in structures, engineers
usually design each structural member to operate at a static stress
equivalent to two thirds of the yield stress, leaving a third as a safety factor
so as that the structure can tolerate some further loading without plastic
deformation. (Some design codes limit the applied stress to half yield
strength). These other loads that can act on the structure are mostly due to
adverse weather conditions such as added weight due to snow fall or
additional forces due to high winds. Figure 7.5 shows this safety margin
between the design stress, design and yield stress, y.
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Choosing materials which can best suit certain applications and the method
to assess a materials suitability is termed material selection. An example
where this process has been optimised to the maximum is the turbine
engine, shown in Figure 8:
As with all aerospace components, weight saving is a big issue. The fan
blades at the front need to be light but strong and resistant to creep so
selecting the correct material is challenging. A titanium alloy is used due to
its excellent mechanical properties and most of all its strength to weight
ratio.
The engines driveshaft running through the centre of the engine is made of
steel. Steel is three times heavier than titanium so there is no real
replacement for this component due to the intense levels of torque that need
to be tolerated by the shaft. Titanium is as strong as steel, but cannot
withstand twisting forces to the same extent.
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Figure 7.10 shows the stress concentration effect of a circular hole in a large
flat plate under tension. Even this simple detail increases the stress at the
edge of the hole by a factor of 3. This means that close to the edges of
holes (such as bolt holes), the maximum stress in the plate is about three
times the nominal applied stress. Sharper notches concentrate the stress by
much more and very sharp notches, such as cracks have a very high
concentration of stress at their tips.
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Figure 7.14 Brittle fracture surfaces where a fatigue crack propagated following
brittle fracture.
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In Figure 16 the smooth flat region with beachmarks identifies that fatigue
has occurred. The final fracture is rough and torn and is at 45 to the fatigue
crack, pointing to ductile overload as the final failure.
7.6 Summary
At the end of this module you should be able to identify the various types of
fracture. You should understand the requirements for designing under
different loading or temperature service and how to choose materials that
will meet these requirements.
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Revision questions
1 What effect does high temperature have on strength?
3 What are the three main factors for brittle fracture to occur?
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Section 8
A b
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Corrosion resistance
Aluminium alloys have excellent corrosion resistant properties due to a
thin self-healing oxide layer and can normally be used unpainted.
Aluminiums corrosion resistance makes it widely used for food
packaging such as aluminium foil, drink and food cans. Other uses range
from gas cylinders to ladders to ski poles. Higher strength alloys will
corrode in some hostile environments and may need protection.
Magnetic properties
Aluminium is non-magnetic which allows its use in applications where no
electromagnetic interference is allowed, such as avionics devices.
Unfortunately, this property means that magnetic particle examination
cannot be used as an NDT method aiming at detecting surface/near
surface defects in an aluminium weld.
Figure 8.2 Extruded complex aluminium sections frictions stir welded together.
Machinability
Milling can be an economic fabrication technique for aluminium because
of the high metal removal rates possible so U or J weld preparations are
easier to produce. These machined preparations can lead to better joint
fit-up, reducing the amount of weld metal required to fill the preparation
and avoiding possible weld defects caused by mismatch.
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Electrical conductivity
Aluminium possesses a high coefficient of electrical conductivity which
combined with a lower price per kg compared with copper, make it the
standard material for overhead transmission lines (with a central steel
strand to carry the weight of the cable). Aluminium alloys have an
electrical conductivity approximately 65% that of copper but because of
their density can carry more than twice the electricity as an equivalent
weight of copper.
Thermal conductivity
Aluminium has a high coefficient of thermal conductivity (237W/mC -
about four times greater than steel) so pure aluminium can be used in
heat exchangers as an alternative to copper tubes. From the welding
point of view, high thermal conductivity is a disadvantage since the heat
tends to dissipate quickly from the heated point.
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Electron beam and laser welding is now used extensively for joining
aluminium components with the advantages of high processing speeds,
ease of automation and low heat input (low distortion). Friction welding
processes (such as friction stir welding) avoid the disadvantages of
fusion welds and can produce extremely strong defect-free welds in
aluminium alloys.
Adhesive bonds
The use of adhesive bonding is well established as a valid method for
making structural joints in aluminium and does not produce residual
stresses or other defects which can occur during welding (hot cracking,
porosity, etc). Unfortunately, adhesive bonded joints have limited life as
most adhesive systems degrade rapidly when the joint is both highly
stressed and exposed to a hot, humid environment.
Thermal expansion
Aluminium expands and contracts with temperature approximately twice
as much as steel its coefficient of thermal expansion being 2410-6 C-1
compared with only 1110-6 C-1 for steel. Greater thermal expansion
leads to greater distortion; expect twice as much distortion in an
aluminium structure compared with steel. Because of the lower Youngs
modulus, thermal stresses in a restrained member are only two-thirds
those in steel.
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Thermal conductivity
Having a high coefficient of thermal conductivity, aluminium is capable of
cooling the weld pool much faster than steel. Since heat is dissipated
much more quickly, a larger included angle is required to prevent lack of
sidewall fusion. If the included angle for a V preparation in structural
steel weldment is approximately 60, this value may need to be
increased to 90 for aluminium. A high thermal conductivity means also
that a larger area will be heated up by welding, thus increasing
distortions and giving a wide HAZ.
Youngs modulus
Aluminium exhibits a low Youngs modulus value, 0.7105N/mm2, a third
that of steel. Because of this, aluminium beams are more prone to
buckling than equivalent steel ones and have lower stiffness and rigidity.
Elastic deflection is therefore a key factor to consider when designing
aluminium structures, which may not be a concern when using steel
instead.
Fatigue resistance
Aluminium alloys are more prone to fatigue than steel because of their
lower Youngs modulus. When designing steel structures, potential
fatigue sites should be identified. The number of fatigue cycles to failure
for a given stress range is normally obtained from an endurance curve,
according to the weld geometry. For a mass-produced component, the
fatigue life can be found by testing. Fatigue is covered in more detail in
Chapter 4.
Tensile strength
Pure aluminium has modest UTS (70-150N/mm2 depending on delivery
condition, annealed or cold worked). For use in structural applications it
is alloyed with different elements to increase its tensile strength up to
650N/mm2. This compares to standard grades of steel which have yield
strengths of 150-450MPa and tensile strengths of 300-650MPa.
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Corrosion
Serious electrolytic corrosion of the aluminium may occur at joints with
other metals unless correct precautions are taken. This can apply even
when using alloys that are otherwise highly durable. Aluminium is also
susceptible to stress corrosion cracking (SCC) which can occur in
aqueous chloride solutions and tropical marine conditions.
Affinity to oxygen
Aluminium forms a tenacious oxide film with a melting point more than
three times that of aluminium. Failure to remove this oxide both before
and during the welding operation results in entrapment of oxides and/or
incomplete fusion giving a joint with impaired mechanical properties. To
produce a sound weld the oxide layer needs to be removed by
mechanical or chemical methods. The use of chemical cleaning must be
considered from the design stages as since the reagents used are highly
corrosive, permanent backing strips and lap joints should be assembled
after chemical cleaning due to possible entrapment. Due to its high
affinity to oxygen, aluminium is mainly welded using gas-shielded arc
welding processes and since the shielding gas column can be affected
by draughts, on-site welding of aluminium is difficult unless special
measures are used to protect the weld area. This high affinity to oxygen
requires larger diameter gas nozzles for TIG and MIG welding which
leads to an increase in included angle and/or an increase of land in U
preparations.
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Non-heat treatable alloys gain strength from cold working. Heat treatable
alloys gain strength from both work hardening and precipitation hardening.
The lower strength of the HAZ must therefore be considered in the design
by allowing for the amount of softening (loss of strength) when calculating
the load carrying capacity of a weld. This may be done by locally thickening
the material in the region of the weld, or by designing the locations of the
welds away from the most highly stressed regions (ie on neutral axes).
Figure 8.5 The loss of strength (and hardness) in the HAZ of welds in aluminium.
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8.8 Summary
At the end of this module you should be able to name some typical
applications of aluminium alloys and the advantages of this material
compared to steel. You should recognise common aluminium imperfections
and solutions to avoid them. You should also be able to recognise typical
weld preps for aluminium alloys.
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Revision questions
1 What is the density of aluminium compared to steel?
4 What effect does the difference in Youngs modulus have on the fatigue
resistance of aluminium welds?
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Section 9
Static Loading
Rev 4 April 2013
Static Loading
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9 Static Loading
9.1 Introduction
For some structures, the main loading does not change over time, it is
essentially static. A typical example of this is a building based on a steel
frame where the frame supports the weight of the building (and the frame
itself) and the weight of the contents. The majority of new buildings are
based on steel frames, because this is also a fast and efficient construction
method. Figure 9.1 is a classic image of construction workers on a 1920s
skyscraper in New York, which shows the steel frame skeleton of the
structure.
Figure 9.1 Construction workers take a break on a New York skyscraper in the
1920s.
9-1
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Figure 9.2 Pylon truss joints. Figure 9.3 Nodal joints in an offshore structure.
Figure 9.5 Free body diagram of a truss bridge (not every force is shown here).
The stress, , that each force, F, imposes is calculated by dividing the force
by the cross sectional area, A, of the member. The units of force or load is
Newtons, N, the units of area is mm2 and the units of tensile stress is
N/mm2, or megapascals, MPa.
9-2
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The elastic design method bases the design stresses on the elastic limit of
the structure, but ensures that the stresses in the structure do not exceed
the yield stress (ie elastic deformation is designed for, but no plastic
deformation occurs). However it is not normally possible to design up to the
yield stress safely due to the presence of material defects, joint/weld
mismatch, unforeseen loads such as wind or snow and degradation over
time.
9-3
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The ratio of the yield stress (or UTS) to the design stress is known as factor
of safety (FoS). The factor of safety depends on the material and the
utilisation of the structural member.
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9-5
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9-6
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Figure 9.12 An X joint Figure 9.13 A K joint Figure 9.14 A T-K joint.
Usually in a K joint the two braces are angled so that their axes meet at the
middle of the chord diameter, to give the joint its strength. It is also possible
to angel the braces more deeply or more shallow and the difference is
known as the eccentricity of the joint.
9-7
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The stresses in nodal joints must be calculated to take into account the
stress concentration that occurs at the intersection of the chord and brace.
The hot spot stress approach was developed to account for the stress
concentration at nodal joints in offshore platforms (Figure 9.19) and has
been readily adopted since it is easy to extract from a numerical model of a
joint and can be measured from strain gauges at the toes of the node joint
welds.
9-8
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9-9
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A b
Figure 9.20 Designing structures from those with a) simple components to those b)
more complex structures.
The various ways that a beam can be carried by a crane illustrates the
different types of loading that can be imposed. Carried vertically it imposes
only tensile stress, but carrying the beam horizontally from a single point
hook will impose bending as well. If the horizontal beam is carried using a
chain attached to each end then compression as well as bending occurs. If
the beam is carried from a chain attached at a single point in the middle, the
loading becomes mainly bending. This is a rather unstable way to carry a
long beam though.
9-10
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Concrete itself has good strength properties in compression but has a very
low strength in tension. This limits the use of concrete in construction and
makes it unsuitable for use in many structural members when used on its
own. However, by introducing a high initial compressive stress such that the
concrete still experiences compression stresses when loaded in tension,
concrete can be used in tension members and in members loaded in
bending. The compression is introduced by pre-stressing steel reinforcing
bars in tension and then pouring the concrete around the bar. The concrete
shrinks when it sets and grips the steel bar. The pre-stressing in the steel
bar is then released and the contraction of the steel bar introduces
compressive stresses in the concrete. One common application is in the
tension flange of concrete members loaded in bending, Figure 9.21. The
term reinforcing-steel is used to describe the use of steel to reinforce any
materials, but is most often used concrete.
9-11
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Figure 9.21 Reinforcing steel bars (rebars) in the tension flange of a concrete
beam loaded in bending.
A range of materials is used for the reinforcing bar and a range of welding
techniques is used for joining bars together. The rebars have a textured
profile (Figure 9.22) to allow them to key into the concrete and provide the
pre-stressing. Reinforcing bar is available in sizes ranging from 6mm up to
50mm diameter. A whole assembly of reinforcing bars will usually be used
and the frame fabricated together before the concrete is poured into a
surrounding mould. The bars are joined together using one of several
methods. The rebars can be welded, they can be joined using a wire joint
where wire is wrapped around bars and tightened. It is also possible to use
a rebar coupler which is a mechanical fixing. Reinforcing bars are available
for a wide range of chemical compositions and mechanical properties. Not
all reinforcing bars are weldable; the weldability is determined by the carbon
equivalent value and the limitations on the content of certain elements.
Rebars are usually welded using MMA or MAG welding processes. Welding
rebars using butt joints (Figure 9.23) is usually used just for load bearing
joints only, because they need joint preparation and possibly backing strip
may be used as well. Lap welds (Figure 9.24) are used for load bearing and
non-load bearing joints. It is possible to weld double sided lap joints as well.
The requirement is for a minimum throat thickness, a, greater and 30% of
the rebar diameter, ie a 0.3d.
9-12
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A b
Figure 9.23 Weld butt joint preparations in steel rebars a and b showing the stages
of filling up the joint when backing is used.
9.8 Summary
At the end of this module you should recognise structural designs for static
loading, such as trusses and nodes. You should understand the different
kinds of static loading and know how to determine the tensile stress and the
bending moment on a beam. It is expected that you can explain different
designs of nodal joint and how they differ from nozzles in pressure vessels.
Finally, you should be able to describe welded joints for joining steel
reinforcement bars for concrete structures.
9-13
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Revision questions
1 Sketch a structure which incorporates a truss frame. How is the load transmitted?
4 Sketch a Y nodal joint and label the brace, chord, heel and toe of the structure.
5 Why are steel reinforcement bars used in structures? List three ways to join
them.
9-14
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Section 10
3 Strain is:
a Bolted joints.
b Magnetic fields.
c Weld distortions.
d Vibration.
5 By how much does a carbon manganese steel beam deflect, compared to an aluminium
alloy beam of the same size under the same load?
a One third.
b Four times.
c The same.
d Twice.
a IIW formula.
b S-N curve.
c Schaeffler diagram.
d A flow chart.
a Prevent vibration.
b Stop corrosion.
c Reduce stress concentrations at openings.
d Balance the weight.
10-1
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8 Fatigue cracks in otherwise sound butt welds transverse to the stress start at:
a The root.
b The toe.
c Interrun ripples.
d Chipping hammer marks.
a Smooth.
b Jagged.
c Torn.
d With a chevron pattern.
14 A 10mm fillet welds indicated with a Z to BSEN 22553 requirements has a nominal:
10-2
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16 The static strength used for designing a building frame is based upon the:
a Percentage elongation.
b Hardness.
c Ultimate tensile strength.
d Yield strength.
a Heat input
b Stress concentration effect
c Thickness]
d Current
18 A mitre fillet weld with two equal leg lengths of 12mm has a throat thickness of:
a 0.8mm.
b 17.0mm.
c 9.5mm.
d 8.5mm.
19 In a cylindrical pressure vessel a lack of fusion flow in the circumferential seams of the
shell experience:
10-3
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a 50% yield.
b 80% yield.
c Yield stress.
d Twice the yield stress.
2 How does the Youngs modulus for aluminium alloys compare to that for steel?
Give the value of Youngs modulus in steel.
4 What is stress?
6 What is the typical level of residual stress in a welded joint, before and after
PWHT?
10-4
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Long question
A lifting lug attached by fillet welds requires a design review. Comment on 50 items
which would be assessed during such a review.
10-5
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Definition
Stonehenge (about 4500 years old) Giza Pyramids (about 4500 years old)
1-1
Course Objectives Course Objectives
1-2
Outline
Weld features.
Types of welded joints.
Design and Construction Welding symbols.
Welded Joint Design Weld positions.
Weld bevels.
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Weld
HAZ
Root
Parent
metal Parent Toe
metal
Weld
Root HAZ
2-1
Heat Affected Zone (HAZ) Weld Zone Terminology
Excess
Maximum solid solid-liquid Boundary weld metal
Temperature weld
grain growth zone
metal
recrystallised zone
partially transformed zone
tempered zone
unaffected base
material
Excess root
penetration
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Weld preparations
Bevels: U, V, J, double V
T joint
Lap joint
2-2
Lap Joint Corner Joints
open closed
t
External corner joint Internal corner joint Double side corner joint
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d
d If t < 10 mm, d = t.
t
t d > 3t If t > 10 mm, slot technique should
be used, in circular holes
but d = minimum 25 mm!
(d = 3t but minimum 25mm see
BS 1011-2).
leg size
leg throat size Mitre fillet
2-3
Fillet Weld Geometry Fillet Weld Toe Blend
Actual
throat
Design throat
Design throat =
actual throat
t1
80
3 mm
20
2-4
Weld Symbols Constructing Welding Symbols
or
Other side Arrow side
Designation Illustration of joint preparation Symbol Single V butt weld with broad
root face (only in BS EN ISO
Square butt weld standard!)
2-5
Weld Symbols Put it Together
Fillet weld
Weld symbol
Reference line
Surfacing (cladding)
Backing run
Double U Double J
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Z10
a7
2-6
Intermittent Fillet Welds Complementary Indications
No. of welds weld length length of
gap Weld all round (peripheral weld)
z 10 3 x 25 (50)
50
25
10
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Root face.
Site (field) weld
Root gap.
Bevel angle.
Practical aspects.
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Single-J Single-U
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2-7
Double Sided Butt Preparations Joint Preparation Terminology
Double sided preparations are normally made on thicker materials, Included angle Included angle
or when access form both sides is unrestricted
Angle of
bevel
Root
Double -Bevel Double -Vee radius
bevel angle
included angle
Root
radius root face
root gap
Joint Design and Weld Preparation Root Gap and Root Face
Bevel angle
Root face and root gap set to:
Allow controlled root fusion.
Reduce the risk of burn-through.
2-8
Weld Preparation Weld Preparation
Welding process impacts upon weld preparation Welding process impacts upon weld preparation
MMA MAG
High heat input process allow a larger root face, less weld
metal required, less distortions, higher productivity.
X
If the gap is too big risk of possible burn-through,
If gap is too small risk of lack of penetration.
Can be flame/plasma cut fast Warning! Backing strips give a built-in crevice
Requires machining slow and
and cheap.
expensive.
Large tolerance set-up can be Susceptible to corrosion.
Tight tolerance easier set-up.
difficult. Give a lower fatigue life.
2-9
Welding Standards Standards
BS EN ISO 9692: Parts 1-4. Welding and allied BS EN ISO 13920: Welding. General tolerances for
welded constructions. Dimensions for lengths
processes. Recommendations for joint preparation.
and angles, shape and position.
BS EN 14324: Brazing. Guidance on the application
of brazed joints. BS EN 1011-2: Welding. Recommendations for
welding of metallic materials. Arc welding of
BS EN ISO 6947: Welds. Working positions. ferritic steels.
Definitions of angles of slope and rotation.
BS EN 25817: Arc-welded joints in steel.
ISO 2553: Welded, brazed and soldered joints - Guidance on quality levels for imperfections.
Symbolic representation on drawings.
2-10
Objectives
Bolts
3-1
Forces Combination of Forces
y Fx
Many forces can be added together
Have a size and a Fy
F
direction.
y FR = F1 + F2 + F3 + F4 + F5
x F2 F3
Can be combined
into a single force. y
F4
Fy
F F1 FR
Can be F5
decomposed into
several forces. x x
Fx
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3-2
Load Displacement Curves Stress
Stress definition
Load Force divided by cross-section area
Applied
force
F
Stress in the
cross section
area
Displacement
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F
A
= tensile stress (N/mm2 or MPa)
F = load or axial force (N)
A = cross section area (mm2)
Strain Strain
L
Strain, L
L Strain,
F L
L L
L = Change in Length
L = Change in Length L = Original Length
L = Original Length
Strain is dimensionless
Strain is dimensionless, can be positive value
(extended) or negative value (compressed)
3-3
Stress-strain curve Youngs Modulus
The tensile stress-strain curve contains typical features which are Extension in the elastic region is proportional to
specific to each material. load.
Elastic
Plastic region
region This relationship is given by Hookes Law which
Ultimate
tensile
is valid for the elastic region only.
strength
Fracture
Youngs modulus:
Stress,
MPa
Stress
E
Yield strength Yield point Strain
Often given in N/mm2 or GPa
Strain, %
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Yield stress:
Stress at which permanent deformation starts to Yield point may not always be
occur. obvious
Rp0.2
Stress, MPa In such cases, the 0.2% proof
strength (Rp0.2) is used as a
design parameter
Ultimate
Tensile
Strength
Necking
Stress,
Point
MPa
Strain, %
3-4
Real and Engineering Stress-Dtrain Curve Fracture
Design assumption: The final failure of the component is the point of rupture
The cross-section area remains Elongation of the material = Strain at fracture
the same.
Engineering stress-strain curve.
Stress, MPa
BUT necking of the material
reduces the REAL cross- Fracture
section area.
Gauge length
3-5
Hardness Hardness Test: Vickers
d1 d2
d
2
d1 d2
d
2
Compression Compression
F
Tension Direct Stress,
Tension A
Q
Shear Stress,
A
Shear Shear
F
Bending Q
Bending Q
3-6
Strain Bending Stresses
Tension (+)
Q
M M
h After bending
Q
Compression (-) Neutral Axis -
A Longitudinal stresses
are zero
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A cantilever beam:
Force, F
Fy
M
Fx
M
Bending stress,
Bending stress s = My/I.
D, 300mm
M = Bending moment (Nmm).
Y = Vertical distance from neutral axis (mm). Bending moment:
I = Second moment of area (mm4).
M=Fxd
= 200 x 300 = 60,000 Nmm
3-7
Second Moment of Area Bending Stress
3-8
Objectives
Time
4-1
Axle Fatigue Failure 1843 Introduction
Mean stress
Time
Minimum stress Time
Smin= 0 Pulsating cycle
Time
Smin
Smin
Time
Smin= -Smax Alternating cycle Smin= Smax/2 Half tensile cycle
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4-2
Fatigue Parameters S-N Curves
Stress ratio (or R-ratio). If applied stress range, , is plotted against number of
applications of load required for failure (N) we obtain the S-N
Smin curve.
R
Smax Stress
range,
Stress range. Failure
No failure
Stress amplitude.
- Half the stress range. No of cycles
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N N N2 N Very High
N1
Endurance
Increase stress - more damage.
limit
Increase number of cycles - more damage. Log N
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Stress history - variation of stress at a point with If stress is applied to a component the stress
time. distribution inside the component would be similar
Constant amplitude stress history - a stress to contour lines.
history in which successive stress fluctuations are The contour lines would run through the material
equal. parallel with the principal direction of the stress.
Fatigue life - number of stress cycles sustained
before failure.
Fatigue strength - stress range which causes
failure at a certain specified life.
4-3
Influence of Notches Effect of a Notch
With notch
Log N
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Fatigue cracks are most expected in high stress Production arc welding
concentration areas. processes lead to the formation
Pre-
of non-metallic intrusions at the
existing
weld toe. sharp flaw
Typically 0.1-0.4mm in depth.
Fatigue life governed by the A
growth of this pre-existing flaw.
Little or no initiation stage.
Fatigue
Factors which affect crack crack
initiation can be quite different
to those that affect crack ~ 50m
growth.
4-4
Fatigue of Welded Joints Effect of Steel Strength on Fatigue Strength
cycles, N/mm2
range, 200
parent material
300
strength.
N/mm2 100
200
50
Steel
350 N/mm2 yield 100
Stress
range R = 0.1
Results
Unbroken
Mean and
95% confidence
intervals
Endurance, cycles
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4-5
Effect of Tensile Residual Stress on Fatigue Improving Fatigue Strength
Superposition of applied Grinding.
and residual stresses,
Burr.
eliminates effect of mean
stress. Disc.
Even when loading is Peening.
compressive, local stress Hammer.
range cycles down from
Needle.
high maximum stress.
Shot.
Fatigue life dependent on
R = min/max full stress range regardless Dressing.
of whether tensile or TIG.
compressive.
Plasma.
4-6
Pressure Vessels
Disadvantages:
Crown Difficult to manufacture.
5-1
Ellipsoidal Dished Heads Torispherical Dished Heads
Advantages: Advantages:
Thickness equal to that of the Smallest axial dimension.
shell. Easy to generate.
Disadvantages:
Ellipse difficult to generate. Disadvantages:
Big axial dimension. Thickness greater than that of the shell.
Axial stress Hoop stress Longitudinal welds subject to higher hoop stress.
Pr
Offset long welds between different courses of
x
2t
the vessel.
Circumferential welds are used to weld the head
to the shell.
With different thicknesses, taper transitions are
used.
Minimum 1:4
Pr Pr
x y
2t t
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5-2
Nozzles Nozzles
Separable joints used to connect plant to vessel A hole in the shell weakens the vessel.
nozzles. To compensate for loss in strength, add
Flange joint most commonly used. reinforcement to the shell or nozzle.
5-3
Making Things Simpler
Design stress for a structure is often 2/3 yield Stress distribution over the cross section is not
stress. always uniformly distributed.
Ensure that the stress in the weld does not Near geometric features and stress concentrators
exceed the maximum allowable design stress. distribution increase the maximum stress.
Joint factors often used to reflect level of NDT At fillet welds, use Hot Spot Stress.
and risk that flaws could be present.
6-1
Hot Spot Stress Notch Stress
Weld metal overmatches parent metal. Partial penetration, double sided butt weld.
Butt welds can usually be neglected.
Full penetration butt weld under uniaxial tension.
P Load, P
Load, P t2 t1
Load, P
Lt
thickness, t Load, P Length , L
Length, L Crack-like
unfused land
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6-2
Fillet Welds Fillet Welds
Advantages: Terms.
Cheap. Toe.
Simple. Root.
Leg length.
Can be made flat (PA) or horizontal (PB).
Weld throat.
Can be made with any number of passes.
Disadvantages: Cheap weld design.
Lack of penetration may occur. East to weld.
Cannot be revealed by NDT. All positions and multi-pass.
Volume (and weight) of weld increases as the square Lack of pen risk.
of the leg length.
Easy to overweld.
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Concave.
Smoother transition at the
weld toe.
Design throat =
Ensure weld throat is big actual throat
enough.
2
a
a
z
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6-3
Summary Revision Question 1
?
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6-4
Static Strength
Load, N
Specimen 1 Specimen 2
Stress is the load divided by the CSA. Stress-Strain curve normalises different specimen
In a tensile specimen, use the gauge CSA. sizes.
Gauge length
Stress,
Width/diameter
Strain,
Design components to operate at stresses less Metals (including steel) lose tensile strength at
than material yield strength. higher temperature.
Limit static stress to 2/3 of yield.
Factor of safety.
y
design
Stress,
design = 2/3y
Strain,
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7-1
Materials Selection: Select the Most Suited
Effect of Temperature on Toughness
Material For a Given Application
But, higher temperatures cause ferritic steel to Key:
Lightweight
increase ductility.
Ni Superalloy
Transition Ti alloy
range Upper
Energy (J)
shelf
Steel
Sudden changes in geometry cause localised areas The stress concentration at the edge of a hole is 3.
of high stress. The maximum stress is three times the applied
stress.
Imagine flow lines which get close together at Sharper notches concentrate the stress much more.
stress concentrations.
Maximum
stress
Applied
stress
7-2
Ductile Fracture Fatigue Failure
Low toughness
Bang
Stress Flaw
7-3
Brittle Fracture Low Toughness Brittle Fracture Stress and Flaws
Low temperature. Residual stress from welding.
Ductile to brittle transition in steels at low temperature.
Applied stress from loading.
Crystalline structure. Strain rate.
Ferritic materials (carbon steel) show a transition while
austenitic materials (stainless steel, aluminium). Higher strain rate more likely to cause brittle
fracture.
Microstructure.
Stress concentrations.
Fine grain size has high toughness.
Martensite or coarse grain HAZ has low toughness. Weld toes, change of section, notches.
Weld defects.
Material thickness.
Thick material has lower effective toughness than thinner. Cracks, lack of fusion.
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7-4
Use of Aluminium Alloys
Light-weight.
High-strength-to weight
Design and Construction ratio.
Design Considerations for
Aluminium
Use for its light weight in:
Trains.
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Cars.
Ships and boats.
Good corrosion resistance ideal for food and drink Generally good weldability, but.
industry foil, packaging, drinks cans. Fusion welds can suffer porosity, lack of fusion,
High electrical conductivity transmission lines, solidification cracking.
welding cables. Loss of strength in HAZ region.
Building industry roofing, windows, doors, Very fluid weldpool.
cladding, fittings. Consider laser welding or FSW.
Wide range of other uses ski poles, ladders, gas Adhesive bonding widely used, has no residual
cylinders. stress, but not for hot/humid environments.
8-1
Disadvantages of Aluminium Other Properties of Aluminium
8-2
Objective
Trusses
Majority of new
buildings based on steel Number of structural
frame. members joined together to
form triangular units.
Frame supports weight
of the building and Transmits loads through
contents. axial forces rather than
Fast and efficient bending.
construction method. Pylon is an example of a
space frame truss.
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Fixed steel jacket structure Various methods exist for linking structural members
Tubular legs and cross members welded together and strengthening structures.
at nodal joints.
Stiffeners
Steel reinforcing
Nodal joint
Braces on truss
9-1
Combination of Forces Stress Calculations
Application: Stress definition:
Forces in truss members of a bridge free-body Force divided by cross-section area.
diagram.
F
A
= tensile stress (N/mm2 or MPa)
F = load or axial force (N)
All the forces are in equilibrium. A = cross section area (mm2)
Note: All the forces are not represented in this diagram.
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Elastic design method: Use design stress which is a fraction of the yield
Ensure that stresses in structure do not exceed yield strength of the parent material.
stress (ie elastic deformation).
9-2
Factor of Safety Material Load Carrying Capacity
Tension. Tension
Tension (+)
Shear. Shear M M
After bending
9-3
Nodal Joint Welds Nomenclature Parts of a Nodal Joint
Crown point Circular sections: Brace
Chord
Heel Toe
Side
max.10
Offset
gap
Eccentricity
Through
Overlap
member
9-4
Eccentricity Parts of a Nodal Joint
Box sections:
Heel Heel
Corner
Corner Corner
e=0 e>0
Side
Side Side
Brace
Corner
Corner Corner
Chord
e<0 Toe Toe
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Pure tension
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9-5
Static Design Static Design
Rebar Purpose
The term reinforcing-steel is used to describe the use In concrete beams the steel bars are embedded in
of steel to reinforce materials, most often concrete. the tension fibres of the beam.
9-6
Joints Types of Joint
9-7