Desene Sudura

Welding Design
Module 4
Module 4 Welding Design

4A Heat Flow
4B Residual Stress and Distortion
4C Fracture and Fatigue
4D Joint Design
4E Welding Symbols
4F Mechanical
M h i lT
Testing
ti
4-2
Module 4 Learning Objectives

Basic understanding of heat flow, heat flow with moving heat
sources, estimation of cooling rates and HAZ
Basic understanding of residual stress and distortion
principles and mitigation methods
Understanding of weld design, weld joints and welding
symbols
y
Basic understanding and purpose of different types of
destructive tests
4-3
Heat Flow
Module 4A
Heat Flow
Heat Flow
Conduction
Radiation
Convection
air
q& rad
q& conv.
q& cond .
4-5
Heat Flow
Conduction
Fouriers Law of Conduction

Heat flow
d
q
q& x = =
dx
A x
Heat
flux
Temp.
gradient
Thermal
conductivity
4-6
Heat Flow
1-D Conduction
dx
Heat generation per unit
volume
q& x A
Q&
C p
dx
q& x+ dx A
Cross sectional Area
A
4-7
Heat Flow
Conservation of Energy
Internal energy = energy in energy out

Specific heat
Density
&
C p
+ q& x A q& x + dx A
Adx = QAdx
t
Internal Energy change = Internal heat generation + heat in heat out
4-8
Heat Flow
But using Taylor series expansion,
q& x + dx = q& x +
q& x
x
dx
q& x
&
Adx = QAdx + q& x A q& x A
dxA
C p
t
x
q& x
&
= Q
C p
t
x
4-9
Heat Flow
Using Fouriers law of conduction
qq& x
=
x
x
Thus,
&
C p
= Q +
t
x x
4-10
Heat Flow
1-D Conduction
To make problem manageable, assume

no internal heat generation

C p
=
t x x
is constant, not dependent on x or temperature
2
Cp
=
t
x 2
t C p x 2
2
=k 2
x
=thermal
diffusivity
m2
sec
4-11
Heat Flow
Conservation of Energy (Cont)
t = 0, = 1
= 0
t = 0, = 0
x
1
t = steady state
2
0
4-12
Heat Flow
1-D Conduction
Steady State without Internal Heat Generation
0 0
& 1
=Q+
2
t
x
2
Giving,
2
x
=0
General Solution
= c1
x
= c1 x + c2
4-13
Heat Flow
Concept of Thermal Resistance
q&
R thermal =
2
V1
q&
V1 V2
R electrical =
i
1 2
V2
4-14
Heat Flow
Concept of Thermal Resistance
but
2
1
q& = A
= A
= A
L
L
x
R thermal =
1 2
L
=
1 2
A
4-15
Heat Flow
Composite Walls
x
1
2
L2
L1
1
R1
R2
3
4-16
Heat Flow
1-D Conduction with Mass Movement
Consider an extrusion process

die
x
v
dx
CV x
CV x + dx
q& x
q& x + dx
Q&
dx
x
x+dx
4-17
Heat Flow
Applying conservation of energy to the control volume
C
Adx = Q& Adx + q& x A q& x + dx A + CV x A CV x + dx A
t
Using Taylor series expansion and simplifying
& q& x
=Q
CV
C
t
x
x
Using Fouriers Law of Conduction
&
2
= Q + 2 CV
C
t
x
x
4-18
Heat Flow
In this case if you look at some location x with respect

to time, the temperature at that location will remain
constant (assuming we are past the transients from
starting the process). Therefore, we can model this as
a Quasi-Steady problem.
0
&
2
C
= Q + 2 CV
t
x
x
2
&
0 = Q + 2 CV
x
x
4-19
Heat Flow
If the cross section of the rod is small, we can assume

that the temperature is constant at every cross section.
In that case we can consider the heat loss due to
convection as a negative internal heat generation rate.
Consider some cross section of area A and perimeter P
P
A
hP
&
&
( )
QAdx = hPdx( ) Q =
A
4-20
Heat Flow
Therefore,
Let
Giving,
hP
2
( ) = 0
2 CV
x
x A
'
2 ' 2
' = ( ),
=
, and
= 2
2
x x
x
x
2 ' V ' hP
'= 0
2
x
x A
Solving,
2
2
V
V
hP
V
V

hP
x + C2 exp
+
+ +
x
' ( x) = C1 exp
2
2
2 A
2 A
4-21
Heat Flow
Applying the boundary conditions.

As
then
'= 0
2
2
V
V
V hP
V hP
+
+ C2 exp
+ +
' ( x = ) = C1 exp
2
2
2 A
2 A
Since the second term goes to infinity than
C2 = 0
4-22
Heat Flow
At
x=0
then
' = ( die ) = 'die
V
V
hP

0
' ( x = 0) = 'die = C1 exp +
2 A
2
Therefore,
C1 = 'die
giving,
V
V
hP

x
' ( x) = 'die exp +
2 A
2
4-23
Heat Flow
Heat Flow with Moving Coordinate System
Consider a very large and very thin plate thickness (h)
y
x
1
dy
d
dw
w
2
4-24
Heat Flow
o
3
quasi - steady
5
6 7
4
final
ttransient
i t
2
1
time
Moving with the welding arc in quasi-steady region, the temperature is
constant with respect to time. Form a new moving coordinate system:
w = x Vt
4-25
Heat Flow
q& y + dy
( C V )
p
q& w
( C V )
dy h
dy
C p Q&
w + dw
dy h
q& w+ dw
dw
q& y
4-26
Heat Flow
Balance heat flow in y direction,
q&
( q& y q& y +dy ) dw h = y dy dw h
Balance heat flow in w direction,
( q&w q&w+ dw ) dy h + ( C pV )w+ dw ( C pV )w dy h =

q&
dw dy h +
C pV ) dw dy h
(
w
w
4-27
Heat Flow
Conservation of energy for control volume
q&
q&
&
C p
dydwh = Q dydwh
dwdyh +
C pV ) dwdyh
(
t
y
w
w
Using Fouriers Law of Conduction
&
C p
=Q+
+
t
w w y y
Conduction

C p v w )
(
+
w
Convection
4-28
Heat Flow
Assuming constant properties and constant heat source

velocity.
2
2
&
C p
=Q+
+
+ C pV
2
2
t
w
y
w
For quasi-steady,
2 2
V
+ 2 =
2
k w
w y
4-29
Heat Flow

3-D Solution for Semi-infinite Plate
Assuming constant properties and constant heat source

velocity.
2
2
2
&
C p
=Q+
+
+
+ C pV
2
2
2
t
w
y
z
w
For quasi-steady,
2 2 2
V
+ 2 + 2 =
2
k w
w y
z
4-30
Heat Flow

4-31
Heat Flow

4-32
Heat Flow

4-33
Heat Flow

2-D Solution for Thin Plate
4-34
Heat Flow

2-D Solution for Thin Plate
4-35
Heat Flow
Cooling Rate Equation
4-36
Heat Flow
4-37
Heat Flow
4-38
Heat Flow

Peak Temperature Equations
At the peak temperature the slope of the temperature

time curve must be zero.
o
at peak
=0
t
t
4-39
Heat Flow

We previously derived
V
( w+ r )
P
= V
e 2
t
2 r
Therefore,
t
w V w
r 2 2 1 + r = 0
w V w
2
1 + = 0
r
2
r
Find relationship between w and r when the point

of interest reaches the peak temperature and then
use thick plate solution to find peak temp.
peak o =
P
2 r
V
( w+ r )
2
4-40
Heat Flow

We force the eq. to fit experimental results by specifying a
known temperature r at known location rr . Then,
e
2
2
c p r rr
1
1
2
+
=
a EI
p o
r o
V
For example, at fusion boundary m is the known peak
temperature and r=d/2 where (d) is the weld bead with is

known location. Then,
1
=
p o
e
c p
2
d
y2
1
+
a EI
m o
V
4-41
Residual Stress and Distortion

Module 4B
Linear Elastic Material
6 stress strain Equations

1
x = x ( y + z )
E
1
y = y ( x + z )
E
1
z = z ( x + y )
E
E - modulus
xy =
Hooks Law Uniaxial Loading x =

Poissons ratio y =
x
E
yz =
z =
x
E
zx =
xy
G
yz
G
zx
G
4-43
Typical Material (Metal)
yield stress
Use linear elastic

perfectly plastic model
4-44
Thermal Strains
x = y = z = = ( o )
= coefficient of thermal expansion
xy = yz = zx = 0
total strain=elastic strain + thermal strain
t = e +
4-45
Linear Elastic Perfectly Plastic Material
= + +
t
elastic plastic thermal

4-46
Example
Steel Bar between two rigid walls
E = 20 106 psi
x
Heating - Elastic Range
=0=
t
x
x
E
Fy = 50 103 psi
= 3.8 10
1
o
F
psi
x = E = 114 o
F
4-47
Simple Distortion Example (Transverse Shrinkage)

Restraint and Temp. Distribution
heating
Heating
k
l x
x = =
+ + p
l
E
x A = k l l =
at heating (thermal stress)
x
k
x
p

A=
+ +
kl
E
x =
E k l + p
E A+ k l
4-48
Small
No plastic strain
Then,
=0
p
EKl ( )
x =
EA + Kl
At the end of cooling there will be no

residual stress and no distortion.
4-49
Large at end of heating
Assume
Calculate
p =0
EKl ( )
x =
EA + Kl
x > Fy
If
then,
p 0
and
x = Fy
A 1
= Fy +
Kl E
p
4-50
Large at end of Cooling
Assume no additional plastic deformation

occurs during cooling.
Calculate
If
x < Fy
( )
EKl p
x =
EA + Kl
then, no plastic deformation occurred
during cooling, and

If
x > Fy
xres
( )
EKl p
=
EA + Kl
then, plastic deformation occurred
during cooling, and
x = Fy
A 1
= Fy +
Kl E
p
4-51
Three Bar Analogy

Suppose we have 3-bar which have the same cross section
area A and same material properties.
heating
4-52
Three Bar Analogy

Jig or fixture used (restraint) during heating
z
Small heating
tm =
+ + mp , mp = 0
E
m = E
comp. spring case
p =0
tx = 0
4-53
Significance of Residual Stress and Distortion

Residual Stress
z
z
z
Degraded Structural Performance

Reduced Service Life
Dimensional Instability
Distortion
z
z
z
z
Dimensional Tolerance and Fit-up Problems

Reduced Strength
Reduced Structural Stability
Inadequate Appearance
4-54
Welding Processes and Their Consequences

During Welding
z
z
z
z
z
z
z
Localized Heat Source (heating, melting solidification, and cooling)

Non-uniform Temperature Distribution (thermal/mechanical mismatch)
Fast Cooling Rate (phases with volume expansion)
Weld Shrinkage (shrinkage strains created in weld & surrounding
metal)
R t i t (internal
Restraints
(i t
l rigidity
i idit and/or
d/ external
t
l constraints
t i t preventing
ti
shrinkage)
Initial Stress Condition (influence thermal strain and residual stress)
Properties of Parent Material (temperature dependent yield stress and
Modulus of elasticity)
After Welding
Residual Stresses
Distortion
4-55
Residual Stresses & Distortion Flowchart
4-56
Factors Influencing Residual Stresses & Distortion

Physical Material Properties
z
Coefficient of thermal expansion, [ (1/K)]

As increases distortion increases
Thermal conductivity, (W/(mK))

As increases distortion decreases
Mechanical Material Properties

z
Yield stress, Fy (ksi), modulus of elasticity, E(ksi)
Welding Process Variables

z
Heat input, travel speed, welding sequence
Jigs and Fixtures or other Clamping Devices

Geometrical Properties
z
Moment of inertia, weld cross sectional area, weight of weld metal,

plate thickness, joint geometries, weld length
4-57
Comparison of Material Properties
Properties
Mechanical Properties
Thermal Properties
Fult
[MPa]
Fy
[MPa]
e
[%]
E
[GPa]
CTE 20 C
[mm/mC]
rCp
[J/m3/C]x1
06
l
[W/m-K]
Tm
[C]
Tliq
[C]
NICKEL BASE
INCONEL 718
1375
1100
25
207
13
3.56
11.4
1298
1336
TITANIUM
TI-6AL-4V
1170
1100
10
114
8.6
2.33
6.7
1660
1660
ALUMINUM
2014
185
95
18
72.4
23
2.46
192
507
638
STAINLESS
STEEL 304
505
215
70
197
17.3
4.00
16.2
1427
1455
Materials
4-58
Non-Linear Distribution of Temperature and

Resulting Residual Stress
DT = 0
Stress = 0
x
A
B
C
1. Section A-A
Y
g
Melted region
C
Plastic deformation
occurs
Tension
2. Section B-B
Compression
D
3. Section C-C
DT = 0
Residual stresses
4. Section D-D
Reference: Welding Handbook, Volume 1, AWS, 1991
4-59
Residual Stresses in Butt Joint

Y
Compression
(A) Distribution of x Along YY
Tension
y
curve 2
Reaction
stress
Tension
curve 1
Compression
Reference: Welding
Handbook, Volume 1,
AWS, 1991
(B) Distribution of y Along XX
4-60
Fundamental Types of Weld Distortion

(a) Transverse Shrinkage
(d) Longitudinal Shrinkage
(b) Angular Change
(e) Longitudinal Bending
(c) Rotation Distortion
(f) Buckling Distortion
4-61
Compatibility
y
x
4-62
Compatibility
2-D Elastic Compatibility
2 y
2 xy
x
R=
+ 2
=0
2
y
x
x y
2
2-D Inelastic Compatibility
2 x 2 y 2 xy 2 x 2 y 2 xy
R + R = 2 + 2
+ 2 + 2
=0
x
x y y
x
x y
y
Elastic
Inelastic
(thermal & plastic)
4-63
Rotational Distortion in Butt Joints
Unwelded Portion of
the Joint Closes
Back Weld to Maintain Joint Opening
Unwelded Portion of
the Joint Opens
In-Plane Distortion Due to Cutting
Reference: Masubuchi, K. Analytical Investigation of Residual Stresses and
Distortions Due to Welding. Welding Journal 39 (12): 525s-537s (1960)
4-64
Longitudinal and Transverse Weld Shrinkage

in Butt Joints
4-65
Effect of Groove Detail and Joint Thickness

on Transverse Shrinkage
Transverse Shrrinkage (in.)
0.15
0.10
0.05
1/4
Area of Weld (in.2)
Reference: Design of Weldments, Omer W. Blodgett, 1976
1/2
3/4
1-1/4
1-1/2
Plate Thickness (in.)
4-66
Effect of Weight of Weld Metal on Transverse

Shrinkage
Increases of Transverse Shrinkage During Multipass Welding of A Butt Joint

Reference: K. Masubuchi, Analysis of Welded Structure, Pergamon Press
4-67
Transverse Shrinkage Causing Angular Distortion
Non-uniform Transverse Weld Shrinkage in

Butt Joints
Transverse Weld Shrinkage in Fillet Welded Tee-Joints

4-68
Moment of Inertia Effect on Angular

Distortion in Butt Joint
Balancing
g the Multi-pass
p
Weld Decreases Angular
Distortion of Butt Joints
4-69
Moment of Inertia Effect on Angular Distortion in

Tee-Joint
Throat
CG of welds
Neutral
axis
Throat
CG of welds
Moment arm
(a) Fillet Weld T

T- Joint
Moment arm
Neutral axis (b) Deeper Penetration Weld
4-70
Angular Change in Fillet Welds Unrestrained

Angular Change of Unrestrained Fillet Weld
(A) Steel
(B) Aluminum
Determination of the Angular Change of Unrestrained Steel and Aluminum Fillet

Welds by Plate Thickness and Fillet Weight per Unit Length of Weld
4-71
Angular Distortion in Fillet Welded Framing

Structures
o
(A)
Free Joint (Unrestrained)
(B) Restrained Joint

4-72
Angular Distortion
L
Angular Pipe Bending
Longitudinal Bending
4-73
Effect of Fillet Weld Size on Longitudinal

Deflection
Effect of Fillet Weld Size on

Longitudinal Deflection in TSection Beams
Reference: Welding Handbook Volume 1, AWS, 1991
4-74
Distortion Comparison Between Steel and

Aluminum Weldments
Transverse Shrinkage of Butt Joint
Aluminum > Steel

Longitudinal Bending Distortion
Aluminum < Steel
4-75
Distortion Comparison Between Steel and

Aluminum Weldments
Angular Change of a Fillet Weld
Reference: Welding Handbook,Volume 1, AWS, 1991
Al < St
4-76
Reduce the Amount of Welding Decrease Weld

Deposit
Reduce bevel
angle and use larger
root opening
30
1/32 to 1/16
U preparation
Double-V preparation
Example: Edge Preparation and Fitup

4-77
Reduce the Amount of Welding

Using Intermittent Welding Technique
Decreasing Length of Weld by Using

Intermittent Welding Technique
4-78
Reduce the Amount of Welding Decrease Leg Size
Decrease Leg Size of Weld Decrease Shrinkage Force

and the Tendency to Distortion
4-79
Minimize Welding Time
(a) 170 amp 25 volt 3 in/min Thick Plate
Variance of Welding
Technique. In Each Case,
Surface Isotherm of 300F is
Shown Surrounding Welding
Source
(b) 170 amp 25 volt 6 in/min Thick Plate
(c) 340 amp 30 volt 6 in/min Thick Plate Solid Curve

310 amp 35 volt 8 in/min Thick Plate Dashed Curve (Same size weld)
(d) 170 amp 25 volt 22 in/min Sheet (t=0.1345 in)
4-80
Presetting the Joints

Before
Welding
After
Welding
The net effect of weld shrinkage pulls the member or

connection back into proper alignment.
4-81
Examples of Presetting the Joints
(d)
(a)
(b)
(c)
(a) (b) Girder, (c) Plate, (d) Fixing of Groove Gap by Wedge
in Single Pass Gas Welding
Pre-welding Position Traced in Solid Lines
Post-welding Position in Broken Lines
Reference: D. Radaj, Heat Effects of Welding, Springer-Verlag, 1992
4-82
Preheat the Joint
Effect of Preheat and

Welding Variables on
Angular Change of Steel
Fillet Welded T-Joints
Reference: Kihara, H., Watanabe, M., Masubuchi, K., and Satoh, K., Researches on Welding
stress and shrinkage distortion in Japan, 60th Anniversary Series of the Society of Naval
Architects of Japan, Vol. 4, 1959
4-83
Prestrain the Joint
(a) Elastic Prestraining
(b) Plastic Prebending

Reference: Kumose, T., Yoshida, T., and Onoue, H, Prediction of angular distortion
caused by one-pass fillet welding, The Welding Journal, 33, 945-956 (1954)
4-84
Example of Elastic Prestraining
Apparatus for Welding T-Joints Submitted to

Elastic Prestrain by Bolting Down Both Free Ends
4-85
Examples of Plastic Prestraining
(b)
(a)
( )
(c)
(d)
(e)
(a) Roof Shaping of Girder Chords
(b) Plane End Section of Cylindrical Shell
(c) Outward Bulging of Spherical Shell with Block Flange
(d) Outward Bulging of Pipe with Circumferential Weld
(e) Inward Drawing of Pipe at Plane End
4-86
Use as Few Weld Passes as Possible

Figure (a)
Poor
Good
Figure (b)
Minimum Number of Passes
4-87
Place Welds Near the Neutral Axis
4-88
Plan the Welding Sequence

Welds are Symmetrical about Neutral Axis
No. 4
3/16 to 3/8
mild steel
channel x
No. 2
No. 1
(a)
No. 3
No.1
No.1
(b)
No.2
(c)
4-89

Welds are Symmetrical about Neutral Axis
No.4
No.1 No.4
No.2
No.3
(d)
No.1
No.1
No.3
(e)
(f)
4-90

Long and Thin Box Sections
(a) During Welding, Top Expands

- Center Bows Up
Temperature
Distribution - Cross
Section
(Turn the Members

Quickly to Protect the
Weld from Cooling)
(b) Shortly after Welding Still Bowed up Slightly
(c) After Cooled - End Very

Slightly Bowed up due to
Contraction of Top
4-91
Place Welds Near the Neutral Axis

Three -Member Column
9
1-3/4
2-1/2
2-1/2
5/8
Neutral
axis
0 682
0.682
CG of welds
(a)
Neutral
axis
0 556
0.556
CG of welds
(b)
4-92
Plan the Welding Sequence Multi-Layer Welding
4
1
2
3
An Example of a Double V-Groove Butt Joint. Suitable Welding
Sequence in Multi-layer Welding can Reduce Angular Distortion
4-93
Plan the Welding Sequence Multi-Layer Welding
(a)
(b)
(c)
Reduction of Angular Distortion by Alternating Weld Pass

Deposition in Double-V Groove
4-94
Plan the Welding Sequence Backstep Welding
Direction of
each bead
segment
B
3
2
C
A
Direction
of Welding
4-95
Plan the Welding Sequence Backstep Welding
Reduction of Transverse Shrinkage as well as Groove Gap

Distortion by Back-Step Welding: Tack Weld Sequence (a), BackStep Welding Sequence in First Layer (b) and Cover Pass (c)
4-96
Distortion Control by Welding Sequence

Welding Sequences
Unwelded Spaces Filled After
Deposition of Intermittent Blocks
(A) Backstep Sequence
(C) Built-up Sequence

Reference: K. Masubuchi, Analysis of Welded Structure, Pergamon Press
(B) Block Sequence
(D) Cascade Sequence

4-97
Methods of Removing Distortion

Flame (Thermal) Straightening
Line heating
Pine-needle heating
Heating in cross section
Spot heating
Triangular heating
Red-hot
R dh th
heating
ti
Reference: Analysis of Welded Structures, Koichi Masubuchi
4-98

Line Heating
Pine-needle Heating
Heating in Cross
Directions
4-99

.........
.........
.........
Spot Heating
Triangular Heating
Red-hot Heating
4-100

(a) Spot Shape
(b) Strip Shaped
(c) Wedge Shaped
Application of Flame Straightening

4-101

(a)
(c)
(b)
(d)
Flame Straightening by Means of Heat Strips and Heat Wedges in

Different Arrangement on Bending-Distorted Girders
Reference: Vinokurov, V. A., Welding stresses and distortion, Wetherby:British Library 1977
4-102
Fracture and Fatigue

Module 4C
Fatigue and Fracture
Linear Elastic Fracture Mechanics
For a perfect solid, the tensile strength

T can be related to Young' s modulus
for the material E.
E
E
to
T =
10
20
For glass, this would be T = 10 6 psi

while actually it is 5 103 to 105 psi
4-104
Brittle Fracture
Griffith glassy materials contain crack like defects which act
as stress raisers.
2 E s
c =
c
s = surface energy
2c
of fracture
c
4-105
Brittle Fracture
For long sharp cracks
c
c
SCF 1 + 2
2
a
a
E
For T = , one gets
10
E a
gives similar results to Griffith' s Criterion
c
20 c
Back calculating crack lengths in glasses,
one gets lengths of order 25 to 2500
atomic distances or 100 - 10,000 A o
4-106

Mode I
22
x2
r
x1
plastic
zone R p
2c
22
4-107
KI = c
x
z
2c
For r=0 stresses are infinite!

Is this realistic?
4-108
y
x
z
x
z
Mode II
Mode III
4-109
Stress Intensity Factors

Stress intensity factor is used to find the stress distribution
and magnitude near the crack tip. It is a function of:
= applied stress
c = half crack length (full crack length for edge cracks)
w= characteristic dimension for the part
c
K ( , c, w) = f c
w
Determined analytically or experimentally as well as by
finite element analysis.
4-110
Fracture Toughness (Kc)

Kc is a material property which indicates the stress intensity
factor above which crack extension will occur
KIC (the plane strain value of Kc) is a linear elastic facture
mechanics parameter which can be used for brittle fracture
z
For real materials, some plastic deformation will occur near the crack
tip.
Linear elastic
Fy
Real material
rp
x
4-111
Fracture Toughness
For plane stress, the size of the plastic zone is found from
Fy =
KI

cos 1 + sin sin
2
2
2 rp
2
where for =00
Fy =
For plane strain,
KI
2 rp
1 K I
rp =
2 F y
1 K I
rp =
6 F y
For LEFM the size of the plastic zone must be small

4-112
Fatigue
Fatigue failure resulting from cyclic deformation with large
plastic strain amplitude is called low cycle fatigue
z
Failure usually occurs in ten to several hundred cycles
Fracture resulting from many thousands of stress cycles

g cycle
y
fatigue
g
below the elastic limit are called high
Phases for Fatigue Failure

z
z
z
Crack initiation stress concentrations at grain boundaries or flaws

Crack propagation The crack propagates on every cycle of loading
Fracture crack long enough for fracture to occur when maximum
stress is reached
4-113
Stress amplitude
S-N Curve
Ferrous
Non-ferrous
am N = C
Fatigue Limit
Log N
4-114
Nonzero Mean Stress
Stress ratio
Stress
R = min
max
Tension-compression
R = 1
max
a
mean
a
min
Time
4-115
Goodman Diagram
10 3 cycles
a m
+
=1
a ult
o
10 4 cycles
constant life lines
10 5 cycles
10 6 cycles
ult
Mean
Stress
4-116
Goodman Diagram
max
constant life lines
10 3 cycles
uultt
10 4 cycles
10 5 cycles
10 6 cycles
min
4-117
Fatigue With Varying Stress Amplitude

Miners Rule
Miners Rule each cycle uses a fraction of the fatigue life.
ni
=1
i =1 N i
For fully reversible tension-compression loading from S-N curve one gets,
ni m
i =1
i =1 C
4-118
Fatigue of Welded Joints

The presence of welded member usually results in drastic
reduction in fatigue life or stress

Causes: Stress Concentrations generally a weld introduces
stress concentrations
Steel
R=0
10 5
10 6
10 7
108
4-119
Joint Design
Module 4D
Joint Design
Common Design Requirements

Proper Weld Design to Meet Following Requirements
z
z
z
z
Strength against rupture (excessive yielding)

Toughness against fracture, especially under dynamic or impact
loading (brittle fracture)
Ductility (ability to stretch) to prevent welding-induced cracking or
cracks due to excessive deformation
Fatigue resistance against cyclic loading
4-121
Joint Design
Essential and Related Design Factors

Proper Weld Design to Meet Following Requirements
z
Materials
Base Metal (e.g. ASTM A36)
Filler Metal (e.g. AWS A5.1)
z
z
Joints/Welds
Welding Process(es)/Procedure Qualification
Joint Thickness
Pipe Outside Diameter
Welding Position
z
z
z
Welder Qualification (per qualified procedure)

Workmanship (including distortion control, heat treatment)
Inspection
4-122
Joint Design
Aspects of Weld Design

Structural Connection Design Elements
Types of Joints and Welds (AWS A3.0 - Standard Terms and
Definitions)
Welding/NDE Symbols (AWS A2.4 Standard Symbols for
Welding, Brazing, and Nondestructive Examination)
Design for Strength
Design for Fracture Resistance
Design for Fatigue Resistance
Effect of Residual Stress and Distortion
4-123
Joint Design
Structural Connection Design Elements

Connection Types
z
z
Nontubular (i.e., plate)

Tubular
Basic Joint Types

z
z
z
z
z
Butt Joint
Tee Joint (including skewed-T)
Lap Joint
Corner Joint
Edge Joint
Basic Weld Types

z
Groove (CJP, PJP)

Further classifications see AWS
A2.4 and A3.0
z
z
z
z
Fillet
Plug and Slot
Continuous vs
vs. Intermittent
Others for Thin Joints: Spot,
Seam
Welding Positions
z
z
z
z
z
Flat (1-G or 1-F)

Horizontal (2-G or 2-F)
Vertical (3-G or 3-F)
Overhead (4-G or 4-F)
Combination (5-G, 6-G, 6-GR)
4-124
Joint Design
Basic Joint Types

Butt joint
z
Continuity of section
Tee joint
z
Flanges or stiffeners
Lap joint
z
No jjoint p
preparation
p
Corner joint
Edge joint
z
Two or more parallel, or nearly

parallel members
4-125
Joint Design
Joint Type Examples
Weld Face
Reinforcement
Butt
Lap
Edge
Tee
Corner
4-126
Joint Design
Basic Joint Type Extension Flanged Joints
Flange T-Joint
Flange Butt Joints

Flange Edge Joints
Flange Corner Joint
Flange Lap Joints
4-127
Joint Design
Butt Joint Extension Spliced Joints

Single-Spliced Butt Joint
Splice Member
Joint Member
Double-Spliced Butt Joint
Splice
Member
Joint Member
Joint Filler
4-128
Joint Design
Edge Shapes of Members
Square
Double-J
Single-Bevel
Flanged Edge
Double-Bevel
Round Edge
Single-J
Round
Edge
4-129
Joint Design
Joint Design Variables
Root Opening
Groove Radius
Included Angle
Root Face (Land)
Dihedral Angle
4-130
Joint Design
Basic Types of Weld

Fillet
Square Groove
Single-V
Groove
Double-V
Groove
Single-U
Groove
Double-U
Groove
Single-Bevel
Groove
Double-Bevel
D
bl B
l
Groove
Single-J
Groove
Double-J
Groove
4-131
Joint Design
Basic Types of Weld
4-132
Joint Design
Groove Weld Examples
Single-Square-Groove Weld
Single-V-Groove Weld
Single-Bevel-Groove Weld
Single-V-Groove Weld
(with Backing)
4-133
Joint Design
Single Groove Weld

Single-Groove
Single-Flare-Bevel-Groove Weld
Single U Groove Weld

Single-U-Groove
Single-Flare-V-Groove Weld
4-134
Joint Design
D bl S
Double-Square-Groove
G
Weld
W ld
Double-Bevel-Groove Weld
Double-V-Groove Weld
Double-J-Groove Weld
4-135
Joint Design
Double-U-Groove Weld
Double-Flare-V-Groove Weld
Double-Flare-Bevel-Groove Weld
4-136
Joint Design
Flare and Edge Welds
Square-Groove Weld and

Flare-V-Groove
a e G oo e Weld
e d in a
Flanged Butt Joint
Edge Weld in a
Flanged Butt Joint
Edge Weld with Melt-through in
a Flanged Butt Joint
4-137
Joint Design
Fillet Weld Examples
Double Fillet Weld
Single Fillet Weld

4-138
Joint Design
Weld Quantities Comparison

(a)
(b)
(c)
Area = 0.56t2
Area = 0.25t2
Area = 0.50t2
Double-BevelGroove Weld
Single-BevelGroove Weld
S=0
0.75t
75t
S
Double-Fillet Weld
4-139
Joint Design
Estimated Relative Costs
Relative C
Cost
20
10
0
0
0.5
1.0
1.5
Plate Thickness, in.
2.0
4-140
Joint Design
Plug/Slot Weld vs. Fillet Weld in Hole
Plug Welds
Fillet Welds
Slot Welds
4-141
Joint Design
Weld Joint Nomenclature

1
6
2
2
5
3
4
1 - groove angle
2 - bevel angle
3 - root face (land)
4 - root opening (root gap)
5 - groove face
1 - throat
2 - weld face
3 - depth of fusion
4 - root
5 - fillet leg length
6 - weld toe
4-142
Joint Design
Groove Weld Nomenclature

Face
Reinforcement
Weld Face
Weld Toe
Root
Reinforcement
Root Surface
Weld Root
4-143
Joint Design
Groove Weld Nomenclature

Groove Weld Made
Before Welding Other Side
Face
Reinforcement
Face
F
Reinforcement
Back Weld
Groove Weld Made

After Welding Other Side
Weld Root
Backing Weld
4-144
Joint Design
Fillet Weld: Convex and Concave

Convexity
Actual Throat
Leg & Size
Effective
Throat
Leg & Size

Leg
Concavity
Theoretical Throat
Size
Actual Throat
Effective throat
Size Leg
Theoretical Throat
4-145
Joint Design
Effective Weld Throat for Design Calculations
Convexity
Concavity
4-146
Joint Design
Welding Technique
Stringer Bead
Weave Bead
4-147
Joint Design
Weld Beads vs. Weld Layers

Weld Beads
Layers
Weld Beads
Layers
4-148
Joint Design
ASME Section IX
Joint Procedure Variables
Paragraph
Brief of Variables
Essential
Supplementary
Essential
Nonessential
.1
Groove Design
.2
Backing
.4
- Backing
.5
+ Backing
.6
6
> Fit-up Gap
.10 Root Spacing

QW-402
Joints
.11
Retainers
.18 Lap Joint Configuration
X
X
4-149
Joint Design
ASME Section IX
Base Material Procedure Variables
Paragraph
Brief of Variables
.2
.3
.6
Q
QW-403
03
Base
Materials
Maximum T Qualified
Penetration
Essential
Supplementary
Essential
Nonessential
X
X
T Limits
.8
T Qualified
.9
9
t pass > 1/2-in

1/2-in.
.10 T Limits (S. Cir. Arc)
4-150
Joint Design
ASME Section IX
Technique Procedure Variables
Paragraph
Essential
Nonessential
.1
Stringer/weave
.7
Oscillation
.9
Multiply to Single Pass/Side
.21
QW-410
QW
410
Technique
Brief of Variables
Supplementary
Essential
1 vs. 2 Sided Welding
26
.26
Peening
.37
Single to Multiple Passes
X
X
4-151
Joint Design
Welding Sequence
Backstep
Block
(Unwelded spaces
filled after welding of
intermittent blocks)
Cascade
4-152
Joint Design
Special Purpose Welds
Staggered
Intermittent
Fillet Weld
Boxing
(End Return)
Chain
Intermittent
Fillet Weld
4-153
Joint Design
Welding Position
1G
1F
1G
2F
3F
5G
4G
1 - flat
2 - horizontal
3 - vertical
4 - overhead
2G
2G
3G
F - Fillet weld
G - Groove weld
6G
4F
4-154
Welding Symbols
Module 4E
Welding Symbols
Standard Location of Elements

Key Elements
z
z
z
z
z
z
z
Arrow
Reference Line
Tail
Weld Symbols
Supplementary
Symbols
Other Details
Only the REFERENCE
LINE and ARROW are

required
Reference line are
always horizontal
Symbol without L-P denotes continuous welds
4-156
Welding Symbols
Symbol Dimensions?
Tolerances, if required, are to be placed in tail
Welding Symbols are usually drawn without dimension units
such as inches or millimeters
But, Welding Symbols to be used for publications or those
requiring high precision should be dimensioned and have the
dimensional tolerances noted within the tail.
4-157
Welding Symbols
Weld Symbols
NOTE:
(1) The reference line is
shown dashed for
illustrative purposes.
(2) Symbols with a
perpendicular leg shall have
the perpendicular leg drawn
h left
l f side
id off the
h
on the
symbol (fillet, bevel-, J-, or
flare-bevel-groove)
Source: AWS A2.4:2007

4-158
Welding Symbols
Supplementary Symbols
Significance of arrow
z
z
Arrow side below reference line

Other side above reference line
4-159
Welding Symbols
Arrow and Other Side Convention Examples
Below reference line
Weld Cross Section
Symbol
Above reference line
Both sides of
reference line
Weld Cross Section
Symbol
Weld Cross Section
Symbol
4-160
Welding Symbols
Break in Arrow of Welding Symbol Examples
Weld Cross Section
Symbol
Weld Cross Section
Symbol
Weld Cross Section
Symbol
4-161
Welding Symbols
Combined Weld Symbols

Combined Weld Symbols
Multiple Arrow Lines
4-162
Welding Symbols
Combined Weld Symbols Examples
Weld Cross Section
Symbol
Weld Cross Section
Weld Cross Section
S b l
Symbol
Symbol
Weld Cross Section
4-163
Welding Symbols
Specification of Extent of Welding Use Multiple

Arrows
Welds
Welds
Symbols
Symbols
4-164
Welding Symbols
Supplementary Information
Supplementary Data
Hidden Members of the

Same as a Visible Member
2 ANGLES
PROCESS
DATA
(CO STD)
TYPICAL
BOTH
ANGLES
Omission of Tail When No References are Required
4-165
Welding Symbols
Field Weld and All-Around Symbol

Flag indicated field weld
Circle indicates that the is to continue along the entire joint
length (i.e., weld all around)
4-166
Welding Symbols
Specification of Extent of Welding Using

Weld All-Around Symbol
SYMBOL
WELDS
SYMBOL
WELDS
4-167
Welding Symbols
Extent of Welding Denoted by Symbols

Using Weld All-Around Symbol
Weld in Several Planes
Weld Around a Shaft
4-168
Welding Symbols
Location and Extent of Fillet Welds
WELDS
Size
Length and
Pitch
SYMBOLS
Welds Approximately
Located
Welds Definitely Located

4-169
Welding Symbols
Length and Pitch of Intermittent Welds
Chain
Intermittent
Welds
WELDS
SYMBOL
Staggered
Intermittent
Welds
WELDS
SYMBOL
4-170
Welding Symbols
Dimensions of Plug and Slot Weld
Partially Filled
Plug Weld
Partially Filled
Slot Weld
4-171
Welding Symbols
Melt-Through Symbol
4-172
Welding Symbols
Melt-Through with Flange Welds
Edge-Flange
Corner-Flange
4-173
Welding Symbols
Application of Typical Welding Symbols Using

Tail
4-174
Welding Symbols
Specification of Extent of Welding Using Tail of

the Welding Symbol
4-175
Welding Symbols
Specification of Completed Weld Using the

Welding Symbol
The weld tail can specify the final contour of the weld as well
as any addition processing steps require to achieve the
contour
Weld Contours and Finishing of Welds
Weld Contours
Flush
Flat
Convex
Concave
C Chipping
G Grinding
H Hammering
M Machining
R Rolling
U - Unspecified
4-176
Welding Symbols
Supplementary Information
The weld tail can also include supplementary information
important the welder/supervisor
z
z
Welding procedure
Additional/specific welding dimensions or tolerances
Tail of the Welding Symbol
Welding Process Spec.
Details of Special
Types of Welds
References
Designated Typical Situations
Weld Dimension
Tolerance
4-177
Welding Symbols
Flush and Convex Contour Symbols
Arrow side flush contour symbol
Other side flush contour symbol
Both sides convex contour symbol

4-178
Welding Symbols
Standard Location of NDE Elements
4-179
Welding Symbols
Standard Location of NDE Elements

The NDE Key elements are similar to the welding key
elements
z
z
z
z
z
z
Reference Line
Arrow
Examination Method Letter
Designations
Extent and Number of
Examinations
Supplementary Symbols
Tail (specifications, codes
or other references)
Examination Method Letter

Designations
Acoustic emission
Electromagnetic
Leak
Magnetic practical
Neutron radiographic
Penetrant
Proof
Radiographic
Ultrasonic
Visual
AET
ET
LT
MT
NRT
PT
PRT
RT
UT
VT
4-180
Welding Symbols
Combined Welding and NDE Symbols

Welding and NDE symbols can be combined on the same
reference line, or on separate multiple reference lines

Combining welding and NDE symbols on multiple reference
lines often clarifies the exact sequence of operations required
UT
4-181
Welding Symbols
NDE Locations
RT
MT
UT
VT
ET
PT
VT
MT
MT
LT+PRT
RT
UT
AET
PT
UT+RT
NDE Combinations
Welding & NDE Symbols
Field Examination
Examine-All-Around
4-182
Welding Symbols
Examples of NDE Symbols

Number of
Examination
MT symbol, both sides for 6 inch length

RT symbol, with
angle of radiation
incidence
Specifications, Codes,
and References
Length to be Examined
Partial Examination
4-183
Welding Symbols
Examples of NDE Symbols

Plane Areas
Area of Revolution
Acoustic Emission
Area of Revolution
4-184
Welding Symbol Applications
Welding Symbols
Complete Joint Penetration with Optional Joint

Geometry
4-186
Welding Symbols
Groove Weld Size & Depth of Bevel Not Specified
4-187
Welding Symbols
Specification of Groove Weld Size (E) Only
Double-V-groove weld with root opening
4-188
Welding Symbols
Groove Weld Size without Depth of Bevel

Specified
4-189
Welding Symbols
Specification of Groove Weld Size (E) and

Depth of Bevel (S)
4-190
Welding Symbols
Combined Groove and Fillet Welds
4-191
Welding Symbols
Root Opening of Groove Welds
4-192
Welding Symbols
Groove Angle of Groove Welds
Groove angle is placed just outside the weld symbol

4-193
Welding Symbols
Groove Angle of Groove Welds
4-194
Welding Symbols
Back or Backing Weld Symbol
Back Weld Symbol
Backing Weld Symbol

4-195
Welding Symbols
Single-V-Groove Weld with Backing
4-196
Welding Symbols
Application of the Consumable Insert Symbol
Joint with Welding Symbol
Joint Geometry with Insert in Place
Joint with Root Pass Combined

4-197
Welding Symbols
Groove Welds with Back Gouging
4-198
Welding Symbols
4-199
Welding Symbols
4-200
Welding Symbols
Skewed T-Joint
4-201
Welding Symbols
Size of Fillet Welds
4-202
Welding Symbols
Length of Fillet Welds
4-203
Welding Symbols
Staggered Intermittent Fillet Welds
4-204
Welding Symbols
Chain Intermittent Fillet Welds
4-205
Welding Symbols
Applications of Stud Weld Symbols
4-206
Welding Symbols
Applications of Surfacing Weld Symbols
4-207
Welding Symbols
Applications of Surfacing Weld Symbols
Multiple Layers
4-208
Mechanical Testing
Module 4F
Mechanical Testing
Mechanical Testing
There are several different sources for mechanical testing
methods
z
z
AWS B4.0M:2000 Standard Methods for Mechanical Testing of

Welds
Several ASTM standards
There are several different sources for acceptance criteria

iincluding
l di construction
t ti d
documents
t and
d qualification
lifi ti
documents
z
z
z
ASME Section IX Welding and Brazing Qualification

AWS D1.1 Structural Welding Code Steel
API 1104 Welding of Pipelines and Related Facilities
4-210
Mechanical Testing
Mechanical Testing
Testing Methods covered in this module
z
z
z
z
z
Hardness Testing
Tension Test
Bend Test
Fillet Weld Break Test
Fracture Toughness Test
4-211
Mechanical Testing
Hardness Testing
Hardness is shorthand for strength
Can characterize change in properties across a weld
Several standard techniques
z
z
z
z
Rockwell (ASTM E-18)

Brinell (ASTM E 10)
Vickers ((ASTM
S
E92,
9 , E384)
38 )
Knoop (ASTM E384)
Knoop
Brinell
Differences
z
z
z
Indentation load sequence

Indenter shape
Property measured
Indentation depth
Indentation area
Vickers
Rockwell
o
120 angle &

0.2mm radius
Calculation of Hardness Value
Scales related to each other

4-212
Mechanical Testing
Macrohardness Test
Rockwell Test
Brinell Test
4-213
Mechanical Testing
Microhardness Test
Vickers
Knoop
4-214
Mechanical Testing
Hardness Tests, Indenters, and Shapes of

Indention
Brinell Indentor
Rockwell Indentor
4-215
Mechanical Testing
Comparison of Hardness Tests
Microhardness testing often used to characterize

changes in strength across a weld and Heat Affected Zone
4-216
Mechanical Testing
Hardness Relationship to Mechanical Properties

Hardness can be used to estimate material strength
z
Estimated tensile strength of steel

510 * HB, HB<175
490 * HB, HB>175
Estimated yield
strength of steel
0
0.33
33* hardness
(Vickers * 10/3 =
Tensile yield)
HB = Brinell Hardness
4-217
Mechanical Testing
Hardness Scale Conversion

Rockwell C
60
Brinell
654
Vickers
697
Tensile ksi
55
560
595
288
50
481
513
245
45
421
446
212
40
390
412
191
35
327
345
163
30
286
302
142
25
253
266
125
4-218
Mechanical Testing
Tension Test
Summary of Method
z
z
Tension testing of welded joints is done by means of a calibrated

testing machine and devices
The test sample is pulled in tension until the sample fails
Significance
z
Tension test provides information on properties of welded joints: load

b i capacities;
bearing
iti
joint
j i t design;
d i
and
dd
ductility
tilit
4-219
Mechanical Testing
Tension Test Summary of Method
Initial Gauge Length

Test coupon in the loading grips
Stress =
Load
Initial ..Cross Sectional .. Area
Strain =
Elongation
Initial ..Gauge ..Length
4-220
Mechanical Testing
Stress-Strain Curve
Parallel to the
original slope line
Area beneath the entire stressstrain curve up to fracture point

is called TOUGHNESS
0.2% offset
Ductility
Modulus of Resilience
4-221
Mechanical Testing
Tension Test Apparatus
Modern Loading System Computer Controlled
Conventional Loading System

for Tensile Strength Only
4-222
Mechanical Testing
Tensile Test - Specimens

All Weld Metal Tensile Test
z
Determine weld metal ultimate tensile

strength, yield strength, elongation and
reduction in area
Reduced Section Tension Test (RST)

z
Gauge Length
Determine ultimate tensile strength only
Specimens
S
i
shall
h ll be
b tensile
t
il ttested
t d iin
the as-welded condition unless the
procedure qualification requires a
PWHT
4-223
Mechanical Testing
Tensile Test - Procedure

Welding Procedure Qualification
Tension test specimen shall be ruptured under tensile load
z Tensile strength shall be computed by dividing the ultimate total load
by the least cross-sectional area of the specimen as calculated from
actual measurements made before the load is applied
Round Tension Specimen
z
Ultimate Tensile Strength
UTS =
Yield Strength at Specified Offset

Percent Elongation
YS =
f =
Maximum .. Load
D 2
4
Load .. @ ..Offset
D 2
Final ..GaugeL .. Length Original ..Gauge .. Length

Original ..Gauge .. Length
Reduced Section Tension Specimen

Ultimate Tensile Strength
UTS =
Maximum .. Load
Original ..Cross Section .. Area
4-224
Mechanical Testing
ASME Section IX QW-150 Tension Test

QW-151.1, Reduced Section Plate
4-225
Mechanical Testing

QW-151.2, Reduced Section Pipe
z
For pipe diameters greater than 3 in.
4-226
Mechanical Testing

QW-151.2, Reduced Section Pipe
z
For pipe diameters less than or equal to 3 in.
4-227
Mechanical Testing

QW-151.3, Turned Specimen
4-228
Mechanical Testing

QW-151.4, Full-Section Specimens for Pipe
z
For pipe diameters less than or equal to 3 in.
4-229
Mechanical Testing
Tensile Test Acceptance Criterion

Reduced Section Tension per AWS D1.1
z
4.8.3.5 Acceptance Criteria for Reduced-Section Tension Test

The tensile strength shall be no less than the minimum of the specified
tensile range of the base metal used
Reduced Section Tension per ASME Section IX

z
QW-153 Acceptance Criteria Tension Test

To pass the tension test the specimen shall have a tensile strength that is
z
z
z
not less than the minimum specified tensile strength of the base metal, or
not less than the minimum specified tensile strength of the weaker of the two
materials if different strength materials are welded, or
not less than the minimum specified tensile strength of the weld metal when a
weld metal having lower room temperature strength than the base metal is
allowed, or
if specimen breaks in base metal outside the weld or fusion line, the test shall
be accepted, provided the strength is not more than 5% below the minimum
specified tensile strength of the base metal
4-230
Mechanical Testing
Guided Bend Test

Summary of Method
z
The specimens are guided in the bending process by a test fixture that
employs a mandrel with wraparound roller or end supports with
plunger
The maximum strain on the tension surface is controlled by the
thickness of the specimen and the radius of the mandrel or plunger
Significance
z
The ductility of a welded joint
4-231
Mechanical Testing
Bend Test Apparatus
Guided Bend
4-232
Mechanical Testing
Guided Bend Test Specimens
Root Bend
Side Bend
Side Bend
Face Bend
Transverse Bend Test Specimens
Face
Bend
Root
Bend
Longitudinal Bend Test Specimens
4-233
Mechanical Testing
Guided Bend Test Procedure

Specimens shall be bent in jigs
The weld and HAZ shall be within the curved portion of the
specimen if not the specimen shall be discarded

Unless otherwise specified, the specimen shall be tested at
ambient temperature and deformation shall occur in a time
period between 15 seconds and 2 minutes
p
Appropriate surface of the specimen, according to its type,
shall be bent such that it is placed in tension
Specimen shall be bent around the correct size mandrel
(plunger) until the specimen is forced into the die until a 1/8
wire cannot be inserted between the specimen and die, or the
specimen is bottom ejected if the roller type jig is used
When specimens wider than 1-1/2 are tested, mandrel must
be at least 1/4 wider than specimen
4-234
Mechanical Testing
ASME Section IX QW-160 Guided Bend Test

QW-161.1, Transverse Side Bend
4-235
Mechanical Testing

QW-161.2 and 161.3, Transverse Face or Root Bend
4-236
Mechanical Testing

QW-161.6 and 161.7, Longitudinal Face or Root Bend
z
Used to test materials with markedly different bending properties

Largely different properties between different base materials
Largely different properties between the weld metal and base material
4-237
Mechanical Testing

QW-162.1, Bend Test Jigs
4-238
Mechanical Testing

QW-162.1, Bend Test Jigs
4-239
Mechanical Testing

The dimensions of the bend test jig depend on the material
that is being bent
4-240
Mechanical Testing
Guided Bend Test Acceptance Criterion

Bend Test per AWS D1.1
z
4.8.3.3 Acceptance Criteria for Bend Test

No discontinuities greater than 1/8 in any direction
The sum of all discontinuities greater than 1/32 but less than 1/8 should
not exceed 3/8
No corner cracks greater than 1/4 with no visible evidence of slag or other
fusion discontinuity
Bend Test per ASME Section IX

z
QW-163 Acceptance Criteria Bend Test

No discontinuities greater than 1/8 in any direction
Corner cracks shall not be considered unless there is evidence of weld
defect
Corner Crack
Discontinuity
4-241
Mechanical Testing
Fillet Weld Break Test

Summary of Method
z
z
One leg of a T-joint is bent upon the other so as to place the root of
the weld in tension.
The load is maintained until the legs of
the joint come into contact with each other
or the joint fractures
Significance
z
To determine the soundness of

fillet welded joints
4-242
Mechanical Testing
Fillet Weld Break Test Procedure

A force as shown or other forces causing the root of the weld
to be in tension shall be applied to the specimen
The load shall be increased until the specimen fractures or
bends flat upon itself
If the specimen fractures, the fracture surfaces shall be
examined visuallyy to the criteria of the applicable
pp
standard
4-243
Mechanical Testing
ASME Section IX QW-180 Fillet Weld Test
4-244
Mechanical Testing
ASME Section IX QW-180 Fillet Weld Test
4-245
Mechanical Testing
Fillet Weld Break Test Acceptance Criteria

Fillet Weld Break Test per AWS D1.1
z
4.30.4.1 Acceptance Criteria for Fillet Weld Break Test

Reasonably uniform appearance and free of overlap, cracks and undercut
within acceptable limits of visual inspection
The broken specimen shall be flat upon itself or the fracture surface shall
show complete root fusion with no inclusion or porosity larger than 3/32 in
greatest dimension
The sum of the greatest dimensions of all inclusions and porosity shall not
exceed 3/8 in the 6 long specimen.
Fillet Weld Break Test per ASME Section IX

z
QW-182 Fracture Test

The fracture surface shall show no evidence of cracks or incomplete root
fusion
The sum of inclusions and porosity shall not exceed 3/8 or 10% of the
section
4-246
Mechanical Testing
Fracture Toughness Tests Summary of Methods

Charpy V-notch - Impact on V-notched specimen
Dynamic Tear - Three point bending of U-notched specimen
loaded at high strain rate by strike
Plane-Strain Fracture Toughness - Plane-strain critical
fracture toughness value obtained at slow loading rates on
compact
p
tension specimen
p
with maximum constraint ((thick
specimen with deep crack) resulting in brittle fracture with
little or no deformation
Drop-Weight Nil Ductility Transition Temperature Drop
weight impact on flat notched specimen with maximum
fracture stress at materials yield stress
4-247
Mechanical Testing
Fracture Toughness Test Significance

Provides a measure of resistance to crack initiation or
propagation or both
The same welding process, procedure, and weld cooling
rates must be used for the test sample and the structure
Fracture toughness of steels is sensitive to service
temperature
p
Shear Lip
Chevron
Markings
Shear Lip
Shear
Deformation
Shear Rupture Dimples
Chevron
Markings
Photograph of Typical
Brittle Fracture Surface
4-248
Mechanical Testing
Fracture Toughness Test Apparatus
CMOD
Crack Tip
Charpy V-Notch Test (right: placement of specimen in anvil)
Three-Point
Bending Test
4W
Clip Gage
Compact Tension Test
Clip Gage
Four-Point Bending Test
4-249
Mechanical Testing
Fracture Toughness Test Specimens
Dynamic Tear
Test Specimen
Charpy V-Notch Impact
Specimen
4-250
Mechanical Testing
Fracture Toughness Test Specimens

Crack Driving Force: Stress
Intensity Factor, KI
K I = a correction.. factor
Drop Weight Nil-Ductility

Temperature Test Specimen
Compact Tension Fracture
Toughness Test Specimen
4-251
Mechanical Testing
Fracture Toughness Test Apparatus
3O~5O
Drop-Weight Nil Ductility Transition Temperature

Test
4-252
Mechanical Testing
Fracture Toughness Test Procedure
Orientation of Weld Metal Fracture Toughness Specimen

in a Double-Groove Weld Thick Section Weldment
4-253
Mechanical Testing
Charpy Energy
y (ft-lb)
Fracture Toughness Test Acceptance Criteria
Test Temperature
Low
temperature
High
temperature
Charpy V-Notch Test Results

4-254
Mechanical Testing
Dynamic Tear Test Results

4-255
Mechanical Testing
Fracture Toughness KIC ASTM A572 Steel
Compact Tension Test Results
4-256

Desene Sudura

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