Design of fillet welds -

Basic concepts
Design of welds
 Imperfections in Fillet welds

Oversize fillet weld Excess convexity

FILLET
WELDED
JOINTS

Asymmetric fillet weld Undersized fillet weld Poor fit-up

Desirable convexity for fillet welds AWS D1.1
Throat area in Un-equal Fillet weld
THROAT THICKNESS OF FILLET WELDS
Effective throat of a Fillet weld
Throat thickness of fillet welds
 Throat thickness in Skewed T-joints

Dihedral

Skewed T joint
Z loss
Penetration /Fusion requirements of Fillet welds

Effect of Weld Penetration in 1-1/2 in. Fillet Welds

EFFECT OF ROOT GAP ON FILLET SIZE
 Effect of increased root gap
‘NOTHIN’
Increasing theWelds
root opening of a T-joint without increasing the fillet weld
size increases the stress on the throat.
Effect of over welding
 Optimize
fillet sizes
 T joints with poor fit-up
‘NOTHIN’ Welds
When machining tolerances are critical
 Partial Penetration FILLET WELDS
Partial Joint Penetration weld (PJP) has a throat dimension
less than the thickness of the material being joined.
An effective throat is associated with PJP groove weld.
Partial Penetration fillet welds
Grooved fillet welds
 Cost of Grooved fillet welds

20
Relative cost
of fillet
Relative cost

10

0 1.5 2.0
0.5 1.0
Plate Thickness in inches
Heat Input decides the
weld size
Distortion in Fillet welds

Illustration of the
formation of angular
distortion in T-joints
connected with various
types of welds ;
P-force causing the joint
deformation ,
r-arm of force P
between the neutral axis
and the mass centre of
the weld cross section.
Heat Input decides the weld size
 Load orientation to fillet welds
Fillet weld transverse
to loading direction
leading to shear failure

Fillet weld Parallel to Fillet weld transverse

loading direction to loading direction
Load orientation of Fillet welds
Parallel and transverse fillet weld-Maximum shear stress in a

= =
45 67.5
Max shear stress in parallel fillet weld Ma shear stress in a transverse fillet weld

The strength of a transverse fillet weld is 1.17 times of the

strength of parallel fillet weld.[0.828*h* max vs 0.707 * h* max ]
The design of the fillet welds uses shear failure as criterion.
To simplify design stress in the transverse fillet weld is shear
stress on the throat area at 45 for any direction of applied
load.
Fillet size considering the direction of loading
Fillet welds in LAP JOINT and T-joint
Load deformation curves for 8 m fillet welds with varying angles to load vector
 Weld length

In load carrying fillet welds, effective length must be

4 times leg size or 38 mm (min).
If not leg size = 0.25*effective length
Often the effective length is taken as L-2s where s is the fillet
size

effective length
Smaller size- longer fillets are preferred
Smaller size- longer fillets are preferred
STRESSES IN FILLET WELDS
Thank you
Heat Input decides the weld size
 Partial
Penetration
FILLET WELDS
 Throat stress, N /mm2 100 150 200
40 30

35 25

Weld throat size in mm

30
20
Weld leg size in mm 25

20 15
15
10
10
5 5

1 2 3 4 5 6
Load, kN / mm
Fillet weld design chart showing strength of welds in terms of
load / mm
Types of Fillet welds

b convex c concave
fillet weld fillet weld
Strength of fillet welds