WELDED CONNECTIONS

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 INTRODUCTION
Efficient and direct way of connecting is by welding
Metallurgical bond by heat or pressure or both
Advantages of welding
• Direct transfer of stress - minimum weight ,
efficiency
• Less fabrication
• Economy - 15% saving in weight in bridges,less
labor
• Neat appearance
• More rigid

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 BASIC WELDING PROCESSES

Gas welding - Oxyacetelene welding , simple , slow,

repair and maintenance work

Arc welding - All structural welding

Electric arc by use of electric energy

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 WELDING PROCEDURE

• Environment
• Welding position
• Current : controls heat input
• Shrinkage
• Preheating

Weldability of steels
Economic welds, good , crack free

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 TYPES OF JOINTS OR WELDS

• Joints:Lap,Tee,Butt and Corner

• Welds: Groove, fillet, plug and slot
• Welded joint description - Type of joint and weld
• Position of welding

(a) Butt joint (c) Tee joint (d) Corner joint

(b) Lap joint

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 COMMON TYPES OF WELDS

(b) Fillet welds

(a) Groove welds
Ends shall be semi
circular
A A A A

Section A-A Section A-

A

(d) Plug weld (c) Slot weld

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Groove welds

Selection of a particular type of groove weld depends

• Size of the plate to be joined

• welding by hand or automatic
• Type of welding equipment
• Accessibility of both sides
• Position of weld

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• Size of butt weld
• Thickness of connected plate for full penetration
• Depth of penetration for partial penetration
• Advantages
High strength,high resistance to impact and cyclic
stress
• Disadvantages
High residual stress , edge preparation and proper
aligning

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 GROOVE WELD DETAILS

Electrod Included angle

Arc e Depth of
penetration Root face

(a) Depth of penetration Root gap

(b) Root gap

Capping run Filling run

Root run

(c) Root run

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• Fillet welds

• Ease of fabrication and adaptability

• Less precision
• No special edge preparation
• Throat of a weld
• Concave and convex surfaces
Weld and leg size
Face of weld
Theoretical throat
s (t=0.707s)
t
Root of weld Te

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 QUALITY OF WELDED CONNECTIONS

• Proper electrodes , welding apparatus and

procedures
• Welding sequence
Doubling up method
Planned wandering method
Step back method

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SEQUENCE OF WELDING OF FILLET WELDS

Doubling - up method for vertical member

13 12 7 5 1 6 8 17 18

11 10 9 3 2 4 14 15 16

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 RESIDUAL STRESSES
• Residual stresses - due to rapid heating and
cooling
• Yield strength of material is upper limit for residual
stresses
LONGITUDINAL RESIDUAL STRESS DUE TO WELD
Tension

- -

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 WELD DISTORTION

a)Transverse shrinkage(b) Angular change (c) Rotational

distortion

(e) Longitudinal bending

distortion
(d) Longitudinal shrinkage (f) Buckling
distortion

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 WELD SYMBOLS

Symbolic representation of welds

(Ref. IS:813 - 1986 ‘ Scheme of symbols for welding’ )

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 DEFECTS IN WELDS

• Incomplete fusion
• Porosity
• Inadequate preparation
• Undercutting - Excessive current or long arc
• Slag inclusion - Failure to remove slag between
runs
• Cracks - Breaks in the weld metal
• Lamellar tearing - Occurs in the base metal
beneath the weld

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 WELD DEFECT TOLERANCE

For joints welded from both sides

• Incomplete penetration - 5% of parent metal
thickness < 2mm
• Length of flaw < 200 mm / meter length
Welded on one side
• Incomplete penetration - 15% of thickness < 3mm
• Slag inclusion < 200 mm / meter weld length
• Total gas pores < 5 per square centimeter of weld
• Thickness upto 10mm , undercut < 0.5mm
• For thickness > 10mm undercut < 1mm
•
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WELD INSPECTION
Visual inspection
Liquid penetrants
Magnetic particles
Ultrasonic testing
Radiography

CONNECTION DESIGN
Static strength of welded joint
• Type and size of the weld
• Manner of welding
• Type of electrode used

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 BUTT WELDS

• Critical form of loading - Tension in

transverse direction

• Yield stress of weld metal and parent metal

in HAZ (Heat affected Zone) is much higher

• Failure always occurs away from the weld

• Toughness and ductility properties are

affected

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 DIFFERENT TYPES OF BUTT JOINTS

(a) Square (d)Single Bevel

(b) Single V (c) Double V

(g) Single U (h) Single J

(e)Double (f) Single U
Bevel

(i)Double J

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 DESIGN
• Direct tension or compression
• Design strength same as parent metal strength
• Effective area equals effective length times
throat size
• For full penetration,thickness of weld ,equals
thickness of thinner part of connection
• Partial penetration welds are avoided
• Throat thickness - 5/8 thickness of thinner part
• Average stress concept
• Permissible stresses - Parent metal values
• Site welds – lower design strengths

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FILLET WELDS
11

11
1
1
1 1

Behaviour
• Lap joints splices
• Shear is the main design consideration
• Side fillets and end fillets
• End fillet loaded in tension - high strength and low ductility
• Side fillet loaded - Limited to weld shear strength (50%
tensile strength) Improved ductility
• Average stress in weld throat
• Fillet weld shape is important for end fillets.

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(A) CONNECTIONS WITH SIMPLE WELD DESIGN,
(B) CONNECTIONS WITH DIRECTION- DEPENDENT WELD DESIGN

P Tension
Shear

P P

(a) (b)

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 DESIGN
Simple approach - Uniform strength
Size of fillet weld  3mm or thickness of thinner part
Effective throat thickness  3 mm
< 0.7t and 1.0t
= k x fillet size
Size
Size (Min. Leg size)
Size

Fillets of unequal leg length Fillets of equal leg length

Penetration Leg length

Size = leg length * 2.4 mm

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 SLOT AND PLUG WELDS

• Provided along with fillet welds in lap joints

• Strength of a plug or slot weld - allowable stress
and nominal area in the shearing plane
Ends shall be semi circular or
have corners rounded to a radius
A A not less than thickness of part
containing slot
A A

Section A-
A Section A-
(a) Slot weld A

(b) Plug
weld

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 ECCENTRIC JOINTS
• Shear and torsion

Torsion , F = (T x s ) / J
fh = (T x v) / J
fv = (T x h ) / J
 =R/L
• Shear and bending

Weld is designed to withstand maximum bending

stress and maximum shear stress separately.

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(a) WELDS SUBJECTED TO SHEAR AND TORSION,
(b) WELDS SUBJECTED TO SHEAR AND BENDING
y
M

e P

x x
c.g of welds
(a)
y
e P P

(b)

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 SUMMARY

• Fundamentals of welding , details of various

welding processes, types of welds, common weld
defects and weld inspection have been
presented.
• Advantages of welding are mentioned.
• Behaviour and design of butt - and fillet - welded
connections in steel structures are explained .
• Truss connections and beam connections are
discussed.

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