Basic weld Design

Part 1-Butt welds

 Weld Joint strength

➢ Extent of joint penetration

➢ Strength of filler wire / weld metal
➢ Discontinuities in the weld

t t
p

t t-p
 Weld Joint strength-Effect of filler material

➢ Matching filler wire

➢ Over-matched filler wire
➢ Under matched filler wire

Weld Efficiency = [ WM strength / PM strength] * 100%

 Weld joint Strength – effect of Penetration

Partially
Penetrated
weld

Extent of fusion in the base material is weld

Penetration
Weld joint strength-effect of defects

Weld with
defects

Weld with
poor contour
 Common defects /discontinuities that can affect weld strength

Poor bead Profiles

Excess penetration Surface Porosity & slag

DISCONTINUITIES
LOF
undercut COMMONLY
ENCOUNTERED IN
WELDING

overlap LOP

Root concavity Hot crack

Misalignment
 key considerations to achieve Full strength

❑ Using a filler metal that results in weld metal with

matching strength of base material.

❑ Achieving full penetration of the thickness in a

groove weld and the required design size in
fillet welds

❑ Obtaining a sound weld free from discontinuities

(metallurgical , geometric and fusion related)
Achieving full Penetration
 Achieving full Penetration

P= Extent of fusion with the applied

process heat input

SMAW PROCESS
Achieving full Penetration
 Achieving full Penetration

SMAW PROCESS

P1

P2

P1 & P2 = Extent of
fusion with the
applied process heat
input
 Achieving full Penetration

SMAW PROCESS

P1

P2

P1 & P2 = Extent of
fusion with the
applied process heat
input
 Achieving full Penetration

Full Penetration can be achieved when welded from

both sides with appropriate heat input for the
thickness under consideration

SMAW PROCESS
 Achieving full Penetration

Full Penetration can be achieved with a backing

plate keeping high root gap.

SMAW PROCESS
Achieving full Penetration

HEAT FLOW
 Achieving full Penetration

Due to small heat sink the edges of the plate gets burnt
resulting in burn through.

HEAT FLOW
 Achieving full Penetration

Providing a root face or land increases the heat sink area and
prevents burning of the edges

HEAT FLOW
 Achieving full Penetration

Providing a root face or

land increases the heat
sink area and prevents
burning of the edges.
The orientation of the arc
also controls proper
fusion.

HEAT FLOW
Method of achieving Full Penetration
 Alternate Method of achieving Full Penetration
Use of consumable insert
 Alternate Method of achieving Full Penetration
Use of Backing strip/plate

Providing a backing strip

WELD JOINTS WITH BACKING DESIGN to achieve full penetration
WELD JOINTS WITH BACKING DESIGN to achieve full penetration
WELD JOINTS WITH BACKING DESIGN to achieve full penetration
WELD JOINTS WITH BACKING DESIGN to achieve full penetration
Full Penetration butt joints
Butt joints with backing
 Method of achieving Full Penetration

Using Grooved joints with appropriate edge preparation

Edge Preparation
Full penetration is achieved by Providing grooves
with

➢ Root gap between joint edges

➢ Chamfer at the joint edges

➢ Suitable root face at the edges

 Groove Dimensions Included angle

Included angle

Root Face

Root Gap
When welding can be done from both sides,
chamfer can be provided on both sides
 Groove Dimensions- Root gap/opening

Depends on

❑ The heat input of the process

❑ The diameter of the electrode / wire

❑ The thermal expansion/ contraction of the
material
 Groove Dimensions- Root Face /Land

Depends on
❖ The heat input of the process
❖ The thermal conductivity of the
material welded

❖ The diameter of the electrode/wire

 Groove Dimensions- Included angle

Depends on
❑The diameter of the electrode

❑The position of welding

❑The thickness of the plates

❑The type of joint
Excess weld metal due increases with groove angle
Choice of type & dimensions of Butt welds
Choice of type & dimensions of Butt welds
Choice of type & dimensions of Butt welds

Weld metal increases with groove angle

Choice of type & dimensions of Butt welds

Weld metal increases with root gap

Selection of Groove shapes for butt welds

Thickness
Heat Input of welding Selection of Process
processes

5
Heat Input kJ/ mm

4
3
GW

2
SMAW

GTAW
SAW

1
CO2 PAW
EBW
1 2 3 4 5 6 7
 The choice of Groove type and angle depends on

➢ welding process
➢ Welding Position
➢ Thickness of the section
➢ The thermal properties of the material

The main objective is to achieve the required

penetration with minimum weld metal deposit
Symmetrical Single V-Groove preparation
For welding in down hand position


Asymmetric Groove angle for welding in Horizontal position
to reduce the gravitational effect on the weld pool

S2
2
 
g

1
s1

 = 55 °
G = 1.6 – 3.15 mm
S = 1.6 - 3.15 mm

1= 10-15 °
2= 45-50 °
Groove angle formation by positioning the
members for welding

g
Groove angle for welding to avoid burning away outer corner
of vertical member

This Groove angle preparation is also used for

minimizing Lamellar tearing
Symmetrical Double V-Groove preparation
For welding on both sides


d2

 S

d1


Asymmetric Double-V Groove angle to facilitate welding in
the horizontal vertical position
2

1
2


1
1 = 30 – 40°
2 = 20°

1= 10-15 °
2= 45-40 °
Symmetrical and Asymmetrical J-Groove type
weld preparations
 Recommended Groove angles in relation to
thickness
Thickness – T inch Groove type
T < 3/4 SV
T - 1/2 to 2 DV
T < 3/4 SB
T - ¾ to 2 DB
T - 3/4 to 1.5 SJ
T > 1.5 DJ
T - 3/4 to 1.5 SU
T > 1.5 DU
 ISO 9262

Welding and allied processes

Recommendations for joint preparation — Part 1:

❖ Manual metal-arc welding,

❖ gas-shielded metal-arc welding,
❖ gas welding,
❖ TIG welding and
❖ beam welding of steels
ISO 9262
ISO 9262
ISO 9262
ISO 9262
ISO 9262
ISO 9262
ISO 9262
ISO 9262
ISO 9262
ISO 9262
ISO 9262
ISO 9262
ISO 9262
ISO 9262
ISO 9262
Type of Groove welds
Grooved butt joints
Grooved butt joints
Weight (gms)of Weld Metal required per meter of weld length
of butt welds with varying root gaps

Root Gap 1 mm Root Gap 2 mm

Thickness
12 16 20 12 16 20
Design

SV 790 1340 2050 840 1410 2120

DV 424 704 1062 502 830 1222

Included angle - 60 deg.

 Optimize fillet
sizes

Effect of
fillet size with
and
without
grooves
On cost
 Optimize
weld type
and size

Improper
selection
Of edge
preparation
Results in
over welding
 Optimize weld type and size
h1
h2

Strong back
10 Selection
of appropriate
Free Edge
preparation
Distortion

h1: h2 - 7:3
5
h1: h2 - 6:4

h1: h2 - 1:1
h1: h2 - 4:6

0 0.5 1 1.5 2 2.5

Plate thickness in inches
 ISO 13920

WELDING –GENERAL TOLERANCES FOR WELDED

CONSTRUCTIONS
DIMENSIONS FOR LENGTHS AND ANGLES –SHAPE AND
POSITION
Thank you