CE 405: Design of Steel Structures Prof. Dr. A.

Varma
CHAPTER 3b. WELDED CONNECTIONS
3b.1 INTRODUCTORY CONCEPTS
Structural welding is a process by which the parts that are to be connected are heated and
fused, with supplementary molten metal at the joint.
A relatively small depth of material will become molten, and upon cooling, the structural
steel and weld metal will act as one continuous part where they are joined.
Fillet weld
Fillet weld
Fillet weld Fillet weld
Fillet weld Fillet weld
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CE 405: Design of Steel Structures Prof. Dr. A. Varma
The additional metal is deposited from a special electrode, which is part of the electric circuit
that includes the connected part.
In the shielded metal arc welding (SA!" process, current arcs across a gap between the
electrode and the base metal, heating the connected parts and depositing part of the
electrode into the molten base metal.
A special coating on the electrode vapori#es and forms a protective gaseous shield,
preventing the molten weld metal from o$idi#ing before it solidifies.
The electrode is moved across the joint, and a weld bead is deposited, its si#e depending
on the rate of travel of the electrode.
As the weld cools, impurities rise to the surface, forming a coating called slag that must
be removed before the member is painted or another pass is made with the electrode.
Shielded metal arc welding is usually done manually and is the process universally used
for field welds.
%or shop welding, an automatic or semi automatic process is usually used. %oremost among
these is the submerged arc welding (SA!",
In this process, the end of the electrode and the arc are submerged in a granular flu$ that
melts and forms a gaseous shield. There is more penetration into the base metal than with
shielded metal arc welding, and higher strength results.
&ther commonly used processes for shop welding are gas shielded metal arc, flux cored arc,
and electro-slag welding.
'uality control of welded connections is particularly difficult, because defects below the
surface, or even minor flaws at the surface, will escape visual detection. !elders must be
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CE 405: Design of Steel Structures Prof. Dr. A. Varma
properly certified, and for critical wor), special inspection techni*ues such as radiography or
ultrasonic testing must be used.
The two most common types of welds are the fillet weld and the groove weld. %illet weld
e$amples+ lap joint , fillet welds placed in the corner formed by two plates
Tee joint , fillet welds placed at the intersection of two plates.
-roove welds , deposited in a gap or groove between two parts to be connected
e.g., butt, tee, and corner joints with beveled (prepared" edges
.artial penetration groove welds can be made from one or both sides with or without edge
preparation.
3b.2 Design of Welded Conne!ions
%illet welds are most common and used in all structures.
!eld si#es are specified in 1/10 in. increments
A fillet weld can be loaded in any direction in shear, compression, or tension. 1owever, it
always f"ils in shear.
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CE 405: Design of Steel Structures Prof. Dr. A. Varma
The shear failure of the fillet weld occurs along a plane through the throat of the weld, as
shown in the %igure below.
a
a
Throat 3 a $ cos45
o
3 6.767 a
a
a
Throat 3 a $ cos45
o
3 6.767 a
%ailure .lane
8

Shear stress in fillet weld of length 8 subjected to load . 3 fv 3

w
8 a 767 . 6
.

If the ultimate shear strength of the weld 3 fw

9n 3
w w
8 a 767 . 6 f
9n 3
w w
8 a 767 . 6 f 75 . 6
i.e., factor 3 6.75

fw 3 shear strength of the weld metal is a function of the electrode used in the SA!
process.
The tensile strength of the weld electrode can be 06, 76, :6, ;6, 166, 116, or 1(6 )si.
The corresponding electrodes are specified using the nomenclature <06==, <76==,
<:6==, and so on. This is the standard terminology for weld electrodes.

The strength of the electrode should match the strength of the base metal.
If yield stress (y" of the base metal is 06 > 05 )si, use <76== electrode.
If yield stress (y" of the base metal is 06 > 05 )si, use <:6== electrode.

<76== is the most popular electrode used for fillet welds made by the SA! method.

T"ble #2.$ in the AIS? Specifications gives the weld design strength
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CE 405: Design of Steel Structures Prof. Dr. A. Varma
fw 3 6.06 %<==
%or <76==, fw 3 6.75 $ 6.06 $ 76 3 21.5 )si
Additionally, the shear strength of the base metal must also be considered. The fillet weld is
connected to the base metal. The area of the base metal subjected to shear stresses by the
fillet weld shall be e*ual to (t@ $ 8w".
This base metal area can fail by shear yielding or rupture. The smaller of the two strengths
will govern. See AIS? specification A4.( on page 10.1>11( for the e*uations A4>2 and A4>4
that can be used to determine the shear strength of the base metal+
%or shear yieldingB 9n 3 1.6 $ 6.0 %y $ gross area of base metal subjected to shear
%or shear ruptureB 9n 3 6.75 $ 6.0 %u $ net area of base metal subjected to shear
where, %y and %u are the yield and tensile strength of the base metal.
%or e$ample+
T
<levation
.lan
T
<levation
.lan
Strength of weld in shear Strength of base metal
3 6.75 $ 6.767 $ a $ 8w $ fw 3 min C1.6 $ 6.0 $ %y $ t $ 8w
6.75 $ 6.0 $ %u $ a $ 8wD
Smaller governs the strength of the weld
Always chec) weld metal and base metal strength. Smaller value governs. In most cases, the
weld metal strength will govern.
In weld design problems it is advantageous to wor) with strength per unit length of the weld
or base metal.
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CE 405: Design of Steel Structures Prof. Dr. A. Varma
3b.2.1 Li%i!"!ions on &eld di%ensions (See AIS? Spec. #2.2b on page 1'.1($) of manual"
*ini%+% si,e -"%in.
( function of the thic)ness of the thinnest connected plate
> given in Table A(.4 of the AIS? specifications
*"/i%+% si,e -"%"/.
( function of the thic)ness of the thic)est connected plate+
> Along edges of plates with thic)ness 6.(5 in., ama$ 3 t or 6.(5 in. whichever is smaller.
> Along edges of plates with thic)ness 6.(5 in., ama$ 3 t > 1/10 in.
*ini%+% leng!0 -L&.
( length (8w" 4 a otherwise, aeff 3 8w / 4
> 9ead #2.2 b
> Intermittent fillet welds+ 8w>min 3 4 a and 1.5 in.
*"/i%+% effe!i1e leng!0 ( 2e"d AISC #2.2b
If weld length 8w E 166 a, then effective weld length (8w>eff" 3 8w
If 8w E 266 a, then effective weld length (8w>eff" 3 8w (1.( , 6.66( 8w/a"
If 8w F 266 a, the effective weld length (8w>eff" 3 6.0 8w
Weld Te2%in"!ions ( 2e"d AISC #2.2b
8ap joint , fillet welds terminate at a distance F a from edge.
!eld returns around corners must be F ( a
0
CE 405: Design of Steel Structures Prof. Dr. A. Varma
E/"%3le 3b.1. Getermine the design strength of the tension member and connection system
shown below. The tension member is a 4 in. $ 2/: in. thic) rectangular bar. It is welded to a 1/(
in. thic) gusset plate using <76== electrode. ?onsider the yielding and fracture of the tension
member. ?onsider the shear strength of the weld metal and the surrounding base metal.
5 in.
5 in.
6.5 in.
6.5 in.
4 in $ 2/ : in.
t 3 6.5 in.
a 3 6.(5 in.
5 in.
5 in.
6.5 in.
6.5 in.
4 in $ 2/ : in.
t 3 6.5 in.
a 3 6.(5 in.
Solution
S!e3 I. ?hec) for the limitations on the weld geometry
tmin 3 2/: in. (member"
tma$ 3 6.5 in. (gusset"
Therefore, amin 3 2/10 in. > AIS? T"ble #2.)
ama$ 3 2/: > 1/10 3 5/10 in. > AIS? #2.2b
%illet weld si#e 3 a 3 1/4 in. > Therefore, OK!
8w>min 3 1.6 in. > &H.
8w>min for each length of the weld 3 4.6 in. (transverse distance between welds, see #2.2b"
-iven length 3 5.6 in., which is F 8min. Therefore, OKI
8ength/weld si#e 3 5/6.(5 3 (6 > Therefore, maximum effective length #2.2 b satisfied.
<nd returns at the edge corner si#e > minimum 3 ( a 3 6.5 in. >Therefore, OK!
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CE 405: Design of Steel Structures Prof. Dr. A. Varma
S!e3 II. Gesign strength of the weld

!eld strength 3 $ 6.767 $ a $ 6.06 $ %<== $ 8w

3 6.75 $ 6.767 $ 6.(5 $ 6.06 $ 76 $ 16 3 55.07 )ips

@ase etal strength 3 min C $ 6.0 $ %y $ 8w $ t B $ 6.0 $ %u $ 8w $ aD

3 min C1.6 $ 6.0 $ 56 $ 16 $ 2/: B 6.75 $ 6.0 $ 05 $ 16 $ 1/4D
3 min C11(.5 B 72.1(5 )ipsD
3 72.1(5 )ips
S!e3 III. Tension strength of the member
9n 3 6.; $ 56 $ 4 $ 2/: 3 07.5 )ips > tension yield
9n 3 6.75 $ Ae $ 05 > tension fracture
Ae 3 J A
A 3 Ag 3 4 $ 2/: 3 1.5 in
(
> See Table G2.1
J 3 6.75 , since connection length (8conn" E 1.5 w > See Table G2.1
Therefore, 9n 3 54.: )ips
The design strength of the member-connection system = !." #i$s. Tension fracture of the
member governs. The end returns at the corners were not included in the calculations.
:
CE 405: Design of Steel Structures Prof. Dr. A. Varma
E/"%3le 3b.2 Gesign a double angle tension member and connection system to carry a factored
load of (56 )ips.
%olution
S!e3 I. Assume material properties

Assume 20 )si steel for designing the member and the gusset plates.

Assume <76== electrode for the fillet welds.

S!e3 II. Gesign the tension member

%rom Table 5>: on page 5>47 of the AIS? manual, select (& 5 $ 2K $ 1/( made from 20 )si
steel with yield strength 3 (06 )ips and fracture strength 3 (01 )ips.
S!e3 III. Gesign the welded connection

amin 3 2/10 in. > T"ble #2.)

ama$ 3 1/( > 1/10 in. 3 7/10 in. > #2.2b
'esign, a 3 2/: in. 3 6.275 in.

Shear strength of weld metal 3 9n 3 6.75 $ 6.06 $ %<== $ 6.767 $ a $ 8w

3 :.25 8w )ips

Strength of the base metal in shear 3 min C1.6 $ 6.0 $ %y $ t $ 8w B 6.75 $ 6.0 $ %u $ a $ 8wD
3 min C 16.: 8w B ;.7:75 8wD )ips

Shear strength of weld metal governs, 9n 3 :.25 8w )ips

9n F (56 )ips
:.25 8w F (56 )ips
8w F (;.;4 in.
Gesign, length of 1/( in. <76== fillet weld 3 26.6 in.
%hear strength of fillet weld = (). #i$s
;
CE 405: Design of Steel Structures Prof. Dr. A. Varma
S!e3 I4. 8ayout of ?onnection
!elding on both
sides of gusset.
8
1
a
8
(
(a
8
2
-".
-b.
-.
!elding on both
sides of gusset.
!elding on both
sides of gusset.
8
1
a
8
(
(a
8
2
8
1
a 8
1
a 8
1
a
8
(
(a
8
(
8
(
(a
8
2
8
2
8
2
-".
-b.
-.
8ength of weld re*uired 3 26 in.
Since there are two angles to be welded to the gusset plate, assume that total weld length for
each angle will be 15.6 in.
As shown in the %igure above, 15 in. of 1/( in. <76== fillet weld can be placed in three
ways (a", (b", and (c".
%or option (a", the AIS? Spec. #2.2b re*uires that the fillet weld terminate at a distance
greater than the si#e (1/( in." of the weld. %or this option, 81 will be e*ual to 7.5 in.
%or option (b", the fillet weld can be returned continuously around the corner for a
distance of at least ( a (1 in.". %or this option, 8( can be either 0.5 in. or 7.5 in. 1owever,
the value of 7.5 in. is preferred. The end returns are provided to ensure that the weld si#e
is maintained over the full length of the weld. These are not re*uired by AIS? Specs.
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CE 405: Design of Steel Structures Prof. Dr. A. Varma
%or option (c", 82 will be e*ual to 5.75 in.
S!e3 4. %racture strength of the member
Ae 3 J Ag
%or the double angle section, use the value of $ from Table 1>7 on page 1>27 of manual.
Assume case (a". Therefore, J 36.::
9n 3 6.75 $ 6.:: $ :.66 $ 5: 3 260.(4 )ips F (56 )ips > fracture limit state is o#!
S!e3 4I. Gesign the gusset plate
9n F Tu > tension yielding limit state
Therefore, 6.; $ Ag $ 20 F (56 )ips
Ag F 7.71 in
(
9n F Tu > tension fracture limit state
Therefore, 6.75 $ An $ %u F (56 )ips
An 6.:5 Ag > Spec. #$
An F 5.747 in
(
Therefore, Ag F 0.70 in
(
Gesign gusset plate thic)ness
3 1.6 in. and width 3 :.6 in.

&ption
J 3
8
$
1
(a" 1>6.;61/7.5 3 6.:: 6.;
(b" 1>6.;61/0.5 36.:0 6.;
(c" 1>6.;61/5.75 3 6.:4 6.;
11
c.g.
$
c.g.
$
1/(
7.5 in.
-".
1/( 7.5 in.
1/( 7.5 in.
1/( 7.5 in.
-usset plate : $ K in.
Two 5 $ 2.5 $ 1/ ( in
1/(
7.5 in.
-".
1/( 7.5 in.
1/( 7.5 in.
1/( 7.5 in.
-usset plate : $ K in.
Two 5 $ 2.5 $ 1/ ( in