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Note 1: when the minimum size of the fillet weld given in the table is greater than the
thickness of the thinner part, the minimum size of the weld should be equal to the thickness of
the thinner part. the thicker part shall be adequately pre-heated to prevent cracking of the weld.
Note 2 : where the thicker part is more than 50-mm thick, special precautions like pre-heating
should be taken.
Desirable
Acceptable
b) where the fillet weld is applied to the square edge of a plate of thickness greater than 6 mm,
size of the weld should be at least 1.5 mm less than the edge thickness. This limit is specified
such that the total strength may be developed without overstressing the adjacent metal. diagrams
(c) where the fillet weld is applied to the rounded toe of the rolled steel section, the size of the
weld should not exceed of the thickness of the section at the toe.
diagrams
(d) End fillet weld normal to the direction of force should be of unequal size with the
thrat thickness of the weld should not be less than 0.5 t,where t thickness of the part.the
thickness of the weld should be negotiated at a uniform slope.
When placing a weld fillet weld, though the welder tries to build up the weld to its full
dimension from the beginning, there is always a slight tapering off where the weld starts
and where it ends.
Therefore, a minimum length of four times the size of the weld is specified. If this
requirement is not met, the size of the weld should be one fourth of the effective length.
For the above reasons, the effective length is taken equal to its overall length minus
twice the size of weld.
End returns are made equal to twice the size of the weld to relieve the high stress
concentration at the ends.
Effective Throat Thickness: the Effective Throat thickness of a fillet weld shall not be
less than 3 mm and generally not exceed 0.7t,or 1.0t under special circumstances- is
thickness of thinner plate.
Throat = a x cos45o
= 0.707 a
a
a
For stress calculations, the effective throat thickness should be taken as K times fillet
size, where K is a constant. Values of K for different angles between tension fusion
faces are given in Table 2. Fillet welds are normally used for connecting parts whose
fusion faces form angles between 60 and 120
Table 2. Value of K for different angles between fusion faces
The uneven stress distribution increases as the width of the plate increases.for this reason
,the perpendicular distance between longitudinal fillet welds is limited to 16 times the
thickness of the thinner plate joined.
Failure Plane
In certain instances, the lengths available for the normal longitudinal fillet welds
may not be sufficient to resist the loads. In such a situation, the required strength may be
built up by providing slot or plug welds.
Plug welds and slot welds are used join overlapping members, one of which has
holes (round for plug welds, elongated for slot welds) in it. Weld metal is deposited in
the holes and penetrates and fuses with the base metal of the two members to form the
joint.
This area is usually referred to as the faying surface and is equal to the area of contact
at the base of the slot or plug. The length of the slot weld can be obtained from the
following relationship:
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