Design for Welding

1. Why Welded Construction

i. ii.

Weldment is lighter in weight than cast or fastened structures, requires less materials Weldment design can be readily modified to changing product requirements

iii.
iv. v. vi.

Production time for weldment is less than that for other manufacturing processes
Weldment will be more accurate with dimensional tolerances than casting Weldments are easier to machine than casting Weldments are tight and leak proof and will not shift

vii. Capital investment for producing weldments is lower than for a castings

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3a. Welding Positions - Plates AWS Classifications - Plates

Fillet
1F 2F 3F

Groove
1G 2G 3G FLAT HORIZONTAL VERTICAL

4F

4G

OVERHEAD

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3a. Welding Positions - Pipes

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints
The terms Welds and Joints are often confused. Theoretically they signify two different aspects

3b. Joints
The junction of members or the edges of members which are to be joined

or have been joined.

There are five basic types of Joints

i. Butt

ii.

Corner

iii. Edge iv. Lap v. Tee

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3b. Joints
i. Butt Joint :

A joint between two members lying approximately in the same plane. Square Butt Joint Used to butt weld light sheet metal. 1/16 to 3/16 thick metal.

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3b. Joints
i. Butt Joint : contd Beveled Butt Joint Used to butt weld heavier pieces of metal together. 3/8 to inch metal can welded using a single V or U joint. Inch metal and up can be welded using a double V or U joint.

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3b. Joints
ii. Corner joint:

A joint between two members located approximately at right angles to each other in the form of an angle
A. Closed corner joint is used on light sheet metal were strength is not required at the joint. B. Half open corner joint is used on heavier metal when welding can only be done on one side. Used when load is not severe C. Open corner joint is used on heavy material. It is the strongest of the corner joints. D. Corner joints on heavy material are welded on both sides. The outside first them reinforced on the inside.

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3b. Joints
iii. Edge joint:

A joint between the edges of two or more parallel or mainly parallel members.

Not very strong. Used mainly to join edges of sheet metal, reinforce flanges of I beams, and mufflers.

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3b. Joints
iv. Lap joint:

A joint between two overlapping members.

A. Single lap joint welded from one side. B. Single lap joint welded from two sides develops full strength. C. Off set lap joint is used when two pieces of metal need to be joined in the same plain.

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3b. Joints
iv. Tee joint:

A joint between two members located approximately at right angles to each other in the form of a T. A- plain tee B- single beveled C- double beveled D- single J E- double J

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3c. Types of Welds
There are two basic type of welds 1. Fillet Welds 2. Groove Welds
However there are other weld types also, 3. Back or backing Weld 4. Plug or slot Weld 5. Spot or Projection Weld 6. Seam Weld 7. Surfacing Weld 8. Flange Weld 9. Stud Weld

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3c. Types of Welds
1. Fillet Welds The most commonly used weld. A weld of approximately triangular cross section joining two surfaces approximately at right angles to each another. It is regarded as being on the joint

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3c. Types of Welds
2. Groove Welds The second most popular weld. A weld made in the groove between two members to be joined. It is regarded as being in the joint.

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3c. Types of Welds
3. Back or Backing Weld A special type of weld which is made on the back side or root side of a previously made weld.

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3c. Types of Welds
4. Plug or Slot Weld These are used with the prepared holes They are considered together since the welding symbol to specify them is the same. If the hole in prepared member is round it is considered a plug weld If the hole in prepared member is elongated it is considered a slot weld.

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3c. Types of Welds
5. Spot or Projection Weld Represented by the same symbol
Can be applied by different welding processes which change the actual weld With Resistance welding, weld is at the interface of the two members With arc, electron beam or laser, the weld melts through one member into other

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3c. Types of Welds
5. Spot or Projection Weld

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3c. Types of Welds
6. Seam Weld In cross-section, it looks similar to a series of spot welds Geometry is influenced by welding processes similar to spot or projection welds

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3c. Types of Welds
7. Surfacing Weld It is composed of one or more stringer beads deposited on base metal as an unbroken surface. Used to build up surface dimensions, provide metals of Different properties, provide Protection from hostile Environment

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3c. Types of Welds
8. Flange Weld Used primarily for light gauge or sheet metal

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3c. Types of Welds
9. Stud Weld Used for attaching studs to flat surfaces

Design for Welding

3. Welding Positions, Joints, Welds and Weld Joints 3d. Weld - Joints

Design for Welding

4. Design of Welds Five basic types of loading
i. ii. Tensile Load Compression Load Short Section

iii. Compression Load Long Section

iv. Bending Load v. Torsion Load

vi. Shear Load

Most loadings can be considered as either one of these or a combination of these

Design for Welding

4. Design of Welds Stress Concentrations
Stress Concentrations
1. Three basic types of notches that result in stress concentration

i.

Design notches both in weldments and in welds

a. b. c. Abrupt change of section e.g hatch opening Incomplete fusion Fillet Welds

ii.

Workmanship notches of weldments but more importantly of welds

a. Lack of penetration

iii. Metallurgical notches a. b. Joining metals of different yield strengths Welding on hardenable steels

Design for Welding

4. Design of Welds Rigid frame structure Continuous Construction
Incorporates Plastic Analysis Specifically suited to welded construction

Members are welded directly together rather than thru connection plates
Provides material saving Greater dimensional accuracy Requires thorough analysis and should be done only by designers well qualified to perform this type of work

Design for Welding

4. Weldment Design Factors
i. ii. Efficient and economical use of materials, selection of process, edge preparation and minimum cross sectional area, position, Design of all welded joints

iii. Service conditions iv. Complete and accurate determination of all applied loads, dead loads, own weight, superimposed loads, impact, fatigue etc v. Determination of allowable stresses (yield stress / safety factor)

vi. Accessibility vii. Back or backing weld viii. Considerations for distortion

Design for Welding

4. Design of Welds Accessibility
Accessibility

Design for Welding

4. Weld Joint Design 4a. Fillet Weld Design
i. Two critical dimensions a. Throat b. Leg Length (determines throat dimensions) ii. Normal Type Fillet i. ii. Equal Leg Length Face at 45 degrees

iii. Throat = 0.707 x shortest leg length iii. Special Type i. ii. Unequal Leg Length Throat = shortest distance between root & theoretical face

iv. Intermittent fillets are specified by pitch and length v. Single fillet welds are prone to cracking when root is subject to tension Double fillets are therefore used

Design for Welding

4. Weld Joint Design 4a. Fillet Weld Design (contd)
iv. Strength Calculations a. Ignore Reinforcement b. Ignore any root penetration c. Size governed by v. Thickness of metals being joined Practical consideration

Sizing the fillet i. Strength is determined by failure area which is governed by throat dimensions ii. Doubling the size of fillet i. ii. Strength is doubled Weight increases by 4 time

Design for Welding

4. Weld Joint Design 4a. Fillet Weld Design Basic Calculation

Design for Welding

4. Weld Joint Design 4a. Fillet Weld Design (Contd)

Design for Welding

4. Weld Joint Design 4a. Fillet Weld Design (Contd)

Design for Welding

4. Weld Joint Design 4a. Fillet Weld Design (contd)

Design for Welding

4. Weld Joint Design 4b. Groove Weld Design

Design for Welding

5. Weld Joint Details 6. Influence of Specifications on Design 6. Design conversion to weldments Redesign to a weldment Direct Copy Analysis of Part 7. Weldment Redesign to Reduce Cost Value Engineering

Design for Welding

Introduction to Welding Codes and Standards
Application standards and codes of practice ensure that a structure or component will have an acceptable level of quality and be fit for the intended purpose.

Design for Welding

8. Welding Symbols

Design for Welding

8. Welding Symbols

Break in arrow means arrow side must be side that beveling or other preparation required.

What does this symbol Represent?

5/16

5/16

Single-Bevel-Groove and Double Fillet Weld Symbol

5/16
5/16

Single-Bevel-Groove and Double Fillet weld Symbols

Chain Intermittent Fillet Weld

Weld both sides each end and 10 inches center to center in between

1/4 1/4

2-10 2-10

10 in

Staggered Intermittent Fillet Weld

Weld ends than 10 inch centers staggered each side

1/4 1/4

2-10 2-10 10 in

10 in

Some Practice Exercises

Some Practice Exercises

Some Practice Exercises

Some Practice Exercises

Some Practice Exercises

Some Practice Exercises

Some Practice Exercises

Some Practice Exercises