The concept of failure is central to the design process,

Static (steady) load: is a stationary force or a couple that does not change in

magnitude, point of application and direction

Stress is dependent on the load characteristics

Strength is an inherent property of the material

Ductile failure: permanent distortion of part geometry for ductile material

Failure: complete fracture for brittle material

Ductile materials:

• Have identifiable yield strength

• Show large amount of strain then brittle materials

• Their tensile and compressive yield strength are almost equal

Brittle materials:

• Do not have identifiable yield strength

• Show smaller amount of strain than ductile materials

• Their tensile and compressive yield strengths are almost equal

• In dealing with brittle materials that stress concentration factor should be taken into account

when calculating the stress

Factor of safety:

• The type of material and how well the material is known

• How controllable are weather environment conditions

• The type of loading and the degree of certainty with which the stresses are calculated

• The type of application

 Welding
Types of weld

I Bultjoint Next to Each other

2
Fillet joint Abou each other

Fillet joint are classified by direction

load
of the

a Parallel load

uh
 bud98209_appa_1011-1066.indd Page 1048 02/12/13 1:21 PM user-f-w-198 /204/MH01996/bud98209_disk1of1/0073398209/bud98209_pagefiles

1048 Mechanical Engineering Design

Table A–20

Deterministic ASTM Minimum Tensile and Yield Strengths for Some Hot-Rolled (HR) and Cold-Drawn (CD) Steels
[The strengths listed are estimated ASTM minimum values in the size range 18 to 32 mm (34 to 114 in). These

strengths are suitable for use with the design factor defined in Sec. 1–10, provided the materials conform to ASTM
A6 or A568 requirements or are required in the purchase specifications. Remember that a numbering system is not a

specification.] Source: 1986 SAE Handbook, p. 2.15.

1 2 3 4 5 6 7 8

Tensile Yield
SAE and/or Process- Strength, Strength, Elongation in Reduction in Brinell
UNS No. AISI No. ing MPa (kpsi) MPa (kpsi) 2 in, % Area, % Hardness

G10060 1006 HR 300 (43) 170 (24) 30 55 86

CD 330 (48) 280 (41) 20 45 95

G10100 1010 HR 320 (47) 180 (26) 28 50 95

CD 370 (53) 300 (44) 20 40 105

G10150 1015 HR 340 (50) 190 (27.5) 28 50 101

CD 390 (56) 320 (47) 18 40 111

G10180 1018 HR 400 (58) 220 (32) 25 50 116

CD 440 (64) 370 (54) 15 40 126
G10200 1020 HR 380 (55) 210 (30) 25 50 111

CD 470 (68) 390 (57) 15 40 131

G10300 1030 HR 470 (68) 260 (37.5) 20 42 137

CD 520 (76) 440 (64) 12 35 149

G10350 1035 HR 500 (72) 270 (39.5) 18 40 143

CD 550 (80) 460 (67) 12 35 163

G10400 1040 HR 520 (76) 290 (42) 18 40 149
CD 590 (85) 490 (71) 12 35 170

G10450 1045 HR 570 (82) 310 (45) 16 40 163

CD 630 (91) 530 (77) 12 35 179

G10500 1050 HR 620 (90) 340 (49.5) 15 35 179

CD 690 (100) 580 (84) 10 30 197

G10600 1060 HR 680 (98) 370 (54) 12 30 201

G10800 1080 HR 770 (112) 420 (61.5) 10 25 229

G10950 1095 HR 830 (120) 460 (66) 10 25 248

bud29281_ch09_475-516.qxd 12/16/2009 7:12 pm Page 479 pinnacle 203:MHDQ196:bud29281:0073529281:bud29281_pagefiles:

Welding, Bonding, and the Design of Permanent Joints 479

Figure 9–7 Reinforcement Reinforcement

A
A typical butt joint.
l l

F
F F F

Throat h Throat h
(a) Tensile loading (b) Shear loading

Figure 9–8 Throat

A transverse fillet weld. D C h

F
h A B
2F
h
F

Figure 9–9 x

Free body from Fig. 9–8. ␪

t 45
h
Fs F

Fn

The average stress in a butt weld due to shear loading (Fig. 9–7b) is
F
τ= (9–2)
hl
Figure 9–8 illustrates a typical transverse fillet weld. In Fig. 9–9 a portion of the
welded joint has been isolated from Fig. 9–8 as a free body. At angle θ the forces on
each weldment consist of a normal force Fn and a shear force Fs . Summing forces in
the x and y directions gives
Fs = F sin θ (a)
Fn = F cos θ (b)

Using the law of sines for the triangle in Fig. 9–9 yields
√
t h h 2h
◦
= ◦ ◦
= ◦
=
sin 45 sin(180 − 45 − θ) sin(135 − θ) cos θ + sin θ
Solving for the throat thickness t gives
h
t= (c)
cos θ + sin θ
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478 Mechanical Engineering Design

Figure 9–5 60°

Butt or groove welds:

(a) square butt-welded on both
sides; (b) single V with 60° 2
bevel and root opening of
2 mm; (c) double V; (d) single 2
bevel. 60°

(a) (b)

60° 45°

(c) (d )

Figure 9–6
Special groove welds:
(a) T joint for thick plates;
(b) U and J welds for thick
plates; (c) corner weld (may
also have a bead weld on inside
for greater strength but should (a) (b)
not be used for heavy loads);
(d ) edge weld for sheet metal
and light loads.

(c) (d)

residual stresses are not severe enough to cause concern; in some cases a light heat treat-
ment after welding has been found helpful in relieving them. When the parts to be welded
are thick, a preheating will also be of benefit. If the reliability of the component is to be
quite high, a testing program should be established to learn what changes or additions to
the operations are necessary to ensure the best quality.

9–2 Butt and Fillet Welds

Figure 9–7a shows a single V-groove weld loaded by the tensile force F. For either
tension or compression loading, the average normal stress is
F
σ = (9–1)
hl
where h is the weld throat and l is the length of the weld, as shown in the figure. Note that
the value of h does not include the reinforcement. The reinforcement can be desirable,
but it varies somewhat and does produce stress concentration at point A in the figure. If
fatigue loads exist, it is good practice to grind or machine off the reinforcement.
bud29281_ch09_475-516.qxd 12/16/2009 7:12 pm Page 477 pinnacle 203:MHDQ196:bud29281:0073529281:bud29281_pagefiles:

Welding, Bonding, and the Design of Permanent Joints 477

• Basic weld symbols as in Fig. 9–2

• Dimensions and other data
• Supplementary symbols
• Finish symbols
• Tail
• Specification or process
The arrow side of a joint is the line, side, area, or near member to which the arrow
points. The side opposite the arrow side is the other side.
Figures 9–3 to 9–6 illustrate the types of welds used most frequently by designers.
For general machine elements most welds are fillet welds, though butt welds are used a
great deal in designing pressure vessels. Of course, the parts to be joined must be
arranged so that there is sufficient clearance for the welding operation. If unusual joints
are required because of insufficient clearance or because of the section shape, the
design may be a poor one and the designer should begin again and endeavor to synthe-
size another solution.
Since heat is used in the welding operation, there are metallurgical changes in the
parent metal in the vicinity of the weld. Also, residual stresses may be introduced because
of clamping or holding or, sometimes, because of the order of welding. Usually these

Figure 9–2 Type of weld

Arc- and gas-weld symbols. Plug Groove

Bead Fillet or
slot Square V Bevel U J

Figure 9–3 60 200

Fillet welds. (a) The number

indicates the leg size; the arrow
should point only to one weld
when both sides are the same.
(b) The symbol indicates that
the welds are intermittent 5 60–200
and staggered 60 mm along on (a) (b)
200-mm centers.

Figure 9–4
The circle on the weld symbol
indicates that the welding is to
go all around.

5
 bud98209_ch09_467-508.indd Page 476 10/20/13 9:18 AM f-496 /204/MH01996/bud98209_disk1of1/0073398209/bud98209_pagefiles

476 Mechanical Engineering Design

in which Ju is found by conventional methods for an area having unit width. The

transfer formula for Ju must be employed when the welds occur in groups, as in
Fig. 9–12. Table 9–1 lists the throat areas and the unit second polar moments of
area for the most common fillet welds encountered. The example that follows is

typical of the calculations normally made.

Table 9–1

Torsional Properties of Fillet Welds*

Unit Second Polar

Weld Throat Area Location of G Moment of Area

1. A 5 0.707hd x50 Ju 5 d 3y12

G y 5 dy2
d
y

d(3b2 1 d 2 )

2. b A 5 1.414hd x 5 by2 Ju 5
6
y 5 dy2
G d

b2 (b 1 d) 4 2 6b2d 2
3. b A 5 0.707h(b 1 d) x5 Ju 5
2(b 1 d) 12(b 1 d)

d2
y5
d 2(b 1 d)

y
G

b2 8b3 1 6bd 2 1 d 3 b4
4. b A 5 0.707h(2b 1 d) x5 Ju 5 2
2b 1 d 12 2b 1 d

y 5 dy2
G d
y

5. b A 5 1.414h(b 1 d) x 5 by2 Ju 5
(b 1 d) 3
6
y 5 dy2

G d
y

6. A 5 1.414phr Ju 5 2pr3

G
r

*G is the centroid of weld group; h is weld size; plane of torque couple is in the plane of the paper; all welds are of unit width.

 bud98209_ch09_467-508.indd Page 480 10/20/13 9:18 AM f-496 /204/MH01996/bud98209_disk1of1/0073398209/bud98209_pagefiles

480 Mechanical Engineering Design

Table 9–2

Bending Properties of Fillet Welds*

Weld Throat Area Location of G Unit Second Moment of Area

1. d3
A 5 0.707hd x50 Iu 5

G
d
y 5 dy2
12
y

2. b d3
A 5 1.414hd x 5 by2 Iu 5
6
y 5 dy2

G d
y

3. b bd 2
A 5 1.414hb x 5 by2 Iu 5

y 5 dy2
2
G d
y

4. b
A 5 0.707h(2b 1 d) x5
b2
Iu 5
d2
(6b 1 d )
2b 1 d 12
d y 5 dy2

y
G

5. b 2d 3
A 5 0.707h(b 1 2d) x 5 by2 Iu 5 2 2d 2 y 1 (b 1 2d )y 2
y 3

G
d y5
d2
b 1 2d

6. b d2

A 5 1.414h(b 1 d) x 5 by2 Iu 5
6
(3b 1 d)

d
y 5 dy2
G

7. b 2d 3
A 5 0.707h(b 1 2d) x 5 by2 Iu 5 2 2d 2 y 1 (b 1 2d )y 2
y 3
d2

G d y5
b 1 2d

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Welding, Bonding, and the Design of Permanent Joints 507

References
Good references are available for analyzing and designing adhesive bonds, including
the following:
R. D. Adams, J. Comyn, and W. C. Wake, Structural Adhesive Joints in
Engineering, 2nd ed., Chapman and Hall, New York, 1997.
G. P. Anderson, S. J. Bennett, and K. L. DeVries, Analysis and Testing of
Adhesive Bonds, Academic Press, New York, 1977.
H. F. Brinson (ed.), Engineered Materials Handbook, vol. 3: Adhesives and
Sealants, ASM International, Metals Park, Ohio, 1990.
A. J. Kinloch, Adhesion and Adhesives: Science and Technology, Chapman and
Hall, New York, 1987.
A. J. Kinloch (ed.), Durability of Structural Adhesives, Applied Science
Publishers, New York, 1983.
R. W. Messler, Jr., Joining of Materials and Structures, Elsevier Butterworth-
Heinemann, Mass., 2004.
E. M. Petrie, Handbook of Adhesives and Sealants, 2nd ed., McGraw-Hill,
New York, 2007.
A. V. Pocius, Adhesion and Adhesives Technology: An Introduction, 2nd ed.,
Hanser Gardner, Ohio, 1997.
The Internet is also a good source of information. For example, try this website:
www.3m.com/adhesives.

PROBLEMS
9–1 to The figure shows a horizontal steel bar of thickness h loaded in steady tension and welded to a
9–4 vertical support. Find the load F that will cause an allowable shear stress, τallow , in the throats of
the welds.

Problem
Number b d h allow
9–1 50 mm 50 mm 5 mm 140 MPa
5
9–2 2 in 2 in 16
in 25 kpsi
9–3 50 mm 30 mm 5 mm 140 MPa
5
9–4 4 in 2 in 16
in 25 kpsi

Problems 9–1 to 9–4 d

F
b

9–5 to For the weldments of Probs. 9–1 to 9–4, the electrodes are specified in the table. For the electrode
9–8 metal indicated, what is the allowable load on the weldment?
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508 Mechanical Engineering Design

Problem Reference
Number Problem Electrode
9–5 9–1 E7010
9–6 9–2 E6010
9–7 9–3 E7010
9–8 9–4 E6010

9–9 to The materials for the members being joined in Probs. 9–1 to 9–4 are specified below. What load
9–12 on the weldment is allowable because member metal is incorporated in the welds?

Problem Reference Vertical

Number Problem Bar Support
9–9 9–1 1018 CD 1018 HR
9–10 9–2 1020 CD 1020 CD
9–11 9–3 1035 HR 1035 CD
9–12 9–4 1035 HR 1020 CD

9–13 to A steel bar of thickness h is welded to a vertical support as shown in the figure. What is the shear
9–16 stress in the throat of the welds due to the force F?

Problem
Number b d h F
9–13 50 mm 50 mm 5 mm 100 kN
5
9–14 2 in 2 in 16
in 40 kip
9–15 50 mm 30 mm 5 mm 100 kN
5
9–16 4 in 2 in 16
in 40 kip

Problems 9–13 to 9–16 d

F
b

9–17 to A steel bar of thickness h, to be used as a beam, is welded to a vertical support by two fillet welds
9–20 as shown in the figure.
(a) Find the safe bending force F if the allowable shear stress in the welds is τallow .
(b) In part a, you found a simple expression for F in terms of the allowable shear stress. Find the
allowable load if the electrode is E7010, the bar is hot-rolled 1020, and the support is hot-
rolled 1015.

Problem
Number b c d h allow
9–17 50 mm 150 mm 50 mm 5 mm 140 MPa
5
9–18 2 in 6 in 2 in 16
in 25 kpsi
9–19 50 mm 150 mm 30 mm 5 mm 140 MPa
5
9–20 4 in 6 in 2 in 16
in 25 kpsi
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Welding, Bonding, and the Design of Permanent Joints 509

Problems 9–17 to 9–20

d

b
c

9–21 to The figure shows a weldment just like that for Probs. 9–17 to 9–20 except there are four welds
9–24 instead of two. Find the safe bending force F if the allowable shear stress in the welds is τallow .

Problem
Number b c d h allow
9–21 50 mm 150 mm 50 mm 5 mm 140 MPa
5
9–22 2 in 6 in 2 in 16
in 25 kpsi
9–23 50 mm 150 mm 30 mm 5 mm 140 MPa
5
9–24 4 in 6 in 2 in 16
in 25 kpsi

Problems 9–21 to 9–24

d

b
c

9–25 to The weldment shown in the figure is subjected to an alternating force F. The hot-rolled steel bar
9–28 has a thickness h and is of AISI 1010 steel. The vertical support is likewise AISI 1010 HR steel.
The electrode is given in the table below. Estimate the fatigue load F the bar will carry if three
fillet welds are used.

Problem
Number b d h Electrode
9–25 50 mm 50 mm 5 mm E6010
5
9–26 2 in 2 in 16
in E6010
9–27 50 mm 30 mm 5 mm E7010
5
9–28 4 in 2 in 16
in E7010

h
h

d
Problems 9–25 to 9–28 F

q 3 mm

b so d 30 h 5

tallow 140 Mpa

E
0.707hL
sa

Ém
F

30mi
50

F
140

0.707 53150 50

h d what is welded Cupidown

Ath

2h

F 49.49 KN

table 9 6 E 70 30.9min f

f 0.707 thx tall

0.707 5 145 512.57 513
N mm

F fxl
512.57 50 50 51.2575
KN
 6 100 d 50 h 8
material of bar ima
1035 HR 50 F
Yi
vertical support
only when HR 9
1020 CD
I
in the weld region CD converts
to HR
 Sy Sat
1035 HR
Bar 270 500
1020 HR 210 380
U.S
vertical support controls the
design
F
tall 0.707 4 1

hand I are known

Tay is
not so
go to table 9 4

Tallow min 0.40 Sy 0.30 Sat

mine 0.40 210 0.30 380

min 84 114
tallow 84
 F
tallow 0.707 X Dx l
F
84
0.707 8 100 100

F 95 02 K N
 F
tallow
0.707 Chxly
100 103
0.707 5 50 30450430

176.80 MPa
total allowed shears pritsec
Primary shear t
t F table a 1
a

T's F case 2 interchad

1 41xhxd
f and d
d here is bi
F
t
1 41 5 50
T 2.83 10 3 F
 shear T
Secondary
T

t
m
Only
miry m ru
J J
M Fx 150
8
ry E
F 175 CSO
TE J
Ju from 9 2
d 364dg
I 6

exchang b and d
50 315032 15032 83.33 103
Jw 6
5 0.707 Xh 0.707 5 83.33 103
XIU
294 58 103 mm 4
Fx 175 25
Ig 294.58
so 015 F MPa
Of o o 015 F MPa
tallow Ct E Y CTLTTY
140 F
0.01512 12.836 103 0.01532
F 6.007 KN
 F
é
bl A
Sy Sat
EIOZOHR 210 380
E IOISHR 190 340
E 7010
393 982
table 9 3

Vertical support controls the design

tallow min 0.4
Sy 03 Sat

min 0.4 190 10.3 340

Tallow
76
tallow

Then
I F
allow www
 Force F wi not cause primary shear
I 0

t
TI due to torsion

5 0.7074 Ju
by 2153
0.707 X r 40 mm

5 mm

7 200 8 x
t
TJ 0.707
XSXZICE
140
7 600 81 40
0.707
XSXZICE
F 20.730 KN
 h
fifty

material
SL Sat
1018 HR 220 400

Electrode table 9 3

they are the smallest values so we

choose 60

E 6010 345 Sat 427

Sy
Design is based in material

Tallow Mine 0.3 Sat 0.4 Sy

min O 3 400 0.4 220
min 120 88
tallow 88 MPa
 F tensile
F
tallow
0.707 thx lx n n number of
sides welded
hn F
o.to txt allow t

75

754
n h s
100 103
0.707 88 75 n h
nh 21.43 mm
I 21 43 mm X
2 10.71 5 mm

3 7.143 mm

best choice to weld 4 5.35mm 6mm

on the four sides

Pattern
2 parallel 2 transverse fillet weld

Type of weld fillet weld

length of weld 75mm 44

size ch 6mm
leg thickness of the weld
one decision we're making is let's weld
a TWO PARALLAL fillet weld

Going back to the

table

Electrode EGO XX
1080 H R zito 4ft
345 427
tallow min O 3x Sat O
Gay
Tallow min O 3 400 0.4 220

Oallow 88 MPa
12 103 12 103 113.15
t
414 x had 1 414 4 75
Y h
 t
MI E sont
Mary Ttt y
Is J
J 0.707 thx Ju
d 36414 7513 753 753
Ju 6 6
281.25 103 mm

J 0.707 3 281.25 103 198.84 103

mm 4

the Far x
g
Myra J
12 10 X 150 37.5 37.5
T m
198.84 103 h moment
e d
the 424.39
guy
b
Thet't because

Betty
tallow the that y
2
88
I 424 34 113.1 424.345

ih 7.78mm 8mm

solved
 Pri shear secondaryshear Remarks
M
Force F
I t A
In from
s
I
1 0.7074 x Iu table 9 2
T
I
Torque T a Ia
table 9 I

Z
Tallow Ct'S CEB Ct's
t's T's can't be added together
since they are not at the same
plane
103 103 59
Ts 2
0.707 6 211225,3
120.06 Mpa
5
Ju
T 8 103 12.00 Mpa
1.414 17 6 25

8 103 ISO X 25
IB 0.707 64 253 I
144.072

Z
tallow COTTLEB Ct's

Tallow 120 06 112336144.07232

tallow 187.92 MPa

 table 9 2

gift
E F
A
m r
O
T

Wd a
b Transverse load
Exerst Shear force

Weld Symbols
Problem 9 i n 3

9
3
ELI 2
e

Sheaf
Fothe
sing allow

d 30
he s i 140 f
T 14014Pa 707 5
5011g
des

F 49.494J

9 7

aim same shape before

E7010 Go to table 9 6
b 50
d 30 i f 707th x Callow
he s
707 5 144

i
f 509.04 Mmm
i F s f l 509.04 50 50

50.9 KN
 5.9 N

q 9 29 12

912

b
tiffin f

d 50 Note when welding ed materials are changed

4 8 to HR
3ar1035HR
V S 1020 CD

Bar 1035 HR v s 1020 Hr

270
1035 HR Sat 500 Sy
Sy 210
1020 HR Sat 380

value
1020 HR is lower in
NII Since UI
design
Hence it is controlling the

table
Shear Tallow v s C 3 Sut m Sy
Fillet

Tallow 114 or 84 MPa

 170

i T allow 84 MPa

100
F 707 8 100

i f 95.02 KN

Ex 9 17 09 20

919
a

studs 1h
É
c 150
d 30
h 5
Tallow 14014Pa i joint fail by Pri shear and 2ndary
Shear

me
 Table 9 1 torsion case 3

A 1.414 hd
1.414 5 50
353.5 mm

I s
Ed

i
E
MI g
Mj
from Table 9 2
Cay I 1 I IIb
Ju d 36 t d 502
so 31307
6 6
B Ju 43.3 10 mm

J 707 h Ju

J 153 1 x 103 want

 J 153.1 X 10 um

Fx 175 15
i Tx s TX 0171 F
153.1 103

Ty's Fx 175 25
153.1 103
Ty 0286 f

r T Tx t
g tty
i Tallow f
i
140 F

i f 3.9 KN

Bar 1020HR Sut 210 5y 380

US 1015 MR Sur
190 Sy 340
E 7010
Sat 393
Sg 482

The
UI is controlling the design
Tallow min 3 Sat 4 Sy

US 36340 4 1907

us 102 76

76 MPa

T Tx t
g tty
From before

76 F f

F 2 12 KN
 Ex9
29_
Given

Tallow 140M
q
MI
s

Prim shear so

2nd Shear
Tf
5 240 40 Tabu
i 140 9 2
707 5 2
214
Ju
ri
f's
9

Sat 400
Sy 220
101s
sat 427
EGO 345
Sy

Y Sy
Tallow min
of C 3 Sat

88 MPa

Callow f
got tht nd

i nh F
7074 ex tallow

100 103
21.43 mm

707 75 88

n I 2 3 4
h 21.43 10.7 7.17 5.28

weld all 4 Sides with h 6mm From table

 Allysidy
2 Parallel x 2 Transverse x fillet weld

i Type
of wild fruit
length of wild 7s mm
 75
35 I Shear
9
07s Weld
torsion
assume 2 Sides

220 Sul 400 Shearttorsio

101s Sy
sat 427
EGO 345
Sy

Y Sy
Tallow min
of C 3 Sat

88 MPa

T
I
E
MI

J 9 37
A and fun tuber
d
J 707 thx Ju

in 2 Sides
i assuming that we welding

A Table a y
Get
Ju cure
2 Sides weld
 C

fifties
c

T's o

o E Mg
T
EL M

and Since Ry and Rx ane same

Ex
i
Ey
12 103 150 37.5 237.5
Ty 7513 75475
7074h x
G

Ex Ey
428.51
 Tallow ti't't g't e

113.15 428.577
i 88
I 428.573

i
h s 7.849 wa

h 8 un

Paterno 2 paralle fillet wild

Electrode EGOXX

Tpe weld fillet

length of meld 75
QI
QUI
Bend
Given
Imax
F 25 KN
h 9mm
Imax T t T
d 200mm
be 25mm

using case 21 Table 9 2

A 1.414 hd 1.414 9 225 25 2545.2

In 20073 3
1.333 106 mm
6

I s h In 9 1.333 106
8.483 10 mm
V2 A
 Primary Shear E

25 1000
MPa
q
I 2545.2
9.822

Secondary Shear E

T
Mf
s
F.de 25 1000 50 29 29
100
8 483
i 44 206 MPa

Letting E

T T t E

9 822 144.2063 45 28414Pa

Hence The Maximum Shear Stress in

the throat of the weld metal is

equal to 45.3 MPa

QI