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Sizing of Steel Welds

M F V

How large should these fillet welds be so that the weld joint never fails ?
ME 538 Welding Design, Fabrication & Quality Control 1

The Allowable Stress Design (ASD) Method

The ASD method is based on: Identification of the worst case loading situation and g stress location of the highest The assumption of linear elastic behaviour of all materials The assumption that the as-welded ultimate tensile strength (UTS) of the electrode will normally be matched to the UTS of the base metal (Note: they may have different d e e co compositions) pos o s) The calculated nominal shear stress in the weld throat (usually the plane of section with the smallest area) Specification of a maximum allowable stress in the throat of the weld and in the base metal which depends on the weld type, loading direction and the material properties
ME 538 Welding Design, Fabrication & Quality Control 2

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Allowable Stress Design Method

The Allowable Stress Design (ASD) method uses a single empirically derived safety factor that accounts for all variations in weld geometry, loads and material properties. This safety factor is applied to the weld metal ultimate tensile strength and the base metal yield strength to obtain maximum allowable stresses in the weld and base metal. The size of the weld must be large enough that: 1) Calculated C l l t d St Stress i in th the Weld W ld Th Throat t Allowable Stress in the Weld Metal and 2) Calculated Stress in the Base Metal Allowable Stress in the Base Metal
ME 538 Welding Design, Fabrication & Quality Control 3

Allowable Stress Design Method Steps for Welded Steel Construction

1) Design the weld joint and select the weld type and base metal alloy 2) Select the matching electrode, i.e., the electrode that will have the same as-welded UTS as the base metal (from Table in the code) 3) Determine the allowable stress in the weld & base metal for that joint, weld and load direction. (from Table in the code and steel properties) 4) ) Apply pp y the weldment safety y factor if required. q 5) Calculate the size of weld that will ensure that the stresses in the weld throat and base metal are less that the allowable stresses. 6) The weld should not be larger that the thinnest member and not smaller than the minimum allowed weld size.
ME 538 Welding Design, Fabrication & Quality Control 4

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Selecting Matching Electrodes

(Table 1111-1 from CSA W59W59-03 Welded Steel Construction)

Note: Overmatched electrodes are not recommended because they are prone to cold cracking or hydrogen cracking and may require use of pre & post heating
ME 538 Welding Design, Fabrication & Quality Control 5

Using Undermatched Electrodes

(Matching Electrode Reqd)

(Undermatched electrodes may be used when the plate will fail before the weld, e.g., when the weld is loaded longitudinally and has a small cross sectional area relative to the plate)
[AWS Handbook, Vol. 1, Fig. 5.37]
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ME 538 Welding Design, Fabrication & Quality Control

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Allowable Stresses in the Weld & Base Metal

(Taken From AWS D1.1 Structural Welding Code - Steel)

See also AWS Standard D1.1 Structural Welding Code, Table 2.3 in .pdf file
ME 538 Welding Design, Fabrication & Quality Control 7

Allowable Stresses in the Weld & Base Metal

(Taken From CSA Standard W59W59-03 Welded Steel Construction)

ME 538 Welding Design, Fabrication & Quality Control

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Allowable Stresses in the Weld & Base Metal

(Taken From CSA Standard W59W59-03 Welded Steel Construction)

ME 538 Welding Design, Fabrication & Quality Control

Xu = Nominal UTS of Electrode Aw = Weld Throat Area T = Allowable Tensile Stress Normal to Weld

Fy = Yield of Base Metal Am = Fusion Boundary Area V = Allowable Shear Stress

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Welds With Various Types of Loads

ME 538 Welding Design, Fabrication & Quality Control

[AWS Handbook, Vol. 1, Fig. 5.34]

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Canadian Standards for Structural Steel

CAN/CSA G40.20-M: General requirements for rolled or welded structural quality steel. Definitions Chemical Composition Variations in Dimensions Methods of Testing Frequency of Testing Heat Treatment Repairs of Defects Marking, etc. CAN/CSA G40.21-M governs chemical and mechanical properties of 8 types and 8 strength levels of structural steels for general construction and engineering purposes. Type G General Construction Steel Type W Weldable Steel Type WT Weldable Notch Tough Steel Type R Atmospheric Corrosion Resistant Steel Type A Atmospheric Corrosion Resistant Weldable Steel Type AT Atmospheric Corrosion Resistant Weldable Notch Tough Steel Type Q Quenched and Tempered Low Alloy Steel Plate Type QT Quenched and Tempered Low Alloy Notch Tough Steel
ME 538 Welding Design, Fabrication & Quality Control 11

Some CSA W59 Limits for Use of Weld Types

Groove and fillet welds may be used to carry any combination of loads at their allowable stresses. Si Single l fill fillet t weld ld and d single i l PJP groove welds ld should h ld not t be used when a bending moment about the longitudinal axis of the weld produces tension at the root of the weld. Fillet welds may be used between fusion faces which form an angle from 60o to 120o.
For angles less than 60o, the fillet weld shall be considered as a PJPG weld. For angles over 120o, the fillet weld shall not be relied upon to transmit any load.

Plug and slot welds in lap joints may be used to transmit shear or to prevent buckling or separation of lapped parts.
ME 538 Welding Design, Fabrication & Quality Control

[CSA W59 Standard]

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Load & Weld Classifications

Primary Loads: These loads cause a direct or membrane stresses on the member member. Secondary Loads: These loads cause bending stresses. Primary Welds: These welds transfer the entire load. If they fail, the weldment fails. Secondary Welds: Simply hold the parts together. The forces on the welds are normally small.
ME 538 Welding Design, Fabrication & Quality Control 13

Stress Analysis of Groove Welds

Effective Throat Area = Weld Length Effective Throat Thickness

Stress = Applied Load / Effective Area

Note: For any groove weld, square or skewed to the direction of stress, the effective weld length is the width of the parts being joined.

Force t
Effective Throat Thickness = t
ME 538 Welding Design, Fabrication & Quality Control

Force

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Complete Joint Penetration Groove Welds

Definition: A complete joint penetration (CJP) groove weld is welded from both sides or from one side with backing, backing having complete penetration and fusion of the weld and base metal throughout the depth of the joint.
Note: For SMAW and FCAW processes, the joint should be back-gouged prior to welding from the other side except where it is expressly p y stated that back-gouging g g g is not mandatory. The effective throat thickness of a CJP groove weld is the thickness of the thinner part. No increase in throat area is permitted for weld reinforcement.
ME 538 Welding Design, Fabrication & Quality Control

To avoid lack of fusion in first weld at root

[CSA W59 Standard]

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Partial Joint Penetration Groove Welds

Definition: A partial joint penetration (PJP) groove weld has less than complete joint penetration. Prequalified PJP groove welds shall also include joints: Welded from one side without steel backing Welded from both sides without back-gouging (NB there are some exceptions stated in the code) Welded from one side for which U-groove preparation from the other side by gouging will not reach sound weld metal for the SAW process
ME 538 Welding Design, Fabrication & Quality Control

[CSA W59 Standard; Clause 10.1.2]

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Partial Joint Penetration Groove Welds

(mm)

(mm)

ME 538 Welding Design, Fabrication & Quality Control

[CSA W59 Standard]

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Partial Joint Penetration Groove Welds

ME 538 Welding Design, Fabrication & Quality Control

[CSA W59 Standard]

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Combined Loading on Groove Welds

Groove welds can also be subjected to multi-axis stresses Shear Stresses: Shear stresses on the effective throat area are combined vectorially. Shear and Direct (Normal) Stresses: are combined into principal stresses (Mohrs circle). The resultant max. shear stress is then compared to the allowable (i.e., Tresca failure criteria).
ME 538 Welding Design, Fabrication & Quality Control 19

Stress Analysis of Fillet Welds

The fillet welds are assumed to carry external loads as shear forces on the throat area. The normal stress on the weld throat is ignored. i e using it with the The shear stress on the throat area is inflated inflated , i.e., allowable stress will produce conservative results. Extensive testing has been perform to determine the allowable stress in the welding code, e.g., CSA W59.

Throat Area = h
ME 538 Welding Design, Fabrication & Quality Control

cos 450 = h

0.707
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Effective Throat of Fillet Welds

The effective throat of a fillet weld is the shortest distance from the root to the face of the diagrammatic weld for all welding processes except for SAW

ME 538 Welding Design, Fabrication & Quality Control

[CSA W59 Standard]

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The Throat of Skewed Fillet Welds

(See also .pdf handouts from AWS Handbook Vol. 1, Fig. 5.38)
ME 538 Welding Design, Fabrication & Quality Control

[CSA W59-3 Welded Steel Construction]

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Minimum Fillet Weld Length and Size

The length of a fillet weld shall be 40 mm or 4 times the size of the fillet, whichever is larger. AWS D1.1 [CSA W59 W59-03] 03] Do not forget the minimum fillet weld size requirements.
CSA W59-03

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Load Carrying Types for Fillet Welded Joints

ME 538 Welding Design, Fabrication & Quality Control

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Stress Distributions in Fillet Welds with Transverse Loads

[Norris, Weld. J., 1945, 24, p. 557s] [Salakian et al., Weld. J., 1937, 16, pp. 1-24]
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Connections for NonNon-symmetric Sections

11.4.5.3 For end connections of single angle, double angles, and similar type members, it is not necessary to completely balance the welds about the neutral axis or axes of such members
[CSA W59-M1989 Standard]
ME 538 Welding Design, Fabrication & Quality Control 26

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Plug, Slot or Spot Welds

M F

M F

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Load Flow Design Assumptions

1) All bending moments, M, are transferred as forces, F, in the flanges 2) All shear forces, V, are carried and transferred only by the web web. 3) Assume all direct forces, H, are carried by the web and flanges
ME 538 Welding Design, Fabrication & Quality Control

[Blodgett, Weld. J., 1982, 61(3), pp. 16-23]

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Load Flow Design & Analysis Procedure

1. Analyze the structure as a whole; thus, obtaining moments, M, horizontal, H, and vertical forces, V, at the connection. 2. Assume that the moment is transferred by forces, F, in the flanges only. 3. Assume that the shear force is transferred by the web only. 4 Assume that the direct force, 4. force H H, is distributed to all welds. 5. Check for and add required stiffening plates to transfer the flange loads to the web by shear without buckling the web.
ME 538 Welding Design, Fabrication & Quality Control 29

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Examples of Load Flow Joint Design

Hydraulic Press in the Engineering 3 High Pressure Lab The overhead cross beam is made from two I beams welded together with reinforcing stiffener plates to prevent web buckling due to transverse loads

ME 538 Welding Design, Fabrication & Quality Control

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Examples of Load Flow Joint Design

Manual Hoist in the Engineering 3 High Pressure Lab

Joint Details
ME 538 Welding Design, Fabrication & Quality Control 31

Examples of Load Flow Joint Design

Structural Steel Connections Statue outside Engineering 2

ME 538 Welding Design, Fabrication & Quality Control

Lower Beam Connection Details Designed using Load Flow Concepts 32

continue onto sizing of steel welds for fatigue load

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