Professional Documents
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Introduction
ISE311-2005
IntroWE/5-97
The field of welding design encompasses many subject areas, which may be broadly
grouped into such topics as joint design, mechanics, and structures.
Joint design includes the various types of grooves and welds as well as tolerance
requirements and welding symbols on drawings. Factors such as material thickness and
welding process influence the selection of a particular joint design.
Mechanics deals with the stress and strain experienced by a welded joint. Moments of
inertia and minimum weld size to support a given load are typical calculations. Fracture
mechanics and fitness-for-service quantify the performance of a welded joint that contains
flaws or discontinuities.
The structures include the different types of construction and their behavior under
various types of loading. Examples of types of construction are box, cellular, and skin on
frame. Many steel and lightweight constructions are not subjected to dynamic loading and
are designed simply for static loads. Bridges and cranes are examples of welded structures
that are subjected to dynamic loads. Boilers, pipelines and pressure vessels can be
subjected to thermodynamic loading.
Welding Design - 97
Welding Design
Joint Design
Joint Types
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Butt joint
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Tee joint
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Flanges or stiffeners
Lap joint
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Continuity of section
No joint preparation
Corner joint
Edge joint
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Butt joints are noted for their continuity of section, with the two welded members lying
in the same plane. For a plate thickness above approximately 3/8-inch, the joint is typically
grooved to ensure complete penetration.
Fillet welds are often made on T-joints.
Lap joints do not require edge preparation. Unlike the butt weld, the load does not
transfer directly across the joint. For this reason, lap joints are not preferred for fatigue
service. Overlap of five times the material thickness is recommended for double fillet
welds in order to limit rotation under load. Resistance spot and resistance seam welding
require lap joints.
Corner joints are often arc-welded with fillet, J-groove or V-grooves.
Two essentially parallel plates come together at an edge joint. It may be possible to
weld this joint without additional filler material.
Welding Design - 98
Welding Design
Joint Design
Weld Types
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Fillet weld
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Approximately triangular
No joint preparation
required
Most common weld in
structural work
Single fillet welds should not be used when an in-service bending moment loads the root
of the weld in tension due to the stress concentration at the weld root. The use of single
fillet welds should be limited in fatigue service.
Double fillet welds limit the rotation of T-joints and corner joints during service and
thereby reduce stress at the weld root.
Penetration is a major concern with the square weld. As such, a double weld is often
used to ensure full penetration. If a root gap is used, a backing bar will keep the molten
weld metal in place.
Welding Design - 99
Welding Design
Joint Design
Weld Types
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Bevel groove
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V-groove
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Only one member is beveled in a bevel-groove. The bevel angle is measured between
the beveled edge and a plane perpendicular to the surface of the non-beveled member.
Joint preparation for beveled welds are easily prepared and work well with corner-joints
and T-joints. Double-bevel welds should be used when plate thickness is greater than 3/4inch, if welding can be accomplished from both sides. The double bevel produces less
distortion because the stresses on opposite sides of the plate offset each other. Also, the
double bevel uses approximately half the weld metal of a single bevel for a given angle.
Both members are beveled in a V-groove. The groove angle is measured from one
beveled surface to the other. Joint preparation is relatively easy, as in the bevel-groove
weld. Double V-groove welds enjoy the same advantages as double-bevel groove welds,
including less weld metal and reduced distortion. Full penetration is required to ensure the
strength of the joint.
Welding Design
Joint Design
Weld Types
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J-groove
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U-groove
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ISE311-2005
IntroWE/5-101
The J-groove weld is well suited for butted corner joints and T-joints. It requires a
minimum of 1/8-inch root face and 1/4-inch root radius. Therefore, the plate material must
be greater than 3/8-inch thick.
Joint preparation for the J-groove weld is more complicated than for the bevel-groove
or V-groove. The edge must be machined, and this increases cost. The double J-groove has
the same advantages as other double welds.
The U-groove comes into play in the welding of thicker plates. It allows access to the
weld root while using less weld metal than a V-groove. As with the J-groove, plate
thickness must be greater than 3/8-inch.
Edge preparation costs are higher than the bevel-groove or V-groove. The edges may be
machined or arc gouged. The double U-groove enjoys the advantages of all double grooved
welds.
Welding Design
Joint Design
6
2
2
5
3
4
4
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1 - groove angle
2 - bevel angle
3 - root face (land)
4 - root opening (root gap)
5 - groove face
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1 - throat
2 - weld face
3 - depth of fusion
4 - root
5 - fillet leg length
6 - weld toe
ISE311-2005
IntroWE/5-102
A proper welding procedure specification calls out details such as root opening, groove
angle and root face. For the design of a fillet weld, the stress calculation will involve the
throat thickness and fillet length. The weld toe is the region where the weld metal meets the
surface of the base plate. The weld toe is often discussed in terms of hardness variations
and discontinuities, such as undercut, which are associated with this region.
Welding Design
Joint Design
Welding Positions
1F
horizontal
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z
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1 - flat
2 - horizontal
3 - vertical
4 - overhead
F - fillet weld
G - groove weld
2F
flat
ISE311-2005
IntroWE/5-103
Welding Design
Welding Codes
Technical Societies
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International Standards
ISE311-2005
IntroWE/5-104
There are many codes and specifications that cover welding design, material
selection, and postweld heat treatment and inspection. Codes have been developed
by industry groups and technical societies.
The ASME and AWS codes are the most widely used in the US for general
construction.
Welding Design
Welding Codes
ISE311-2005
IntroWE/5-105
Welding Design
Welding Codes
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z
z
ISE311-2005
IntroWE/5-106
Welding Design
Welding Codes
ISE311-2005
IntroWE/5-107
7. Stud welding
8. Strengthening and repairing existing structures
12 Mandatory annexes: e.g., effective throat, requirements for impact testing, flatness of
girder webs, guideline on alternate method for determining preheat
12 Nonmandatory annexes: e.g., guide for specification writers, sample welding forms,
contents of prequalified WPS, safe practices
ANSI/AWS D1.1 provides pre-qualified joint designs (example above), as well as filler
metal and preheat selection guidelines. Pre-qualified joints, as given in Section 3 of D1.1,
are exempt from the WPS testing required under Section 4 of the code, provided the written
WPS conforms to all provision of Section 3 of the code. This exemption can save
considerable time in the structural design. However, the engineer should still evaluate the
appropriateness of the joint selection. The welders that use pre-qualified joints are required
to be qualified themselves in conformance with Section 4, Part C.
Welding Design
Discontinuities
Discontinuities in a
welded joint can influence
mechanical properties
Codes establish size
limits for acceptable
discontinuities
Discontinuities
unacceptable by a given
code are called defects
and are subject to repair
ISE311-2005
IntroWE/5-108
Stress applied to a material is magnified by flaws in the material, e.g., cracks. A stress
intensity factor quantifies this magnification of the applied stress. The fracture toughness of
a material is the critical value of this stress intensity factor that causes fracture.
The term Engineering Critical Assessment is used for the analysis of a structure that has
flaws (cracks) and will be subjected to stress. Several factors must be considered in order
to make a realistic prediction of the likelihood of catastrophic (brittle) failure of such a
structure: temperature, crack geometry, magnitude of the stress, strain rate, and yield
strength of the material.
Welding Design
Inspection
Nondestructive Evaluation
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z
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Radiography
Ultrasonics
Magnetic particle
Fluorescent penetrant
Dye penetrant
transducer
defect
ultrasonic
wave
C
B
ISE311-2005
IntroWE/5-109
Welded joints can contain discontinuities such as undercut and trapped slag inclusions.
Welding codes, such as ANSI/AWS D1.1 set size and frequency limitations on the
occurrence of these discontinuities. Discontinuities which exceed these limitations are
referred to as defects and must be repaired. Discontinuity and defect are legal terms and
should be used properly when reporting weld inspections for code compliance.
Four basic types of nondestructive testing (NDT) are used to evaluate welded joints. A
radiograph is an x-ray of the weld and can show internal discontinuities that cannot be
detected by visual methods. Ultrasonic testing uses a transducer to push sound waves into a
material. Echoes of the sound from the top and bottom surface of the plate appear as blips
on the screen of the oscilloscope used in the procedure. Internal discontinuities appear as
additional blips between the blips that indicate the top and bottom surface of the plates.
Discontinuities that penetrate the surface of welded joint can be located by magnetic
particle, fluorescent penetrant, and dye penetrant methods. In magnetic particle testing, a
region of the joint is magnetized by passing current through it. Magnetized particles are
poured onto the surface; discontinuities disrupt the regularity of the magnetic field and are
outlined by the magnetic particles. In the dye and fluorescent methods, penetrant liquids are
applied to the surface of the joint and soak into the surface discontinuities. The remaining
penetrant is wiped away. Ultraviolet light is used to locate the discontinuities in the
fluorescent particle method. For dye penetrant, a white developer is sprayed over the
cleaned surface; the dye (usually red) leaches through the white coating to reveal the
location of the discontinuity.
Welding Design
Fatigue Design
Fatigue
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Tension - Tension
Stress
Tension - compression
Tension - tension
Tension - Compression
ISE311-2005
IntroWE/5-110
The fatigue life of non-welded material is generally divided into two phases: crack
initiation and crack growth. First the cyclic nature of the stress initiates a crack. Once the
crack is initiated, it acts as a stress concentrator. The amplified stress at the crack tip causes
the crack to propagate. Failure occurs when the structure can no longer support the applied
stress. In terms of the overall fatigue life of a material, the crack initiation stage can be as
high as 90%. In other words, it takes a long time for the crack to develop. Once the crack
does initiate, it grows quickly and causes failure. Structural designs that include sharp
corners or notches are prone to fatigue failure. The corners and notches act as initial stress
concentrators, which help to initiate fatigue cracks.
Welded joints have essentially no crack initiation phase; subsequently they can have
10% of the fatigue life of a non-welded material.
Welding Design
Fatigue Design
Intrusion
ISE311-2005
IntroWE/5-111
Welds are associated with having pre-existing discontinuities that act as initiation sites
for fatigue. These weld discontinuities include slag intrusions, undercut, and lack of
penetration (among others). With these fatigue crack initiation sites already present in the
structure, crack growth can begin almost immediately.
Fatigue is often noted to start at the weld toe due to the presence of the aforementioned
slag intrusions as well as the geometry of the weld toe (angle, radius and undercut), both of
which act as stress concentrators. Grinding, peening, or dressing of the weld toe with a final
GTAW pass can act to reduce the incidence of discontinuities.
General design factors, such as the avoidance of lap joints in favor of butt joints, can
also increase the fatigue life of welded structures.
Welding Design
Fatigue Design
Fatigue Appearance
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ISE311-2005
IntroWE/5-112
Welding Design
Fatigue Design
Class B
ANSI/AWS D1.1 provides fatigue design lines for six stress categories. General fatigue
guidelines include the following:
1) Partial penetration groove welds loaded in tension transverse to the longitudinal axis of
the weld cannot be used where design criteria indicate that cyclic loading could produce
failure.
2) Groove welds made from one side only cannot be used if the welds are made with
backing (other than steel) that has not been qualified to Section 4. There are exceptions for
secondary or non-stress carrying members, and for corner joints meeting certain criteria.
3) Intermittent groove welds are prohibited.
4) Intermittent fillet welds are prohibited, with a given exception.
5) Bevel grooves and J-grooves in butt joints for other than the horizontal position are
prohibited.
6) Plug and slot welds on primary tension members are prohibited.
7) Fillet welds < 3/16-inch are prohibited.
Welding Design
Fatigue Design
ISE311-2005
IntroWE/5-114
The weld stress category is determined by matching the weld to a series of examples
given in ANSI/AWS D1.1. The stress range is determined by subtracting the minimum
design stress from the maximum design stress. The fatigue life of a welded joint is located
by matching the stress range to the stress category and then reading the cycle life value for
that point. The design curves reflect a safety factor below the mean as determined through
fatigue testing.
Example 1: A category D weld joint, designed for a stress range of 5 ksi has a fatigue
life of 7 million cycles.
Example 2: A category B weld joint, designed for a stress range of 10 ksi should not fail
in fatigue. This assumes a properly qualified weld with no defects.
An important note on weld design
Welds are generally designed to ensure that the strength of the metal across a given
throat thickness can support the maximum stress. Fatigue, however, occurs independent of
metal strength. Changing the base metal to a higher strength will not result in longer
fatigue life. Fatigue is often noted to occur at the toe of the weld, although it can still
occur through the throat of the weld. In fact, there are different stress categories for stress
on the weld metal as opposed to stress on the base metal at the weld toe, as was pointed out
on the previous page.
Welding Design
Heat flows from the weld area and causing the joint area
to expand
Thermal expansion and contraction from welding result
in permanent stress and distortion
Higher heat input welds are more prone to residual
stress and distortion
ISE311-2005
IntroWE/5-115
The heat produced by welding produces thermal expansion in the surrounding material.
The stresses associated with this expansion continue to change until the joint returns to
ambient temperature. A pattern of permanent stress may be left in the joint; this is referred
to as residual stress. Permanent strain left in the joint is referred to as distortion.
High energy input welding processes, such as the submerged arc process, are more
likely to produce residual stress and distortion. Laser and electron beam welds, with their
overall low heat input, tend not to produce residual stress or distortion problems.
Welding Design
Distortion
Rotational Distortion
Longitudinal Bending
Angular Change
Buckling
ISE311-2005
IntroWE/5-116
Welding Design
Eliminating Distortion
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Preset members to
counteract distortion
Fixtures to clamp
workpiece in place
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Stress-relief heat
treatment
In order to reduce distortion, the piece being joined may clamped into position. This
method will reduce distortion, but may increase the residual stress in the joint after welding.
Another method of reducing distortion is to weld the plates with a preset. If two plates
typically distort upwards by 5 after they are welded, then position the plates with a 5
downward preset before welding.
Heat treatment after welding can be used to relieve residual stress. In steels, stress relief
is accomplished in the 1100-1200F temperature range.
Welding Design
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Tension
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Compression
ISE311-2005
IntroWE/5-118
As a weld cools, it attempts to contract more than the base metal, since the base metal
was not heated to as high a temperature. As the weld shrinks, it is restrained by the
surrounding base metal. Thus, after welding, a state of residual tension is produced in the
weld. The base metal near the weld is in compression, which balances out the tension to
yield a net force of zero on an unrestrained plate. The presence of restraint can affect this
stress pattern.