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Welded Joints
Welded Joints
Introduction
Aweldedjointisapermanentjointwhichisobtainedbythe fusionoftheedgesofthetwopartstobejoinedtogether,withor withouttheapplicationofpressureandafillermaterial.Theheat req iredforthef required fusion sionofthematerialma maybeobtainedby b burningofgas (incaseofgaswelding)orbyanelectricarc(in caseofelectricarcwelding).Thelattermethodisextensively usedbecauseofgreater speed ofwelding. Welding gisextensively yusedinfabricationasanalternative methodforcastingorforgingandasareplacementforboltedand rivetedjoints.Itisalsousedasarepairmediume.g.toreunite metal latacrack, k tobuild b ldupasmall llpartthat h has h broken b k off ffsuch h asgeartoothortorepairawornsurfacesuchasabearing surface. surface
AdvantagesandDisadvantagesof WeldedJointsoverRivetedJoints
1) Theweldedstructuresareusuallylighter thanrivetedstructures.Thisisduetothe reason thatinwelding, reason, welding gussetsorotherconnectingcomponentsarenotused used. 2) Theweldedjointsprovidemaximumefficiency(maybe100%)whichisnotpossible incase ofriveted joints. 3) Alterationsandadditionscanbeeasilymadeintheexistingstructures. 4) Astheweldedstructureissmoothinappearance,thereforeitlookspleasing. ) Inweldedconnections,thetensionmembersarenotweakenedasinthecaseof 5) rivetedjoints. 6) Aweldedjointhasagreatstrength.Oftenaweldedjointhasthestrengthofthe parentmetalitself. p 7) Sometimes,themembersareofsuchashape(i.e.circularsteelpipes)thatthey afforddifficultyforriveting.Buttheycanbeeasilywelded. 8) Theweldingprovidesveryrigid joints. joints Thisisinlinewiththemoderntrendof providingrigid frames. 9) Itispossibletoweldanypartofastructureatanypoint.Butrivetingrequires enoughclearance. clearance 10) Theprocessofweldingtakeslesstime thantheriveting.
DisadvantagesandDisadvantagesof WeldedJointsoverRivetedJoints
1) Sincethereisanunevenheatingandcoolingduring fabrication,thereforethemembersmaygetdistortedor additionalstressesmaydevelop. develop 2) Itrequiresahighlyskilledlabour andsupervision. 3) Sincenoprovisioniskeptforexpansionandcontractionin theframe,thereforethereisapossibilityofcracks developinginit. 4) Theinspectionofweldingworkismoredifficultthanriveting work.
Welding g Processes
Theweldingprocessesmaybebroadly classifiedintothefollowingtwogroups: groups 1) Weldingprocessesthatuseheatalone e.g. fusion welding. 2) Weldingprocessesthatuseacombinationof heatandpressuree.g.forge welding.
Fusion Welding g
Incaseoffusionwelding welding,thepartstobejointedareheldinpositionwhile themoltenmetalissuppliedtothejoint.Themoltenmetalmaycome fromthepartsthemselves(i.e.parentmetal)orfillermetalwhichnormally havethecompositionoftheparentmetal. metal Thejointsurfacebecome plasticorevenmoltenbecauseoftheheatfromthemoltenfillermetalor othersource. Thus,whenthemoltenmetalsolidifiesorfuses,thejointisformed. Thefusionwelding,accordingtothemethodofheatgenerated,maybe classifiedas: 1.Thermit welding, 2.Gaswelding,and 3.Electricarcwelding.
Thermit Welding g
Inthermit welding, welding amixtureofironoxideandaluminium calledthermit is ignitedandtheiron oxideisreducedtomolteniron.Themoltenironis pouredintoamouldmadearoundthejointandfuseswiththepartstobe welded Amajoradvantageofthethermit weldingisthatallpartsofweld welded. sectionaremoltenatthesametimeandtheweldcoolsalmostuniformly. Thisresultsinaminimumproblemwithresidualstresses.Itis f d fundamentally ll amelting l and dcastingprocess. Thethermit weldingisoftenusedinjoiningironandsteelpartsthatare toolarge g tobemanufacturedinonep piece, ,suchasrails, ,truckframes, , locomotiveframes,otherlargesectionsusedonsteamandrailroads,for sternframes,rudderframesetc.Insteelmills,thermit electricweldingis employedtoreplacebrokengearteeth teeth,toweldnewnecksonrollsand pinions,andtorepairbrokenshears.
Gas Welding g
Agasweldingismadebyapplyingtheflameofanoxy acetyleneorhydrogengasfromaweldingtorchuponthe surfacesofthep prepared p j joint.Theintenseheatatthewhite coneoftheflameheatsupthelocalsurfacestofusionpoint whiletheoperatormanipulatesaweldingrodtosupplythe metalfortheweld. Afluxisbeingusedtoremovetheslag.Sincetheheatingrate i gaswelding in ldi is i slow, l therefore th f itcanb beused donthinner thi materials.
Inshieldedarcwelding,theweldingrods coatedwithsolidmaterialareused,as showninFig. Theresultingprojectionof coatingfocusesaconcentratedarc stream,whichprotectstheglobulesof metal lfrom f the h airandpreventsthe h absorptionoflargeamountsofharmful oxygenandnitrogen.
Arc Welding g
Electriccurrentflowingthroughahighresistanceairgap generatesanintensearcwithtemperaturesrangingfrom o C. 3,000 , to5,500 ,
Arc welding isthe most common method used with structural steel welding.
Forge g Welding g
Inforgewelding welding,thepartstobejointedarefirstheatedtoa propertemperatureinafurnaceorforgeandthen hammered.Thismethodofwelding gisrarely yusednowadays. y Anelectricresistanceweldingisanexampleofforgewelding. Inthiscase, ,thep partstobej joinedarep pressedtogether g andan electriccurrentispassedfromoneparttotheotheruntilthe metalisheatedtothefusiontemperatureofthejoint. Theprincipleofapplyingheatandpressure,either sequentiallyorsimultaneously,iswidelyusedintheprocesses k known asspot,seam,projection, j i upsetand dfl flash hwelding. ldi
ElementsofaWelding gSymbol y
Aweldingsymbolconsistsofthefollowingeightelements: 1.Referenceline, 1 line 2 Arrow, 2. Arrow 3.Basicweldsymbols, 4.Dimensionsandotherdata, 5 Supplementarysymbols, 5. symbols 6. 6 Finishsymbols, symbols 7.Tail,and8.Specification,processorotherreferences.
Minimumareaoftheweldorthroatarea, A=Throat thickness Length ofweld =t l=0.707s l Ift istheallowabletensilestressfortheweldmetal,thenthetensilestrengthof thejointforsinglefilletweld, tarea Allowable All bl t il stress t F=Th Throat tensile = 0.707s l t
andtensilestrengthofthejointfordouble filletweld,
F =2 0.707 s l =1.414s l
Notes
1. Ifthereisacombinationofsingletransverseanddoubleparallelfillet weldsasshowninFig.,thenthestrengthofthejointisgivenbythesumof strengthsofsingletransverseanddoubleparallelfilletwelds. Mathematically, F =0.707s l1 t +1.414s l2 2. Inordertoallowforstarting gandstopping pp gofthebead, ,12.5mmshould beaddedtothelengthofeachweldobtainedbytheaboveexpression.
3. Forreinforcedfilletwelds,thethroat dimensionmaybetakenas0.85t.
Special CasesofFilletWeldedJoints p
Circularfilletweldsubjectedtotorsion. torsion
Weknowthatshearstressforthematerial,
Thisshear Thi h stress t occursi inah horizontal i t lplane l along l a l legof fth thefill fillet t weld.Themaximumshearoccursonthethroatofweldwhichis inclinedat45 tothehorizontalplane. Lengthofthroat,t=ssin45 =0.707s Maximum shear stress d =Diameter ofrod, r =Radius ofrod, T =Torqueactingontherod, s=Size(orleg)ofweld, t =Throat thickness, J=Polarmomentofinertiaofthe weldsection
Special CasesofFilletWeldedJoints p
Circularfilletweldsubjectedtobendingmoment..
Weknowthatthebendingstress,
Thisbending Thi b di stress t occursi inah horizontal i t lplane l along l a l legof fth the filletweld.Themaximumbendingstressoccursonthethroatofthe weldwhichisinclinedat45 tothehorizontalplane. Lengthofthroat,t=ssin45 =0.707s g stress Maximum bending d=Diameter ofrod, M =Bendingmomentactingon therod, s =Size(orleg)ofweld, t =Throat thickness, Z =Section S i modulus d l of fthe h weld ld section
F =t l t
andtensilestrengthfordoubleV buttjointasshowninFig Fig.(b)
P=(t1 +t2)l t
t1 = Throatthicknessatthetop,and t2 = Throatthicknessatthebottom. l= Lengthofweld. weld Itisgenerallyequal tothewidthofplate.
Note:Forstaticloadingandanytypeofjoint,stress concentrationfactoris1.0.
f=Resistanceofferedbytheweld perunitlength.