BITS Pilani

Pilani Campus

VINAYAK KALLURI

BITS Pilani
Pilani Campus

Welding
Welding is used for making permanent joints. A weld is defined by the American Welding society (AWS) as a localized fusion of materials or nonmetals produced either by heating the materials to the required welding temperatures with or without the application of pressure, or by the application of pressure alone, and with or without the use of filler materials

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Classification of welding processes

Welding Process

Arc
Carbon arc Metal arc MIG TIG Plasma arc Submerged arc Electro-slag

Gas

Resistance

Solid State

Misc

Butt Spot Seam Projection Percussion

Friction Ultrasonic Diffusion Explosive

Oxy-acetylene Air-acetylene Oxy-hydrogen

Thermit Electron-beam Laser

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MASTER CHART OF WELDING AND ALLlED PROCESSES

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Welding from automation point of view

0xyfuel gas welding (OFW)

Shielded metal arc welding (SMAW)

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Welding from automation point of view

Gas tungsten arc welding (GTAW)

Gas metal arc welding (GMAW)

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Welding -Fundamentals

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Welding -Fundamentals

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Welding -Fundamentals

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Welded Joints

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SPECIFICATION OF WELD SYSTEM

The AWS standard welding symbol

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ARC AND GAS WELDING SYMBOLS

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Fillet welds

(a) The number beside triangle indicates the leg size. The arrow need to point only to one weld when the weld on all sides is same. (b) Here the weld symbol indicates that he weldment is intermittent and staggered at 60 mm length at an interval of 200 mm (centre to centre distance).
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Fillet welds

Circle on the weld symbol indicates that the welding is to go all around.
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Different groove preparations for butt joints

Square butt welded on both sides.

Single V with 60o bevel and root opening of 2 mm

Double V

Single bevel
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Different groove preparations for fillet joints

T joint for thick plates

U and J joints for thick plates

Corner weld, meant only for light loads

Edge weld for sheet metal and light loads

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Stress Analysis and Design of Welded Joints

Butt joint Lap joint or Fillet joint
Parallel fillet joint (weldment parallel to the load) Transverse fillet joint (weldment perpendicular to the load direction)

Shear welded joint

Both primary and secondary shear stresses act Line weld concept is useful

Bending welded joint

Throat shear stress equal to 1/1.414 times the bending stress acts. Line weld concept is useful
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ANALYSIS OF BUTT JOINTS

Typical butt joints with possible loading. Reinforcements, though can increase the area taking the load, normally for fatigue loading induce stress concentration at location like A and hence normally removed by grinding or machining.

= F / hl

= F / hl
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Typical transverse fillet weld

C D B

Fs = F sin Fn = F cos t h h 2 = = o o sin 45 sin 135 (cos + sin )

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The stresses at any angle in the weldment are

Fs = F sin Fn = F cos t h h 2 h = = = t (cos + sin ) (cos + sin ) sin 45o sin 135o

Fs Fs F sin (cos + sin ) F sin cos + sin2 = = = = A tl hl hl

) )
2

Fn Fn F cos (cos + sin ) F cos2 + sin cos = = = = A tl hl hl

The resultant von-Mises stress is

' = ( + 3
2

F = hl

[(cos + sin cos ) + (sin + sin cos ) ]

2 2 2
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The stresses at any angle in the weldment are

The maximum
' max

von - Mises stress occurs at 62.5

2 . 16 F = ' = 62 . 5 o = hl 1 . 196 F = 62 . 5 o = hl 0 . 623 F = 62 . 5 o = hl

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Parallel Fillet Weld: Welding Code Method

h t= (cos + sin ) For = 45 0 , t = 0 .707 h

= F / 0 .7 0 7 h l = 1 .4 1 4 F / h l
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Problem
The figure (b=d=50mm) shows a horizontal steel bar of thickness h = 5 mm loaded in steady tension and welded to a vertical support. Find the load F that will cause an allowable shear stress is 140 MPa in the throats of the welds.

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Minimum Weld-Metal Properties

Table 93
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Stresses Permitted by the AISC Code for Weld Metal

Table 94
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SHEAR WELDED JOINT

Primary shear stress:

=V / A
Secondary shear stress:

= Mr / J
Twisting moment:

M = Fa

J = Second polar moment of area of the weldments about the cetroid of the weldment areas =

[J

Gi

+ A i ri 2 =

] [(I

xx

+ I yy

) + Ar ]
2 i i i
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An example of unequal weldments

b1 = 0.707 h1 d 2 = 0.707 h2 h1 = leg size of weldment - 1 h2 = leg size of weldment - 2
The total throat area against primary shear

A = A1 + A2 = t1d + t 2b
Secondary shear estimation needs the estimation of the total second polar moment of area of the two weldments together.
t1 d 3 dt 13 t1 d 3 dt 13 (I x )1 = ; (I y )1 = ; J G1 = (I x )1 + (I y )1 = + 12 12 12 12 3 3 bt 2 t 2b 3 bt 2 t2b 3 (I x )2 = ; (I y )2 = ; J G 2 = (I x )2 + (I y )2 = + 12 12 12 12
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An example of unequal weldments

The centroid G can be located as follows.

A1 x1 + A2 x2 x= A A1 y1 + A2 y2 y= A

r1 =

[(x x
(

+ y

];

r2 =

[(x
)

x ) + (y 2 y )
2

J = J G 1 + A1 r12 + J G 2 + A 2 r22

) (

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The concept of line weldments

J = 0.707hJ u J u = Second polar moment of area for unit weld throat size

A = 0.707 hd

x =0 y = d /2

J u = d 3 / 12

The different patterns and their properties are listed in Table 9-1.
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Torsional Properties of Fillet Welds

J = 0.707hJ u

(Table 9-1, page:484)

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Few torsion cases and equivalent line weldment diagrams

Note: check the orientation

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Problem
A torque T=2 kN-m is applied to the weldment as shown. Estimate the maximum shear stress in the weld.

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Problem
A 20 mm thick steel bar is welded to a vertical support by two fillet welds. Find the safe bending force F if the permissible shear stress in the welds is 180 MPa.

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BENDING WELDED JOINT

V Primary shear stress, ' = A

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BENDING WELDED JOINT-Contd.

Secondary shear stress: A throat shear of is induced. where
is the bending stress calculated by the following formula. In deriving the formula the weldments have been treated as line welds and also the distance between them is treated as simply equal to d, which is the depth of the rectangular pattern.

bd 2 Iu = 2 bd 2 I = 0.707hI u = 0.707 h 2 Mc Md / 2 1.414 M = = = 2 I 0.707hbd / 2 bdh

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Bending Properties of Fillet Welds

I = 0.707hI u

(Table 9-2; page:488-489)

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Bending Properties of Fillet Welds - contd.

(Table 9-2; page:488-489)

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Few bending cases and equivalent line weldment diagrams

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Problem
The Fig shows a welded steel bracket loaded by a static force. Find the factor of safety if the allowable shear stress in the weld throat is 120 MPa.

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Welded Joint under Fatigue loading

The conventional methods will be used In fatigue, the Gerber criterion is best; however, you will find that the Goodman criterion is in common use. For the surface factor, forged surface should always be assumed for weldments unless a superior finish is specified and obtained.

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Fatigue Stress-Concentration Factors, Kfs

Table 95

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Problem
The weldment is subjected to a completely reversed force F. The hot rolled steel bar is 10 mm thick and is of AISI 1010 steel. The vertical support is of AISI 1010 steel. The electrode is 6010. Estimate the completely reversed load F the bar will carry.

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A = 721.14 mm 2 For the electrode (table 9 - 4) S ut = 427 MPa S1 e = 0.5S ut = 213.5 MPa k a = 272 (427) -.995 = 0.656 kb = 1 k c = 0.59 S se = 82 .7 MPa K fs = 2.7 (Table 9 - 5) K fs a K fs m 1 + = Se S ut nf K fs Fa a = = S se (For n f = 1 & m = 0 ) A Fa = 22.09 kN
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For the member, AISI 1010 (table A - 20) Sut = 320 MPa S'e = 0.5Sut = 160 MPa k a = 57.7(320)-0.718 = 0.917 kb = 1 k c = 0.85 Sse = 124.7 MPa K fs = 1 (assume) K fs Fa a = = Sse A Fa = 37.4 kN

F = min {above two values} = 22.09 kN.

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