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FILLET WELDS

A weld of approximately triangular cross section joining two surfaces, approximately at


right angles to each other.
Fillet welds are most common and used widely.
The fillet weld is used to make lap joints, corner joints, and t- joints.

FILEET WELD TERMS


Root : The root of the weld is the point where the faces of the metallic members meet.
Throat Thickness : The theoretical throat of a weld is the shortest distance from the
root to the hypotenuse of the triangle.
Leg length or Size of weld : The side of the triangle is taken as the leg length or size of
weld.

Types of fillet weld:


(a)Side fillet
(b)End fillet
(c) Diagonal fillet

Diagnol fillet weld


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Weld specifications (IS800-2007):


Minimum size of weld:
The size of fillet weld should not be less than 3 mm nor more than the thickness of

the thinner part joined.


To ensure fusion, minimize distortion, and to avoid the risk of cracking IS 8002007 and IS 816 provide for a minimum size weld based on the thickness of the
pieces being joined .

MINIMUMUM SIZE OF A SINGLE RUN FILLET WELD (AS PER 800-2007)

Thickness of thicker part


Over, mm Up to and including, mm
10
10
20
20
32
32
50

minimum size ,mm


3
5
6
8 for first run,10 for minimum
Size of weld

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.

Maximum fillet weld size along edges:


The maximum size of fillet weld used along the edges of pieces being jointed is limited to
prevent the melting of base material at the location where the fillet would meet the corner of
the plate, if the fillet were made to the full plate thickness. The maximum size is equal to the
thickness of the plate.
(a).Along the edge of the plate, less than 6-mm thick, the maximum size is equal to the
thickness of the plate.
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Desirable

Acceptable

Not acceptable because of


reduced throat thickness

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.

End fillet weld normal to direction of force


MINIMUM EFFECTIVE LENGTH OR AREA FILLET WELD:

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

STRESS DISTRIBUTION IN WELDED JOINTS.


The stress distribution in welded joints is complex and non-uniform figure show typical
stress distribution at service load for longitudinal fillet welds in a lap joint.
The actual variation of shear stress in the weld from points A to B depends on the length
of the weld and also the ratio of the width of plates being joined distribution.
Thus it is seen that there is a series stress concentration at the edge of the plate.in order
to control it,the length of the longitudinal (side)fillets should not be less than the width
of the plate.

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

Over lapping of the fillet weld


The overlap of plates to be fillet welded in a lap joint should not be less than 4 times the
thickness of the thinner part .
diagram

Slot Welds or Plug Welds

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.

Slot weld and plug weld

Plug and slot weld

Specifications for design of plug and slot weld (IS 816-1969):


(a)The width or diameter should not be less than three times the thickness or
25 mm whichever is greater
b) Corners at the enclosed ends or slots should be rounded with a radius not less
than 1.5 times the thickness or 12 mm whichever is greater, and
(c) The distance between the edge of the part and the edge of the slot or hole, or
between adjacent slots or holes, should be not less than twice the thickness
and not less than 25 mm for the holes.
The limitations given in specifications for the maximum sizes of plug and slot welds are
necessary to avoid large shrinkage, which might be caused around these welds when
they exceed the specified sizes.
The strength of a plug or slot weld is calculated by considering the allowable stress and
its nominal area in the shearing plane.

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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