Simple Connections WELDED - CONCEPTS & CODES onWelding is the process of joining two steel pieces (the base metal) together by heating them to the point that molten filler material mixes with the base metal to form one continuous piece. Webster's defines welding as "to unite (metallic parts) by heating and allowing the metals to flow together...". The process of welding is quite complex and the strength of welds is highly dependent on metallurgy, welding procedure, and the skill of the welder.WELDING PROCESS Shielded Metal Arc Welding (SMAW) - also known as manual, stick or hand welding. It is a manual arc welding process that uses a consumable electrode covered with a flux to lay the weld. The coating has two purposes: it forms a gas shield to prevent impurities in the atmosphere from getting into the weld and it contains a flux that purifies the molten metal.WELDING PROCESS Gas Metal Arc Welding (GMAW) — also known as Metal Insert Gas (MIG) welding or Metal Active Gas (MAG) Welding. It is a welding process in which an electric arc forms between a consumable wire electrode and the workpiece metal(s), which heats the workpiece metal(s), causing them to melt and join. GMAW EQUIPMENT AND SETUPWELDING PROCESS Flux Cored Arc Welding (FCAW) — this process is almost similar to GMAW process, the difference is that the filler wire has a center core which contains flux. The flux itself is relied upon to generate the necessary protection from the atmosphere, producing both gaseous protection and liquid slag protecting the weld.WELDING PROCESS Submerged Arc Welding (SAW) -— the process requires a continuously fed consumable solid or tubular (metal cored) electrode. The weld pool is protected from the surrounding atmosphere by a blanket of granular flux fed at the welding gun.WELDABILITY OF MATERIALS Metallurgy has a strong influence on the ability to weld different types of steel. It is important to match weld materials to the base metals that are being connected. Table 5.1.1 Matching Filler Material for BGSCM Problems Base Metal SMAW SAW Fy < 50 ksi [E60XX or E70XX|F6XX or F7XXTYPE OF WELDS Groove welds - Groove welds are generally used to fill the gap between the two pieces being connected. They are called groove welds because the edges of the materials being joined are prepared so that there is a groove of some shape formed when the pieces are first laid together. The weld metal fills the groove.TYPE OF WELDS Fillet welds - Fillet welds do not penetrate the gap between the parts being connected. A fillet weld generally has a triangular cross section with one leg of the triangle being attached to each piece being connected. Fillet welds are very common and are used for a variety of connections.TYPE OF WELDS Slot and plug welds - Slot & Plug welds are similar to fillet welds in that they do not penetrate the gap between the parts being connected. These welds fill a slot or hole in one of the pieces being connected with the connection being between the edge of the slot or hole on the one piece and the surface of the other piece. The welds can be made in conjunction with fillet welds to shorten the lap of two pieces where space is limited.TYPE OF WELDS Flare bevel welds - Flare bevel welds are used when joining curved surfaces such as rods and HSS to other surfaces.DESIGN SHEAR STRENGTH PER UNIT LENGTH OF FILLET WELD Rn 2 Ru ; O=0.75 Rn = 0.75[0.707 W Fry, Fay = 0.6 Fey weld ultimate weld ultimate tensile strength E6000: Fi, = 60ks! = 415MPa E70xx: Fu, = 7OKsi = 485MPa E800: F;,, = 8Oksi = 5SOMPa Check Base-Metal Shear a. Shear yield strength: @Rn = 1.0[0.6F, thk] b. Shear rupture strength: ®Rn = 0.75(0.6F, thk] *For longitudinal and transverse welds, use larger nominal strength from RN Row + Row b. RN =O.85Rg) + 1-SRoeThe minimum length of a fillet weld may not be less than four times the nominal leg size of the weld. Should its length actually be less than this value, the weld size idered effective must be reduced to one-quarter of the weld length. The maximum size of a fillet weld along edges of material less than 1/4 in thick equals the material thickness. For thicker material, it may not be larger than the (terial thickness less 1/16 in, unless the weld is specially built out to gi ss. For a plate with a thickness of 1/4 in or more, it is desirable the weld back at least 1/16 in from the edge so that the inspector can clearly see the edge of the plate and thus accurately determine the dimensions of the weld throat.MINIMUM SIZE OF FILLET WELD To 6 inclusive Over 6 to 13 Over 13 to 19 Over 19MAXIMUM SIZE OF FILLET WELD of Maximum Size of Fillet Weld, mm BU lg mm less than 6 mm $ thickness of the material 6mm or more < thickness of the material - 2mmMINIMUM LENGTH OF FILLET WELD The minimum permissible length of a fillet weld is four times its size. where: w = weld size L = length of weld MAXIMUM LENGTH OF FILLET WELD AISC does not impose a limit on the length of welds, but for end-loaded welds, there are some restrictions. End-loaded welds are longitudinal welds at the end of an axially loaded member. If the length exceeds 100 times the weld size, a reduced effective length is used in the computation of strength. The effective length is obtained by multiplying the actual length by a factor b, where B=1.2-0.002¢/w)<1.0 If the length is larger than 300 times the weld size, use an effective (= actual length of weld length of 180w. END RETURNS When a weld extends to the end of a member, it is sometimes continued around the corner, as shown in the figure. The primary reason for this continuation, called an end return, is to ensure that the weld size is maintained over the full length of the weld. The AISC Specification does not require end returnsExample 7.12 A plate u: mber is Figure 7.40. The welds are “/¢-inch fillet welds ma connected parts are of A3 ime that the tensile s adequate, and determine the available strength of the welded « FIGURE 7.40. [Sed De OTTO CO EC ELE LIE CRC u LU UE ag welds and A572 Gr, 50 for the connecting members. Size Oypera RCO BCU tam) COR ee Cu eee Cea aT COST EL ay hy = $45 MP, smExample 7.15 Aplate' X 4 of A36 steel is used as a tension member to carry ase of 6 kips and a live load of 18 is to be attached to a plate, as shown in Figure 7.43. Design a welded connection. E70XX electrodes will be used. FIGURE 7.43 A36 steelSAMPLE PROBLEM 4; (Eccentric Welded Connection - Analysis) For the given welded bracket shown, a. Calculate ultimate shear force on welds b. Calculate design shear strength of welds use E60xx and w = 8mm c. Check adequacy of fillet weld