WELDED

CONNECTIONS
Unit – I

ALPINE SKI HOUSE

DEFINITION AND TYPES
OF WELDING PROCESS
• Welding is a process of connecting two pieces of metals by application of heat (fusion) with
or without pressure.

• TYPES OF WELDING PROCESS:

1) Forge welding
2) Thermit welding
3) Gas welding
4) Resistance welding
5) Electric arc welding
ADVANTAGES OF WELDING
1. As no hole is required for welding, hence no reduction of area. So,
structural members are more effective in taking the load.

2. In welding, filler plates, gusseted plates, connecting angles etc. are not
used, which leads to reduced overall weight of the structure.

3. Welded joints are more economical as less material is required.

4. The efficiency of welded joints is more than that of the riveted/bolted

joints.

5. The welded joint look better than the bulky riveted/bolted joints
ADVANTAGES OF WELDING
6. The speed of fabrication is faster in comparison with the riveted joints.

7. Complete rigid joints can be provided with welding process.

8. The alteration & addition to the existing structure is easy as compare to

rivet joints.

9. No noise is produced during the welding process as in the case of riveting.

10. The welding process requires less work space in comparison to riveting.

11. Any shape of joint can be made with ease.

DISADVANTAGES OF WELDING
1. Welded joints are brittle & therefore their fatigue strength is less than
the members joined.
2. Due to uneven heating & cooling of the members during the welding,
the members may distort resulting in additional stresses.
3. Skilled labor & electricity are required for welding
4. No provision for expansion & contraction is kept in welded connection
& therefore, there is possibility of cracks.
5. The inspection of welding work is more difficult & costlier than the
riveting work.
6. Defects like internal air pocket, slag inclusion & incomplete penetration
are difficult to detect.
ASSUMPTIONS IN WELDING

1. The welds connecting the various parts are homogeneous, isotropic,

elastic elements.

2. Parts connected by the weld are rigid and their deformations are
therefore neglected.

3. Only stresses due to external loads are considered. Effects of residual

stresses, stress concentrations and shape of the welds are neglected.
TYPES OF WELDS
Classification based on their formations:

1. Butt weld

2. Fillet weld

3. Plug weld

4. Slot weld

5. Spot weld
BUTT WELD:
• Also called as groove weld

• Plates to be connected are placed end to end and are then welded

• Used to connect members in same planes

• Designed for axial forces (tension, compression) and shear in special

cases

• Designated by their throat dimension – called as throat thickness.

BUTT WELD:

Butt weld

Partially penetrated Fully penetrated (or)

(or) Single butt weld Double butt weld
BUTT WELD:
DESIGN OF BUTT WELD:
• A butt weld is specified by the size of the weld. Size of the weld is defined
by the effective throat thickness.

Specification:
1. Size of the weld
2. Effective length of the butt weld
3. Effective area of the butt weld
4. Reinforcements
DESIGN OF BUTT WELD:
1. Size of the weld (S): (clause 10.5.7.1.2, IS 800:2007)
Size of the weld is specified by its effective throat thickness as follows:

(a) The size of the butt weld is the thickness of the thinner plate.

(b) The effective throat thickness in case of complete penetration

is taken as the thickness of the thinner part.
Double-V, Double-U, Double-J & Double Bevel butt joints are the
examples of completely penetrated butt weld.

te = thickness of the thinner plate

DESIGN OF BUTT WELD:
1. Size of the weld (S):
(c) In case of incomplete penetration of butt weld the effective throat thickness is
taken as the 7/8th of the thickness of the thinner part. But for purpose of stress
calculation the effective throat thickness should not exceed 5/8th of the thickness of
the thinner part.

te = 7/8 ×thickness of the thinner plate

= 5/8 ×thickness of the thinner plate ----- for calculation

(d)The difference in thickness between the two plates should not be more than 25%
of the thickness or 3mm whichever is more.

(e) If difference is more than 25% tapering less than 1 in 5 is to be done.

DESIGN OF BUTT WELD:
2. Effective length of the butt weld (lemin): (CLAUSE 10.5.4.2, IS 800:2007)
It is the area of the butt weld for which the specified size (i.e. the throat
thickness) of the weld exists. Or length of the weld for which required size of
welding is done.

The effective length should not be less than four times the size of the weld.
Otherwise size of the weld must be taken as the one fourth of the effective
weld length.
lemin > 4S

Note:- In drawing only effective lengths are shown, the welder must provide
an additional length of 2S to get the overall depth.
DESIGN OF BUTT WELD:
3. Effective Area of the butt weld (Ae):
It is the area of the butt weld for which the specified size (i.e. the throat
thickness) of the weld exists.
Ae = te × le

Stress in the butt weld : The stresses of the butt weld should be taken equal to
the stresses of the parent metal in the case of shop weld.

These values are reduced to 80% in case of field weld.

DESIGN OF BUTT WELD:
4. Reinforcement :
Reinforcement is the extra weld metal which make the throat dimension at least
10% greater than the thickness of the weld material.

• The extra deposit of metals above the thinner plate between 1 mm to 3 mm is

not considered for stress calculation or design.

reinforcement ⊁ 3mm

• The reinforcement is provided to increase the efficiency of the joint.

DESIGN STRENGTH OF BUTT WELD:
i) The design strength of butt weld in tension or compression is governed by yield
(from IS 816)

𝑓𝑦 𝐿𝑤 𝑡𝑒
𝑇𝑑𝑤 =
𝛾𝑚𝑤
Lw = effective length of weld, in mm
fy = smaller of yield stress of weld and parent material, in MPa
te= effective throat thickness, in mm
γmw = partial safety factor
= 1.25 for shop welding and
= 1.5 for site welding
Strength of butt weld ≥ strength of main member
DESIGN STRENGTH OF BUTT WELD:
ii) The design strength of butt weld in shear is also governed by yield,

𝑓𝑦𝑤1 𝐿𝑤 𝑡𝑒 𝑓𝑦 𝐿𝑤 𝑡𝑒
𝑉𝑑𝑤 = =
𝛾𝑚𝑤 3𝛾𝑚𝑤

Lw = effective length of weld, in mm

fyw = smaller of shear stress of weld and parent material, in MPa
1

te= effective throat thickness, in mm

γmw = partial safety factor
= 1.25 for shop welding and
= 1.5 for site welding
DESIGN STRENGTH OF BUTT WELD:
Stresses due to individual forces: (clause 10.5.9, IS 800:2007)
When subjected to either compressive or tensile due to axial force or shear
force alone, the stress in the weld is given by

𝑃
𝑓𝑎 𝑜𝑟 𝑞 =
𝑡𝑒 𝐿𝑤

fa = calculated normal stress due to axial force, in Mpa

q = shear stress , in Mpa
P = force transmitted (Axial force N or Shear force Q)
Lw = effective length of weld, in mm
te= effective throat thickness, in mm
DESIGN STRENGTH OF BUTT WELD:
Combination of stresses: (clause 10.5.10.2.2, IS 800:2007)
If bearing stress, (fbr) is combined with bending stress (fb) (tensile or
compressive) and shear stresses (q) under the most unfavorable conditions of
loading, the equivalent stress (fe) is obtained from the following formula:

𝒇𝒆 = 𝒇𝟐𝒃 + 𝒇𝟐𝒃𝒓 + 𝒇𝒃 𝒇𝒃𝒓 + 𝟑𝒒𝟐

fb = calculated stress due to bending, in Mpa

q = shear stress , in Mpa
fbr = calculated stress due to bearing, in Mpa
 DESIGN PROCEDURE OF BUTT WELD:
i) In case of complete penetration of groove weld,
No design calculation is required as,
strength of weld at joint = strength of the connected member

ii) In case of incomplete penetration of groove weld,

Step 1: effective throat thickness is computed
te = 5/8 × thickness of thinner member
Step 2: required Lw is computed
strength of the weld = strength of the members connected
Step 3: Design strength of butt weld is calculated
𝑓𝑦 𝐿𝑤 𝑡𝑒
𝑇𝑑𝑤 =
𝛾𝑚𝑤
 DESIGN OF BUTT WELD:
Q) Two plates of thickness 12 mm and 10 mm are to be jointed by a groove
weld. The joint is subjected to a factored tensile force of 250 kN. Assuming an
effective length of 150 mm, check the safety of the joint for
a) Single-V groove weld joint and,
b) Double-V groove weld joint.
Assume Fe 410 grade steel plates and that the welds are shop welded.
DESIGN OF BUTT WELD:
DESIGN OF BUTT WELD:
 DESIGN OF BUTT WELD:
Q) A groove weld is used to connect 2 plates 180mm× 18mm each. Determine
the design bending strength of the joint if it is subjected to a moment of 13 kN-
m. also determine the adequacy of the joint if the shear force at joint is 200kN.
Assume the welds to be of double U shop weld.
DESIGN OF BUTT WELD:
DESIGN OF BUTT WELD:
 DESIGN OF BUTT WELD:
Q) A joint is subjected to a factored shear force of 300 kN. Assuming single-V
groove weld joint find the effective length of the weld if the thickness of thinner
plate is 8 mm. Assume Fe 410 grade steel plates and that the welds are shop
welded.