Types of Fillet Joints

Fillet joints are a type of welded joint where two members are joined together at an
angle, typically a 90-degree angle, with a curved transition. The curved transition,
called a fillet, is formed by welding along the junction between the two members.
Fillet joints are versatile and commonly used in various applications due to their
simplicity and effectiveness. There are different types of fillet joints, each with its
own characteristics and applications 1. Here are some of the different types of fillet
joints:
1.
1. Concave Fillet Joint: In a concave fillet joint, the weld forms a concave curve
between the two members. The weld is wider at the base and gradually tapers
towards the top. This type of fillet joint provides increased weld strength due to
its larger volume. Example Application: Concave fillet joints are often used in
structural steel applications, such as in the construction of buildings, bridges, or
heavy machinery, where high load-bearing capacity is required

2. Convex Fillet Joint: In a convex fillet joint, the weld forms a convex curve
between the two members. The weld is narrower at the base and gradually widens
towards the top. This type of fillet joint provides good weld penetration and is
easier to inspect for quality. Example Application: Convex fillet joints are
commonly used in piping systems, such as in the fabrication of pipelines or
plumbing, where a smooth and continuous weld is required to ensure fluid flow
without obstruction

3. Flat Fillet Joint: In a flat fillet joint, the weld forms a flat surface along the
junction between the two members. The weld is evenly distributed and flush with
the surface of the members. This type of fillet joint provides a clean appearance
and minimal protrusion. Example Application: Flat fillet joints are widely used in
sheet metal fabrication, such as in the manufacturing of panels, cabinets, or
enclosures, where a flush and aesthetically pleasing joint is desired

4. Variable Fillet Joint: A variable fillet joint refers to a fillet joint where the
weld size varies along the length of the joint. This can be achieved by adjusting
the welding parameters or using different welding techniques. Variable fillet
joints allow for control over the strength, flexibility, or stress distribution in the
joint. Example Application: Variable fillet joints are commonly used in
applications that require specific mechanical properties or stress concentration
control. This can include the fabrication of structures subjected to dynamic loads
or components that require localized strength variations 1.

5 essentials of welding

A. CORRECT SELECTION OF WELDING ELECTRODES

Welding rod selection

Stick electrodes are available in a wide range of types, each of which provides
different mechanical properties and operates with a specific type of welding power
source. There are several factors to consider in welding rod selection:

 Base metal properties

 Tensile strength
 Welding current
 Base metal thickness, shape and joint fit-up
 Welding position
 Specification and service conditions
 Environmental job conditions

Before you power up your machine and pick up your electrode holder, learn more
about each of these factors.

Base metal properties

The first step in choosing an electrode is to determine your base metal composition.
Your goal is to match (or closely match) the electrode composition to the base metal
type, which will help ensure a strong weld. If you’re in doubt about the composition
of your base metal, ask yourself these questions:

 What does the metal look like? If you’re working with a broken part or
component, check for a coarse and grainy internal surface, which usually
means the base material is a cast metal.
 Is the metal magnetic? If the base metal is magnetic, chances are good that
the base metal is carbon steel or alloy steel. If the base metal is not magnetic,
the material could be manganese steel, 300 series austenitic stainless steel or a
non-ferrous alloy such as aluminum, brass, copper or titanium.
 What kind of sparks does the metal give off when touched by a grinder?
As a rule of thumb, more flare in the sparks indicates a higher carbon content
such as in A-36 grade steel.
 Does a chisel “bite” into the base metal or bounce off? A chisel will bite
into a softer metal, such as mild steel or aluminum, and bounce off of harder
metals, such as high carbon steel, chrome-moly or cast iron.

Tensile strength

To prevent cracking or other weld discontinuities, match the minimum tensile strength
of the electrode to the tensile strength of the base metal. You can identify a stick
electrode’s tensile strength by referring to the first two digits of the AWS
classification printed on the side of the electrode. For example, the number “60” on an
E6011 electrode indicates that the filler metal produces a weld bead with a minimum
tensile strength of 60,000 psi and, as a result, would work well with a steel of similar
tensile strength.
Welding current

Some electrodes can be used with only AC or DC power sources while other
electrodes are compatible with both. To determine the correct current type for a
particular electrode, refer to the fourth digit of the AWS classification, which
represents the type of coating and type of compatible welding current (see Figure 1).

The type of current you use also influences the penetration profile of the resulting
weld. For example, a DCEP compatible electrode, such as an E6010, delivers deep
penetration and produces an extremely tight arc. It also has the ability to “dig”
through rust, oil, paint and dirt. A DCEN compatible electrode, such as an E6012,
provides mild penetration and works well when bridging two joints or welding high
speed, high current fillet welds in the horizontal position.

An AC compatible electrode, such as an E6013, produces a soft arc with medium

penetration and should be used to weld clean, new sheet metal.

Base metal thickness, shape and joint fit-up

Thick materials require an electrode with maximum ductility and low hydrogen to
prevent weld cracking. Electrodes with AWS classification numbers ending in 15, 16
or 18 provide excellent low–hydrogen properties and good toughness (high impact
values) to accommodate for residual stress.

For thin materials, you will need an electrode that produces soft arcs, such as a 6013.
Also, smaller diameter electrodes will provide shallow penetration to help prevent
burn-through on thinner materials.

You’ll also want to assess the joint design and fit-up. If you’re working on a joint
with a tight fit-up or one that is not beveled, use an electrode that provides a digging
arc to ensure sufficient penetration, such as an E6010 or E6011. For materials with
wide root openings, select an electrode, such as an E6012, that creates a concave weld
face suitable for bridging gaps and making groove welds.

Welding position

To determine what position(s) a particular electrode is qualified for, refer to the third
digit in AWS classification. Here’s how you decipher the qualified electrode position:

1 = flat, horizontal, vertical and overhead

2 = flat and horizontal only

For example, a 7018 electrode can be used in the flat, horizontal, vertical and
overhead positions.

Specification and service conditions

Make sure to assess the conditions that the welded part will encounter throughout its
service. If it will be used in high heat or low temperature environments subjected to
repetitive shock loading, a low hydrogen electrode with higher ductility will reduce
the chance of weld cracking. Also, be certain to check for welding specifications if
you’re working on critical applications such as pressure vessel or boiler fabrication. In
most cases, these welding specifications will require you to use specific types of
electrodes.

Environmental job conditions

To achieve the best results, you should always remove excessive mill scale, rust,
moisture, paint and grease. Clean base metals help prevent porosity and increase
travel speeds. If cleaning your base metal is not possible, E6010 or E6011 electrodes
deliver a deep penetrating arc that has the ability to cut through contaminants.

Choosing welding rods

Consideration of the above factors will help you overcome the challenges of selecting
the correct stick electrode for your particular application. However, given the wide
range of available electrodes, several solutions may exist for one application. If you
need additional assistance with electrode selection, your local welding supply
distributor or a company representative of a reputable filler metal manufacturer can
serve as an excellent resource.

B. CORRECT ARC LENGTH

: The correct arc length varies with each electrode and application. As a good starting
point, arc length should not exceed the diameter of the metal portion (core) of the
electrode. For example, an 1/8-inch 6010 electrode is held about 1/8 inch off the base
material.
Excessively long arcs (too much voltage) produce spatter, low deposition rates,
undercuts and often leaves porosity.

C. CORRECT CURRENT SETTING: The electrode you select will determine

whether your machine should be set up in DC positive, DC negative or AC. Make
sure you have it set correctly for your application. Electrode positive provides about
10 percent more penetration at a given amperage than AC. On the other hand, DC
straight polarity, electrode negative, welds thinner metals better.) The correct
amperage setting primarily depends on the diameter and type of electrode you select.
The electrode manufacturer usually indicates the electrode’s operating ranges on the
box or enclosed materials. Select your amperage based on the electrode (a general rule
of thumb is 1 amp for each .001-inch of electrode diameter), welding position (about
15 percent less heat for overhead work compared to a flat weld), and visual inspection
of the finished weld. Adjust your welder by 5 to 10 amps at a time, until the ideal
setting is reached.

D. CORRECT ANGLE OF ELECTRODE: Stick welding in the flat, horizontal

and overhead positions uses a drag or backhand welding technique. Hold the electrode
perpendicular to the joint, and then tilt the top in the direction of travel approximately
5 to 15 degrees. For welding vertical up, use a push or forehand technique and tilt the
top of the electrode 0 to 15 degrees away from the direction of travel.
Manipulation of electrode: Each welder manipulates the electrode a little differently.
Develop your own style by observing others, practicing and noting which techniques
produce the best results. On material 1/4 inch and thinner, you don't typically need to
weave weaving the electrode because the bead will be wider than necessary. In many
instances, you'll just need a straight bead.

To create a wider bead on thicker material, manipulate the electrode from side to side,
creating a continuous series of partially overlapping circles in a ‘Z,’ semi-circle or
stutter-step pattern. Limit side-to-side motion to two times the diameter of the
electrode core. To cover a wider area, make multiple passes or use stringer beads.

E. CORRECT TRAVEL OF SPEED: Your travel speed should allow you to keep
the arc in the leading one-third of the weld pool.

Traveling too slowly produces a wide, convex bead with shallow penetration and the
possibility of cold-lapping, where the weld appears to be simply sitting on the surface
of the material.

Excessively fast travel speeds also decrease penetration and create a narrower and/or
highly crowned bead. It can also possibly lead to underfill or undercut, which is when
the area outside of the weld is concave or recessed. Note toward the end of the bead in
the image below how the bead appears inconsistent as if the puddle were trying to
keep up.