Ch 16: Joining Methods

Rivets and Welded

Joints

Mir M. Atiqullah, Ph.D.

Mechanical Engineering Technology

Southern Polytechnic State University

Adapted from Hamrock Text

Why Join ?

Cant make them big enough

Cant make the shape
Cant transport
Cheaper
Different materials
Different manufacturer at different locations
ummm makes manufacturing sense..???
Adapted from Hamrock Text

Joining can be done by..

Press Fit

Welding

Adhesive

Rivets

Screws

Major Joining Methods

How else can you assemble/join 2 parts together?

Some are permanent, some are not, some are in-between..
Adapted from Hamrock Text

Riveted Fasteners

Rivets are used to join thin or sheet materials, specially

ductile metals and alloys.

It is a semi permanent joint, meaning normally it is

permanently joined with rare occasions of disassembly.

..

Adapted from Hamrock Text

Why use rivets..?

Will not come off due to shaking/vibration etc

Inexpensive, when done in assembly setup
Lightweight
Does not necessarily need through hole
Can be done w/o access to other side

Why not use rivets..?

Not as strong as threaded fastener

Can not be disassembled, normally.
Causes stress concentration/crack..

Adapted from Hamrock Text

Failure Modes for Fasteners in Shear

Figure 16.18 Failure modes due to shear loading of riveted fasteners. (a)
Bending of member; (b) shear of rivet; (c) tensile failure of member; (d)
bearing of member on rivet.
Adapted from Hamrock Text

Types of Rivets

pop rivets!

Setting rivets
Adapted from Hamrock Text

Example 16.9

Figure 16.19 Group of riveted

fasteners used in Example 16.9.
(a) Assembly of rivet group; (b)
radii from centroid to center of
rivets; (c) resulting triangles; (d)
direct and torsional shear acting
on each rivet; (e) side view of
member. (All dimensions in
inches.)

Adapted from Hamrock Text

Welded Joints

Defn: Joining materials (metals, plastic) by causing diffusion

at the joint/interface by applying heat and/or pressure.
Often a filler material is used, to strengthen the joint.
This is in contrast with soldering and brazing, which involve
melting a lower-melting-point material between the work
pieces to form a bond between them, without melting the
work pieces. But HOW???
Surface diffusion (atomic)

Adapted from Hamrock Text

Welding Methods

Electric Arc Welding ( TIG, MIG, ..)

Gas Welding ( Oxy Acetylene,..)
Resistance Welding ( Spot welding, roll welding)
Energy Beam - laser, electron beam, etc
Solid State Welding- does not melt the parent
materials. E.g.

Ultrasonic ( most common for polymers), explosion,

friction, hot pressure, induction, ..
Adapted from Hamrock Text

Weldability

The quality of a weld is also dependent on the combination of

1.

materials used for the base material and

2.

the filler material.

3.

Not all metals are suitable for welding, and not all filler
metals work well with acceptable base materials.

Adapted from Hamrock Text

Common Welding Joint Types

(already covered in Mfg. course)
1. Square butt joint,
2. Single-V preparation
joint,
3. Lap joint,
4. T-joint.
5. Corner
5

Adapted from Hamrock Text

Weld Symbols

Figure 16.20 Basic weld symbols.

Adapted from Hamrock Text

Fillet Weld Lap or corner

(a) Cross-section of weld
showing throat te and legs he

Throat- the thinnest

section of the weld-45
from sides.
Under Tensile load as
shown, the shear stress
occurs along the throat
parallel to the load.
(b) shear planes.

Adapted from Hamrock Text

See Welded Joints handout for

Design calculations.

Parallel and Transverse

Loading

Welded joints fail by shear at both parallel

and transverse locations.
P
P
1.414 P
Shear Stress =
=
=
te Lw .707he Lw
he Lw
P
To avoid Failure =
< (S sy )weld
te Lw
What is LW?
What is the factor of safety?
Adapted from Hamrock Text

Bending-Normal stress

In bending, welds experience transverse shear as well as

normal stress.
Effective moment of inertia

I = te I u Lw = 0.707he I u Lw

Where, Iu =unit moment of inertia (?) and

Lw=Length of weld.

See table 16.12 again.

Force per unit length of weld is w=P.a/Iu where a= distance

from weld to applied load. Finally,
Now calc principal stresses and
then use MSST or DET for design.
Adapted from Hamrock Text

Mc
=
I

Geometry
of Welds

Table 16.12 Geometry of welds and parameters used

when considering various types of loading.
Adapted from Hamrock Text

Torsion-Shear Stress

Loads on the weld include both direct d and torsional t

stresses.

V Tr
= d + t = +
A J
r= distance from centroid of weld to the farthest point of weld
J= polar moment of inertia= te Ju =0.707 he Ju
Ju= Unit polar moment of inertia, as given in Table 16.12 p-747

= d + t < (S sy )weld
Adapted from Hamrock Text

See next the weld

geometry

More Geometry of Welds

Table 16.12 (cont.) Geometry of welds and parameters used when

considering various types of loading.
Adapted from Hamrock Text

Even more Geometry of Welds

Table 16.12 (cont.) Geometry of welds and parameters used when

considering various types of loading.
Adapted from Hamrock Text

Final Geometry of Welds

Table 16.12 (cont.) Geometry of welds and parameters used when

considering various types of loading.
Adapted from Hamrock Text

Weld Strength

Table 16.13 Minimum strength properties of electrode classes.

Electrode Strength: E80XY
Ksi

Variables ( current etc.)

Position (flat, vertical, overhead)

Given yield strength of weld, and type of loading
calc
allowable stress. Given design stress, now calc ns.
Adapted from Hamrock Text

Welds in Fatigue
Heat Affected Zone (HAZ)- area around weld where
heat treatment has been altered due to high temp.
Use the following fatigue strength reduction factors to
standard strengths of welding rod and parent materials for
design.

Table 16.14 Fatigue strength reduction factors for welds.

Q: Where would you use this value of Kf ?
Adapted from Hamrock Text

Weld Quality Assurance

Defects

Voids
Cracks
Improper thickness
Inclusion (of foreign materials, slugs.)

Testing Methods

Visual
X-ray
Ultrasound
Destructive tensile, bending, peeling(sheet metal) etc.

Adapted from Hamrock Text

Summary

Rivets
Welded Joints Types, throat, leg, toe !
Total sh. Stress = direct stress + T..
Unit moment of inertia
Unit polar moment of inertia
Welding Inspection
HAZ -?
Adapted from Hamrock Text