WELDING DOCUMENTATION

(BBX 10504)
C4 : INTRODUCTION AND UNDERSTANDING OF
WELDING JOINT GEOMETRY
By
MR. MOHD HAFIZ BIN GHAZALI
Faculty of Technical and Vocational Education
Introduction
• A welded joint is a permanent joint which is obtained by the fusion of
the edges of the two parts to be joined together, with or without the
application of pressure and a filler material.
• The heat required for the fusion of the material may be obtained by
burning of gas (in case of gas welding) or by an electric arc (in case of
electric arc welding) .
• The latter method is extensively used because of greater speed of
welding.
• Welding is extensively used in fabrication as an alternative method for
casting or forging and as a replacement for bolted and riveted joints.
• It is also used as a repair medium to reunite metal at a crack, to build
up a small part that has broken off such as gear tooth or to repair a
worn surface such as a bearing surface.
• Permanently joining two or more metal parts by the fusion of edges of
the metals
Without pressure & filler material = Welding
With pressure = Forge Welding
Without pressure, separate metal =fusion welding

• Fusion welding = gas heating, electric arc

Type of welding joint
Type of welding joint
LAP Welding Joint
Lap joint is a joint between two overlapping members (work piece) mostly
used because of its good mechanical properties especially when welded on
both sides. The different type includes :

Bevel groove
J-groove
Flare bevel group
Butt Welding Joint
Is a joint which is formed by placing the ends of two parts together. It is
the simplest type of joint used to join metal or plastic parts together, it is
include
Square butt
Bevel groove
V-groove
j-groove
U- grove
Tee Welding Joint
Is made by intersecting two parts at right angles (90 degree) and one part
lies at the center of the other. It is called a T joint as the part welded look
like english letter “T”. It types is include

Fillet
Plug
Slot
Bevel groove
J-groove
Use of CLAMS in welding
For welding activity to be up to standard and prevent unnecessary weld
defects as a beginner in welding, CLAMS acronym is very important. It
stands for the following
• C is for the welding current
• L is for the length of Arc
• A is for the electrode angle
• M is for the manipulation of the electrode
• S is for the speed of travel
Strength of welded joint
It is seen that strength of a welded joint gets affected mainly by the
following factors

Crack initiation : possible crack from cooling melted metal

Defects : various of defects like incomplete penetration, porosity, slag
inclusion
Stress concentration : change in welding geometry after welding may
introduce stress concentration in the structure.
Welding defect
Destructive Test
Lamellar Tearing
Advantages of welded joints
Advantages of welded joints
• The welded structures are usually lighter than riveted structures. This is due to the
reason, that in welding, gussets or other connecting components are not used.
• The welded joints provide maximum efficiency (may be 100%) which is not possible
in case of riveted joints.
• Alterations and additions can be easily made in the existing structures.
• As the welded structure is smooth in appearance, therefore it looks pleasing.
• In welded connections, the tension members are not weakened as in the case of
riveted joints.
Advantages of welded joints
• A welded joint has a great strength. Often a welded joint has the strength of the
parent metal itself.
• Sometimes, the members are of such a shape (i.e. circular steel pipes) that they
afford difficulty for riveting. But they can be easily welded.
• The welding provides very rigid joints. This is in line with the modern trend of
providing rigid frames.
• It is possible to weld any part of a structure at any point. But riveting requires
enough clearance.
• The process of welding takes less time than the riveting.
Disadvantages of welded joints
• Since there is an uneven heating and cooling during fabrication,
therefore the members may get distorted or additional stresses may
develop.
• It requires a highly skilled labor and supervision.
• Since no provision is kept for expansion and contraction in the frame,
therefore there is a possibility of cracks developing in it.
• The inspection of welding work is more difficult than riveting work.
Tugasan case study

https://www.astroawani.com/berita-malaysia/kren-tumbang-
kampung-baru-tiga-cedera-kereta-remuk-160035
Tugasan diberi pada 29/04/2021
Tugasan dihantar pada 6/5/2021

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