WELDING

6TH GROUP PDF REPORT

Authors:
Andrade, John Phillip
Angat, David Lloyd
Delgado, Rohnel June
Morales, Christian Patrick
Omillo, Jan Precious
Palma, Sam Lorraine
Pasquel, Wendy
TABLE OF
CONTENTS
CHAPTER 1 WELDED CONNECTIONS...........................1

GENERAL……………………………………………………………..1

HISTORY……………………………………………………………..1

SHIELDED METAL ARC WELDING(SMAW)………………..2

GAS METAL ARC WELDING(GMAW)……….………………..3

GAS TUNGSTEN ARC WELDING(GTAW)……………………3

FLUX-CORED ARC WELDING(FCAW)……………………….4

ELECTRON BEAM WELDING(EBW)………………………….4

ADVANTAGES OF WELDING…………………………………..5

FORMS OF WELDED JOINT…………………………………….6

TYPES OF WELDS…………………………………………………6

GROOVE WELDS…………………………………………………..6

ALLOWABLE STRESSES ON WELDS…………………………7

FILLET WELDS……………………………………………………..8

EFFECTIVE AREA OF WELDS…………………………………..9

LIMITATIONS OF FILLET WELD………………………………9

CAPACITY OF EQUAL LEG FILLET………………………….10

TYPES OF GROOVE WELD…………………………………….11

PLUG AND SLOT WELDS……………………………………….12

COMBINATION OF WELDS……………………………………12

MIXED WELD METAL……………………………………………12

WELDING SYMBOLS…………………………………………….13

BALANCED WELD GROUP……………………………………..14

ECCENTRICALLY LOADED WELDED CONNECTION……15

CONNECTIONS WITH SHEAR AND BENDING

STRESSES………………………………………………………….16

PROPERTIES OF WELD GROUP……………………………..17

CHAPTER 1
WELDED CONNECTIONS

1.1 GENERAL
Welding is a process by which metallic parts are connected by
heating their surfaces to a plastic or fluid state and allowing he
parts to flow together and join(with or without the addition of
other molten metal. This technique was discovered during efforts
to manipulate iron into useful shapes.

1.2 HISTORY
Welded blades were developed in the 1st millennium CE, the
most famous being those produced by Arab armourers at
Damascus, Syria. The process of carburization of iron to produce
hard steel was known at this time, but the resultant steel was
very brittle. The welding technique—which involved interlayering
relatively soft and tough iron with high-carbon material, followed
by hammer forging—produced a strong, tough blade.
In modern times the improvement in iron-making techniques,
especially the introduction of cast iron, restricted welding to the
blacksmith and the jeweler. Other joining techniques, such as
fastening by bolts or rivets, were widely applied to new products,
from bridges and railway engines to kitchen utensils.
 Modern fusion welding processes are an outgrowth of the need
to obtain a continuous joint on large steel plates. Rivetting had
been shown to have disadvantages, especially for an enclosed
container such as a boiler. Gas welding, arc welding, and
resistance welding all appeared at the end of the 19th century.
The first real attempt to adopt welding processes on a wide scale
was made during World War I. By 1916 the oxyacetylene
process was well developed, and the welding techniques
employed then are still used. The main improvements since then
have been in equipment and safety. Arc welding, using a
consumable electrode, was also introduced in this period, but the
bare wires initially used produced brittle welds. A solution was
found by wrapping the bare wire with asbestos and an entwined
aluminum wire. The modern electrode, introduced in 1907,
consists of a bare wire with a complex coating of minerals and
metals. Arc welding was not universally used until World War II,
when the urgent need for rapid means of construction for
shipping, power plants, transportation, and structures spurred
the necessary development work.

1.3 SHIELDED METAL ARC WELDING(SMAW)

Shielded metal arc
welding (SMAW) is the
simplest, least
expensive, and mostly
widely used arc welding
process. It is often
referred to as ‘stick
welding’ or manual metal arc welding. This process produces
coalescence of metals by heating them with an arc between a
covered metal electrode and the base metal work piece.
Shielding is provided by decomposition of the electrode covering.
The main function of the shielding is to protect the arc and the
hot metal from chemical reaction with constituents of the

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 atmosphere. The electrode covering contains fluxing agents,
scavengers, and slag formers (1). Pressure is not used in the
process, and the filler metal is obtained from the electrode. All
ferrous metals can be welded in all positions using SMAW.

1.4 Gas Metal Arc Welding (GMAW)

This welding process uses a continuously fed electrode through a
welding gun and the operator needs to pull a trigger in order to
feed the consumable electrode through. Between the base
material and the electrode an electric arc forms, which heats the
material until it reaches the melting point that makes it possible
to get it joined with another.
The main advantages of choosing the MIG style for welding
include the reduction of waste thanks to the higher electrode
efficiency, the minimal weld clean up required, lower heat inputs,
and reduced welding fumes. Moreover, this is the easiest welding
technique to learn, which makes it suitable for beginners and
DIY enthusiasts.

1.5 Gas Tungsten Arc Welding (GTAW)

Also known as Heliarc welding, TIG is a welding process that
uses a tungsten electrode that is not consumable to heed the
base metal and create a molten puddle for the by using this
method, you can create are no filler metal or autogenous weld in
order to melt two pieces of metal together. You can also add an
external filler rod into the molten puddle in order to be able to
create a weld bead and increase the mechanical properties of the
metal.
The main advantages of using this welding technique as an
enthusiast or a professional include the ability to weld very thin
materials, the high quality cleaning welds, and the highly
aesthetic weld beads. Moreover, with this technique you can
weld a wide range of alloys and obtains spatter free wells so you
don't have worry as much about debris.

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1.6 Flux-Cored Arc Welding (FCAW)
This technique is rather similar to the MIG welding method, as it
also requires an uninterruptedly fed electrode, but instead of a
solid wire, it needs a tube-shaped wire full with flux. You can
choose from two types of flux core wire, which are socially and will
shield wires. social good wires are a good solution for outdoor use,
as they work even in windy situations. n the other hand, double
shield uses an external shielding gas and the flux in order to guard
the modern weld puddle.
The main advantages of this technique include the higher electrode
efficiency that creates less waste than other types of welding
methods, as well as the lower hit inputs. With the flux-cored arc
welding, there is no need for external shielding gas, and you get
reduced welding fumes regardless of the metal used for welding.
this is also a rather clean type of welding, as you don't have to
deal with lots of debris.

1.7

ELECTRON BEAM WELDING (EBW)

This type of welding involves firing a ray of high velocity
electrons at the materials that require welding. This technique
transforms energy from the electrons into sheets in order to melt
the welding materials, which can then merge and fuse together.
This type of welding is used in multiple industries, with

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 applications ranging from
fully automated automotive
inline part production to
high-cost aircraft engine
industry. Some examples of
products that are created
with electron beam welding
include aerospace
components, transmission
assemblies, and bimetal saw
blades.
Because this is a vacuum-based process electron beam welding
is a perfect choice for sealing of electrical components and pre-
evacuated housings. This technique allows joining of dissimilar
metals, such as those with different thermal conductivities and
melting points, something that is generally difficult to achieve
with other welding methods. This is also a good technique for
those who want to weld a thick material to a thin material.

1.8 ADVANTAGES OF WELDING

1. In welded connections, in general, few pieces are used. This
will speed up the detailing and fabrication process.
2. In welded connections, gusset and splice plates. May be
eliminated. Bolts or rivets are not needed either. Thus, the
weight of a welded steel structure is somewhat less than that
of the corresponding bolted structure.
3. Connecting unusual members(such as pipes) is easier by
welding than by bolting.
4. Welding provides truly rigid joint and continuous structures.

One possible drawback of welding is the need for careful

execution and supervision.

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1.9 FORMS OF WELDED JOINT

1.10 TYPES OF WELDS

The two common types of welds in welded structures are groove

welds and fillet welds. Fillet welds are commonly used in the
world of structural steel design.

1.11 GROOVE WELDS

According to the AWS (American Welding Society) a groove weld
is a weld on a work piece surface, between work piece edges,
between work piece surfaces, or between work piece edges and
surfaces. The actual weld groove is a channel in the surface of
the work piece or an opening between two joint members
providing space to contain weld metal. There are 9 types of
single grooves welds and 7 types of double groove welds. All
groove welds – other than square and flare groove welds –
require metal to be removed from either one or both faces of the
work-piece.

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1.12 FILLET WELDS
Fillet welds should be as small as permitted by design – for
example, an 8mm leg length fillet weld contains over 80% more
weld metal than a 6mm leg length fillet. The size of a fillet weld
is determined by the loads that it is expected to carry. It can
therefore be of any size that the designer specifies although
there are practical limitations with respect to both minimum and
maximum throat thickness. The maximum size of fillet weld is
generally that of the thickness of the thinner of the two items
being joined but very large fillet welds
may cause unacceptable distortion and/or
extremely high residual stresses.
The throat is the shortest distance from
the root to the face of the weld. To
measure this dimension in a regular mitre
or flat faced fillet weld is relatively simple.
The shape is that of an isosceles triangle,
the throat being 0.7 of the leg length.
Convex, concave and deep penetration
welds, however have throat thicknesses
as illustrated in Fig. 1

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 For equal legs, the throat is

For unequal legs, the throat is

√
t=( w∗h)/( ( ( w2 ) + ( h 2 ) ) )

1.13 EFFECTIVE AREA OF WELDS

The effective area is generally determined by multiplying the
length of the weld and effective throat. The effective throat is a
function of the weld size. The determination of effective throat
size is a bit different for each type of weld.
The effective throat chosen for any weld design will be the
LARGER of:
- the minimum requirement for ensuring a good bond with the
base metal and
- the minimum required to develop the strength required to
transfer the design forces.

1.14 LIMITATIONS OF FILLET WELD

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 The maximum size of fillet welds of connected parts shall be: (a)
Along edges of material less than ¼” (6mm) thick; not greater
than the thickness of the material, (b) Along edges of material
¼” (6mm) or more in thickness; not greater than the thickness
of the material minus 1/16” (2mm), unless the weld is especially
designated on the drawings to be built out to obtain full-throat
thickness. In the as-welded condition, the distance between the
edge of the base metal, and the toe of the weld is permitted to
be less than 1/16 in. (2mm) provided the weld size is clearly
verifiable.

1.15 CAPACITY OF EQUAL LEG FILLET

Load capacity, P=Fv x 0.707∗w∗L
Fv=0.3 Fu

Where,
w = size of weld(leg)
L = total length of weld
Fv = allowable shearing stress of weld metal

Size of weld Allowable load(kN/mm)

inches mm E 60 XX E 70 XX E 80 XX
electrode electrode electrode
Fu = 60 ksi Fu = 70 ksi Fu = 80 ksi
Fu = 415 Fu = 485 Fu = 550
MPa MPa MPa
Fv = 0.3Fu Fv = 0.3Fu Fv = 0.3Fu
Fv=124 Fv=145 Fv=165
MPa MPa MPa

3/16 4.76 0.417 0.488 0.555

1/4 6.35 0.557 0.651 0.741
5/16 7.94 0.696 0.814 0.926
3/8 9.52 0.835 0.976 1.111
1/2 12.7 1.113 1.302 1.482
5/8 15.9 1.394 1.630 1.855
3/4 19.2 1.683 1.968 2.240

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1.16 Types of groove weld

- Square groove weld. The square-groove is a butt welding

joint with the two pieces being flat and parallel to each other.
- Single V weld. Single butt welds are similar to a bevel joint,
but instead of only one side having the bevelled edge, both
sides of the weld joint are beveled.
- Single-bevel groove weld. A groove weld in which one
member has a joint edge beveled from one side.
- Single U groove weld. Single-U butt welds are welds that
have both edges of the weld surface shaped like a J, but once
they come together, they form a U.
- Single J groove weld. Single-J butt welds are when one
piece of the weld is in the shape of a J that easily accepts
filler material and the other piece is square.
- Flare V weld. Commonly used to join two rounded or curved
parts. The intended depth of the weld itself is given to the left
of the symbol, with the weld depth shown in parentheses.
- Flare bevel weld. A flare-bevel weld is a weld between a
radius and a flat part. A common one is welding a round-bar
to a piece of plate, perhaps as a stop in a mechanical part.

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1.17 Plug and slot welds
When the slot is small and completely filled with
weld metal then it is called plug weld, but if the
periphery of the slot is filled with weld metal then
it is called slot weld.

1.18 Combination of welds

A combined weld associates one or more welds to be performed
in the same welding operation sequence. For combined welds,
you can select the following options alternatively or in
combination: reinforced—Combines two welds, one fillet weld
plus one groove or butt weld, to create a reinforced weld.

1.19 Mixed weld metal

When notch-toughness is specified, the process consumables for
all weld metal, tack welds, root pass and subsequent passes,
deposited in a joint shall be compatible to assure notch-tough
composite weld metal.

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1.20 Welding symbols

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1.21 Balanced weld group
When designing weld groups, it can be advantageous to design the
weld layout such that the center of resistance of the welds aligns
with the center of force of the connected member. Doing so
prevents the need to analyze the welds as eccentrically loaded
weld groups. A weld group whose center of resistance aligns with
the center of force is said to be "balanced"

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1.22 Eccentrically loaded welded connection

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1.23 Connections with shear and bending stresses

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 REFERENCES
- Gillesania, D. (1997). Fundamentals of structural steel design
with theory of structures.
- https://www.britannica.com/technology/welding
- https://www.sciencedirect.com/topics/materials-
science/shielded-metal-arc-welding
- https://me-mechanicalengineering.com/types-of-welded-
joints/
- https://www.sciencedirect.com/topics/engineering/fillet-weld
- https://www.bgstructuralengineering.com/BGSCM13/BGSCM0
05/BGSCM00503.htm
- http://weldinganswers.com/the-reason-behind-minimum-
weld-sizes/
- https://www.millerwelds.com › deci...Web resultsDeciphering
Weld Symbols | MillerWelds

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