Welding Connection

WELDED CONNECTION I
Teaching Resources (c) IIT Madras, 1

SERC Madras, ANNA Univ,
Introduction
Efficient and direct way of connecting is by welding
Metallurgical bond by heat or pressure or both
Advantages of welding
• Direct transfer of stress - minimum weight ,
efficiency
• Less fabrication
• Economy - 15% saving in weight in bridges,less
labor
• Neat appearance
• More rigid

COMPARISON OF APPEARANCE OF RIVETED
AND WELDED PLATE GIRDERS
(a) Bolted girder section
(a) Welded girder section

FUNDAMENTALS OF WELDING
• Tendency of atoms to bond and form metallic bonds
• Inter diffusion between the materials
• Diffusion in liquid , solid or mixed state
• Real surfaces are not smooth and clean
• Welding process needs some form of energy-Heat or
pressure or both
• Heat alone applied - eg.Gas Tungsten Arc welding,
Shielded metal arc welding,
Submerged arc welding
• Pressure alone - eg. Cold welding, Roll welding
• Both pressure and heat - eg. Resistance welding ,
Friction welding
TWO IDEAL SURFACES BROUGHT TOGETHER
TO FORM A WELD
Metal A
Metal B (b) After weld

(a) Before
weld

TWO IRREGULAR SURFACES FORMING A WELD
Oxide
layer
Metal B
Metal B
Absorbed
layer
Metal A
Metal A
Surface contaminants Addition of filler material
Metal B
Metal A
Near perfect weld

BASIC WELDING PROCESSES
Gas welding - Oxyacetelene welding , simple , slow,

repair and maintenance work
Arc welding - All structural welding
Electric arc by use of electric energy

• Shielded Metal Arc Welding
• Coated electrode from gaseous shield to exclude
oxygen.
• Also deposits slag in molten metal.Because of less
density
• floats and shields and slows cooling.
• Coating shields the arc ,coats the molten pool against
oxidation, stabilising the arc and provides alloying
element weld metal.
• Type of welding electrode decides strength,ductility
and corrosion resistance.
• Lightly coated and heavily coated
• Automatic or Semi automatic
SHIELDED METAL ARC WELDING (SMAW) PROCESS -1
Electrode
Coating on electrode
Arc stream
Slag Gaseous shield
Weld Molten pool
Penetration depth
Base
metal

• Submerged arc welding
• Arc is covered by powdered flux

• High quality, ductility , impact resistance , corrosion
resistance
• More heat impart; hence deeper penetration.
Flux tube
Electrode Molten
Slag pool
Penetration depth
Weld
Base metal

• Manual Metal Arc Welding
• Manually operated; hence requires skill electrode
in a steel core wire(3.2 - 6.0 mm diameter)
• Flux contains manganese and silicon
• Low capital cost and freedom of movement
• Advantageous for short welds
• Metal Active Gas Welding
• The arc and weld pool are protected by an inert
gas, often carbondioxide.
• Flux is not necessary
• Welding is easier
• Highly suitable for fillet welded joints

Electroslag welding process
• Vertical automatic welding.
• Electrode is immersed in molten slag and the

melt is heated to high temperature.
• Weld pool forms at the bottom of the slag pool

and forms the weld joining the faces.Useful for
joining thick sections in vertical position.

ELECTROSLAG WELDING PROCESS-1

• Stud Welding
• Shear connectors in composite construction
• Another form of arc welding
• Stud main be plain bar with an upset head or

threaded
• Stud is the electrode

WELDING PROCEDURE
• Environment
• Welding position
• Current : controls heat input
• Shrinkage
• Preheating
Weldability of steels
Economic welds, good , crack free

Factors affecting Weld Cracking
• Joint restraint
• Bead shape
• Carbon and alloy content of the base metal
• Cooling rate
• Hydrogen and nitrogen absorption

TYPES OF JOINTS OR WELDS
• Joints:Lap,Tee,Butt and Corner

• Welds: Groove, fillet, plug and slot
• Welded joint description - Type of joint and weld
• Position of welding
(a) Butt joint (c) Tee joint (d) Corner joint

(b) Lap joint

COMMON TYPES OF WELDS
(b) Fillet welds

(a) Groove welds
Ends shall be semi
circular
A A A A
Section A-A Section A-

A
(d) Plug weld (c) Slot weld

Groove welds
Selection of a particular type of groove weld depends
• Size of the plate to be joined

• welding by hand or automatic
• Type of welding equipment
• Accessibility of both sides
• Position of weld

• Size of butt weld
• Thickness of connected plate for full penetration
• Depth of penetration for partial penetration
• Advantages
High strength,high resistance to impact and cyclic
stress
• Disadvantages
High residual stress , edge preparation and proper
aligning

CLASSIFICATION BASED ON POSITION
Backup plate
Shaping of surface and backup plate
(a) Flat (c)

(b) Horizontal
Vertical
(d) Overhead
TYPICAL EDGE PREPARATION FOR BUTT WELD
Root opening R
(a) Bevel with feathered (b) Bevel with backup plate

edge
R
Land (root face)
R
(c) Bevel with a land (d) Double bevel with a
spacer

GROOVE WELD DETAILS
Electrod Included angle

Arc e Depth of
penetration Root face
(a) Depth of penetration Root gap

(b) Root gap
Capping run Filling run
Root run
(c) Root run

TYPICAL CONNECTIONS WITH GROOVE WELD
Single bevel groove

weld
( a) Corner joint Square groove Double V groove weld

weld (b) Butt joint
Square groove
weld
(c) Edge Joint

• Fillet welds
• Ease of fabrication and adaptability

• Less precision
• No special edge preparation
• Throat of a weld
• Concave and convex surfaces
Weld and leg size
Face of weld
Theoretical throat
s (t=0.707s)
t
Root of weld Te

TYPICAL FILLET WELD CONNECTIONS
Size = s*t Size = s

s Throat
s Throat =0.707s
t s
Root Root
(1) Unequal legs (I1) Equal legs

CROSS SECTION OF A FILLET WELD
st s st
(a) Concave (b) Convex (c) Under cutting

QUALITY OF WELDED CONNECTIONS
• Proper electrodes , welding apparatus and

procedures
• Welding sequence
Doubling up method
Planned wandering method
Step back method

SEQUENCE OF WELDING OF FILLET WELDS
Doubling - up method for vertical member
13 12 7 5 1 6 8 17 18
11 10 9 3 2 4 14 15 16

Planned Wandering Method for Welding
Long Butt Joint with Two Operators
3 5 2 4 1 4 2 5 3
Step Back Method for Welding Long

Joint With Two Operators
Operator (2) Operator (1)
1 2 3 4 5

RESIDUAL STRESSES
• Residual stresses - due to rapid heating and
cooling
• Yield strength of material is upper limit for residual
stresses
LONGITUDINAL RESIDUAL STRESS DUE TO WELD
Tension
- -

WELD DISTORTION
Three basic dimensional changes

• Transverse shrinkage
• Longitudinal shrinkage
• Angular distortion
Methods to overcome distortion
• Minimize distortion by controlled welding
procedures
• Acceptable limits
• Techniques to remove distortion

WELD DISTORTION
a)Transverse shrinkage(b) Angular change (c) Rotational

distortion
(e) Longitudinal bending

distortion
(d) Longitudinal shrinkage (f) Buckling
distortion

WELD SYMBOLS
Symbolic representation of welds
(Ref. IS:813 - 1986 ‘ Scheme of symbols for welding’ )

DEFECTS IN WELDS
• Incomplete fusion
• Porosity
• Inadequate preparation
• Undercutting - Excessive current or long arc
• Slag inclusion - Failure to remove slag between
runs
• Cracks - Breaks in the weld metal
• Lamellar tearing - Occurs in the base metal
beneath the weld

LACK OF FUSION (OR) INCOMPLETE FUSION
Lack of sidewall fusion
Lack of interpass
fusion
Lack of root fusion

LACK OF PENETRATION
Incorrect
sequence
Omission of backgouging or
inadequate backgouging with
too small a root gap

TYPICAL EXAMPLES OF UNDERCUT DEFECT.
(a) WIDE AND CURVED, (b) NARROW AND CRACK LIKE
Undercuts Undercuts
Undercuts
(a) (b)

SLAG INCLUSION
Not cleaned or
incorrect electrode
Slag trapped in
undercut
Narrow
LAMELLAR TEAR
root gap

WELD DEFECT TOLERANCE
For joints welded from both sides

• Incomplete penetration - 5% of parent metal
thickness < 2mm
• Length of flaw < 200 mm / meter length
Welded on one side
• Incomplete penetration - 15% of thickness < 3mm
• Slag inclusion < 200 mm / meter weld length
• Total gas pores < 5 per square centimeter of weld
• Thickness upto 10mm , undercut < 0.5mm
• For thickness > 10mm undercut < 1mm
•
WELD INSPECTION
Visual inspection
Liquid penetrants
Magnetic particles
Ultrasonic testing
Radiography
CONNECTION DESIGN
Static strength of welded joint
• Type and size of the weld
• Manner of welding
• Type of electrode used

BUTT WELDS
• Critical form of loading - Tension in transverse direction

• Yield stress of weld metal and parent metal in HAZ(Heat
affected Zone) is much higher
• Failure always occurs away from the weld
• Toughness and ductility properties are affected

DIFFERENT TYPES OF BUTT JOINTS
(a) Square (d)Single Bevel

(b) Single V (c) Double V
(g) Single U (h) Single J

(e)Double (f) Single U
Bevel
(i)Double J

LOAD APPLIED IN TRANSVERSE
DIRECTION OF BUTT WELD
Longitudinal direction
Transverse direction
(a) (b)
Load applied in transverse direction Longitudinal shrinkage

DESIGN
• Direct tension or compression
• Design strength same as parent metal strength
• Effective area equals effective length times throat size
• For full penetration,thickness of weld ,equals thickness of
thinner part of connection
• Partial penetration welds are avoided
• Throat thickness - 5/8 thickness of thinner part
• Average stress concept
• Permissible stresses - Parent metal values
• Site welds - 80% of permissible value

PARTIAL PENETRATION WELD
BUTT WELDING OF MEMBERS WITH

(A)&(B) UNEQUAL THICKNESS (C) UNEQUAL WIDTH
Taper not exceeding 1 in 5
Taper not exceeding 1 in 5
Weld
(a) (b)
Not less than t/4 OR up to

the dimension of thicker
material
t
(c)
FILLET WELDS
Behaviour
• Lap joints splices
• Shear is the main design consideration
• Side fillets and end fillets
• End fillet loaded in tension - high strength and
low ductility
• Side fillet loaded - Limited to weld shear strength
(50% tensile strength) Improved ductility
• Average stress in weld throat
• Fillet weld shape is important for end fillets.

•Optimum weld shape - Shear leg < 3 times tension leg
•Fillet welds are stronger in compression than in tension
FILLET (A) SIDE WELDS AND (B) END WELDS
(a)
(b)

AVERAGE STRESS IN THE WELD THROAT
t11
s1 t11
t1
s1t1

(A) CONNECTIONS WITH SIMPLE WELD DESIGN,
(B) CONNECTIONS WITH DIRECTION- DEPENDENT WELD DESIGN
P Tension
Shear
P P
(a) (b)

DESIGN
Simple approach - Uniform strength
Size of fillet weld  3mm or thickness of thinner
part
Effective throat thickness  3 mm
< 0.7t and 1.0t
Size
= k  fillet size
Size (Min. Leg size)
Size
Fillets of unequal leg length Fillets of equal leg length
Penetration Leg length

Size = leg length * 2.4 mm

Table 1 Minimum size of first run or of a single run fillet weld
Thickness of thicker part
Over (mm) Up to and including Minimum size

(mm) (mm)
- 10 3
10 20 5
20 32 6
32 50 8 First run
10 Minimum size of fillet

t
¾
1.5 mm
Specified size t
(a) (b)
(a) fillet welds on square edge of plate, (b) fillet welds

on round toe of rolled section
Table 2. Value of K for different angles between fusion faces
Angle between 60° - 90° 91°-100° 101°-106° 107°-113° 114°-120°

fusion faces
Constant K 0.70 0.65 0.60 0.55 0.50

END RETURNS
End returns
P P

SLOT AND PLUG WELDS
• Provided along with fillet welds in lap joints

• Strength of a plug or slot weld - allowable stress
and nominal area in the shearing plane
Ends shall be semi circular or
have corners rounded to a radius
A A not less than thickness of part
containing slot
A A
Section A-
A Section A-
(a) Slot weld A
(b) Plug
weld

ECCENTRIC JOINTS
• Shear and torsion
Torsion , F = (T s ) / J
fh = (T v) / J
fv = (T h ) / J
t =R/L
• Shear and bending
Weld is designed to withstand maximum bending

stress and maximum shear stress separately.

(a) WELDS SUBJECTED TO SHEAR AND TORSION,
(b) WELDS SUBJECTED TO SHEAR AND BENDING
y
M
e P
x x
c.g of welds
(a)
y
e P P
(b)

VARIATION OF BENDING AND SHEAR STRESSES
L 3 V/ 2(weld area)
Vertical weld Bending stress Shear stress

WELD PROVISION FOR CARRYING SHEAR AND MOMENT

SUMMARY
• Fundamentals of welding , details of various

welding processes, types of welds, common weld
defects and weld inspection have been
presented.
• Advantages of welding are mentioned.
• Behaviour and design of butt - and fillet - welded
connections in steel structures are explained .
• Truss connections and beam connections are
discussed.


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WELDED CONNECTION I

Teaching Resources (c) IIT Madras, 1

Teaching Resources (c) IIT Madras, 2

(a) Bolted girder section

(a) Welded girder section

Teaching Resources (c) IIT Madras, 3

Metal B (b) After weld

Teaching Resources (c) IIT Madras, 5

Near perfect weld

Gas welding - Oxyacetelene welding , simple , slow,

Arc welding - All structural welding

Electric arc by use of electric energy

Teaching Resources (c) IIT Madras, 7

Teaching Resources (c) IIT Madras, 9

• Arc is covered by powdered flux

Teaching Resources (c) IIT Madras, 10

Teaching Resources (c) IIT Madras, 11

• Vertical automatic welding.

• Electrode is immersed in molten slag and the

• Weld pool forms at the bottom of the slag pool

Teaching Resources (c) IIT Madras, 12

Teaching Resources (c) IIT Madras, 13

• Shear connectors in composite construction

• Another form of arc welding

• Stud main be plain bar with an upset head or

• Stud is the electrode

Teaching Resources (c) IIT Madras, 14

Teaching Resources (c) IIT Madras, 15

Teaching Resources (c) IIT Madras, 16

• Joints:Lap,Tee,Butt and Corner

(a) Butt joint (c) Tee joint (d) Corner joint

Teaching Resources (c) IIT Madras, 17

(b) Fillet welds

Section A-A Section A-

(d) Plug weld (c) Slot weld

Teaching Resources (c) IIT Madras, 18

Selection of a particular type of groove weld depends

• Size of the plate to be joined

Teaching Resources (c) IIT Madras, 19

Teaching Resources (c) IIT Madras, 20

(a) Flat (c)

(a) Bevel with feathered (b) Bevel with backup plate

Teaching Resources (c) IIT Madras, 22

Electrod Included angle

(a) Depth of penetration Root gap

Capping run Filling run

(c) Root run

Teaching Resources (c) IIT Madras, 23

Single bevel groove

( a) Corner joint Square groove Double V groove weld

(c) Edge Joint

Teaching Resources (c) IIT Madras, 24

• Ease of fabrication and adaptability

Teaching Resources (c) IIT Madras, 25

Size = s*t Size = s

Teaching Resources (c) IIT Madras, 26

(a) Concave (b) Convex (c) Under cutting

Teaching Resources (c) IIT Madras, 27

• Proper electrodes , welding apparatus and

Teaching Resources (c) IIT Madras, 28

Doubling - up method for vertical member

Teaching Resources (c) IIT Madras, 29

Step Back Method for Welding Long

Teaching Resources (c) IIT Madras, 30