Structural Steel Design 1

Welded
Connections

Dr. Sulaiman Al-Safi.

2
Welded Connections

3
Welded Connections

4
Welded Connections

Welding Definition: Welding is the most

efficient and direct way of connecting metal
pieces. It is defined as a process of creating a
strong metallurgical bond between two metal
pieces by joining and heating them to a plastic
or fluid state (melting) and allowing the pieces
to flow together and join, with or without filler
material or pressure.

5
Welded Connections
History of Welding:
5500 B.C. Egyptians recognize “forge welding” for copper and gold.
800 A.D. “Damascus Sword”-Layers of metal forge welded to high
strength.
1877 A.D. Elihu Thompson, Electric resistance welding possibility
recognized.
1889 A.D. P. Strohmeyer introduced the concept of coated electrodes
(Shielded Arc Weld), (SMAW).
1903 A.D. Fouche & Picard introduced oxyacetylene cutting and
welding techniques.
1932 A.D. Gas Metal Arc Welding (GMAW).
1990 A.D. Welding Automation (Robotics).

6
 Advantages of Weld
• Economic - eliminate gusset plate, splice plate and bolt
head saving
• Wide range of application than bolting (steel pipe column),
• Welded structures are more rigid
• Welding Fusing results in truly continuous structures
• Easier to make changes in design and to correct errors
during erection
• Relative Silence of weldingsaving on detailing,
fabrication and erection
• Fewer pieces are used ( time)

7
 Types of Welding
Welding is the process to unite various pieces of metal by creating a strong
metallurgical bond. Bond is achieved by heat or pressure or both. Welding
is generally performed by either electric (Arc Welding) or by gas (Gas
Welding). Most of the welding is done using electric supply.
• Arc Welding
An electric arc (Spark) is formed between the metal pieces and an
electrode brings them to melting point
• Gas Welding
• A mixture of oxygen and some suitable gas (acetylene) is burned at
a tip of blowpipe held in welder’s hand or by machine. The flame
produced can be for cutting and/or welding. Gas welding is relatively
cheaper, it is a slow process., used for repair and maintenance
purposes..

8
1 – Shielded Metal Arc Weld (SMAW):
A process of producing heating with an arc between a covered metal
electrode and the work pieces.
most popular welding technique.
Shielding is obtained from decomposition of the electrode covering.
Filler metal is obtained from the electrode.
The electrode coating performs the following:
o Produce gaseous shield to exclude oxygen.
o Introduce deoxider material to improve grain.
o Produce a blanket of slag to retard cooling and prevent oxidation.
The SMAW process is designated by AWS as “E6OXX” or “E7OXX”
e.g. (E 6013)

9
 2 – Submerged Arc Weld (SAW)
In this process the automatically fed
arc (spool) is protected by a blanket
of granular material called “flux”.

This flux material acts to improve weld quality and to protect it

from the air. Most (SAW) processes are used in welding shops
and not at site. (SAW) is designated by AWS as:(“FXXX-EXXX” )

10
3 – Gas Metal Arc Weld (GMAW):
The electrode is fed constantly
through a spool, and the protection is
provided constantly by some gas
mixture.
Initially, inert gases were used such as Argon, hence
called “MIG” process.
Carbon
. Dioxide (CO2) is a popular gas with this process
Recently, mixture of Argon, Helium and CO2 are used for better
weld characteristics

11
4 – Flux Arc Weld (FCAW):
Flux: A material used during arc welding to
clean the surfaces of the joint chemically, to
prevent atmospheric oxidation and to
reduce impurities and/or float them to the
surface. Weld base metal
This method was developed in 1958, very similar to (steel)

(GMAW), but the filler material is a tabular rod on a 1mm

spool that contains the flux material inside it. The

Inner flux
internal flux assumed similar role for the shield on the
SMAW process.

12
5. Electrodes Welding (EGW).
6. Electro slag Welding (ESW).
7. Stud Welding.

13
 INCREASING
DIFFICULTY

FLAT

HORIZONTAL OVERHEAD

VERTICAL

14
Filler Material Requirements

American Welding Society (AWS)

Classification System

• The AWS system distinguishes

the tensile strength, weld
position and, coating and
current.
• Manufactures may and do use
there own numbering system
and produce electrodes that do
not fit in the AWS system.

15
Filler Material Requirements (Matching Filler Metals)

16
Filler Material Requirements (Matching Filler Metals)
Base Metal (ASTM) Matching Filler Metal

A36 (Fy=250 MPa) ≤ 20 mm thick 60- and 70-ksi (420-490 MPa) filler metal
A36 (Fy=250 MPa) > 20 mm., A588[a],
A1011, SMAW: E7015, E7016, E7018, E7028
A572 Gr. 50 (Fy=345 MPa) and 55 (Fy=380 Other processes: 70-ksi (490 MPa) filler
MPa), A913 Gr. 50 (Fy=345 MPa) , metal
A992 (Fy=345 MPa) , A1018
A913 Gr. 60 and 65 80-ksi (560MPa) filler metal
A913 Gr. 70 90-ksi filler metal
[a ] For corrosion resistance and color similar to the base metal, see AWS D1.1/D1.1M
clause 3.7.3.
Notes:
In joints with base metals of different strengths, either a filler metal that matches the
higher strength base metal or a filler metal that matches the lower strength and
produces a low hydrogen deposit may be used when matching strength is required.

17
A – Butt Joints:
Requires full penetration “groove welding ”, but it eliminates eccentricity
and more pleasant to view. Suitable for shop welding.

B – Lap Joints:
Is the most common, due to ease of fitting, requires “fillet weld”, and can
.
be double-sided

C – Tee Joints:
Useful for fabricating
“Built-up” sections
D – Corner Joints:-
E – Edge joints:-

18
A) Groove Welds :
Is used to weld members
aligned in the same plane.
The weld should have the same
strength of the base material (or
even greater).
B) Fillet Welds :
More popular as they require no
special alignment of pieces, nor
edge preparation.

19
A) Groove Welds :
Is used to weld members
aligned in the same plane.
The weld should have the same (b) Fillet weld.
(a) Groove weld.
strength of the base material (or
even greater).
B) Fillet Welds :
More popular as they require no
special alignment of pieces, nor
edge preparation.

20
C) Slot Weld :
They can be used in
addition to fillet welds
when more areas of weld
are required.
D) Plug Weld :
Same as above

21
22
23
 A w = te  L w
where:
Aw = Effective area of weld.
te = Effective throat thickness.
Lw = Length of weld.

t2
t1 t t
te = t

te = t 1

24
Available Strength of Welded Joints, ksi (MPa)

25
Available Strength of Welded Joints, ksi (MPa)

26
Available Strength of Welded Joints, ksi (MPa)

27
28
Fillet welds are assumed to have a cross section of 45 right triangle, as shown. The
size of the weld is the leg of the triangle, Denoted as (w). The failure plane (the
weakest section) is along the “throat” of the weld, denoted as (t);
Where (t = 0.707 w). The length of the weld (L)
is the length of the shear plane along the weld.

Effective Area of Fillet Welds: Aw = te  Lw

where,
Aw = Effective area of weld.
te = Effective throat thickness = 0.707 w
Lw = Effective Length of weld.

29
Fillet welds are assumed to have a cross section of 45 right triangle, as shown. The
size of the weld is the leg of the triangle, Denoted as (w). The failure plane (the
weakest section) is along the “throat” of the weld, denoted as (t);
Where (t = 0.707 w). The length of the weld (L)
is the length of the shear plane along the weld.

Effective Area of Fillet Welds: Aw = te  Lw

where,
Aw = Effective area of weld.
te = Effective throat thickness = 0.707 w
Lw = Effective Length of weld.

30
1 – Minimum Size of Fillets Welds :
The minimum size of fillet
welds shall be not less
than the size required to
transmit calculated forces,
nor the size as shown in
the AISC Table J2.4.

2 – Maximum Size of Fillets Welds :

The maximum size of fillet welds of connected parts shall be:
(1) Along edges of material less than 1/4 in. (6 mm) thick; not greater than the thickness of the
material.
(2) Along edges of material 1/4 in. (6 mm) or more in thickness; not greater than the thickness of the
material minus 1/16 in. (2 mm), unless the weld is especially designated on the drawings to be built
out to obtain full-throat thickness. In the as-welded condition, the distance between the edge of the
base metal and the toe of the weld is permitted to be less than 1/16 in. (2 mm), provided the weld
size is clearly verifiable.

31
3 – Minimum Effective Length of Fillet Welds :
The minimum length of fillet welds designed on the basis of strength shall be not less than four times the
nominal weld size, or else the effective size of the weld shall not be taken to exceed one-quarter of its
length. For the effect of longitudinal fillet weld length in end connections upon the effective area of the
connected member,
l min > 4 x w with a minimum of 38 mm
w < l /4
The effective length of fillet welds shall be determined as follows:
(1) For end-loaded fillet welds with a length up to 100 times the weld size, it is permitted to take the
effective length equal to the actual length.
(2) When the length of the end-loaded fillet weld exceeds 100 times the weld size, the effective length
shall be determined by multiplying the actual length by the reduction factor, , determined as:

 = 1.2 - 0.002(l /w)  1.0 (J2-1)

where
l = actual length of end-loaded weld, mm
w = size of weld leg, mm
(3) When the length of the weld exceeds 300 times the leg size, w, the effective length shall be taken as
180w.

32
Select a suitable fillet weld size for the connection shown below:
Solution :- 12mm
Maximum weld size
For 12 mm thick plate:
25 mm
𝑤𝑚𝑎𝑥 = t − 2 𝑚𝑚 = 12 − 2 = 10 𝑚𝑚

Minimum weld size for the 25 mm thick plate = 8 mm

Select a weld size in - between 8 mm and 10mm

Note : Maximum weld size controlled by thin plate,

Minimum weld size controlled by thick plate.

33
The design strength, Rn and the allowable strength, Rn /, of welded
joints shall be the lower value of the base material strength
determined according to the limit states of tensile rupture and shear
rupture and the weld metal strength determined according to the limit
state of rupture asbase
For the follows:
metal: R𝒏 = F𝒏 BM ABM
For Welds: R𝒏 = F𝒏 𝒘 Awe
Where
ABM = cross-sectional area of the base metal, mm2
Awe = effective area of the weld, mm2
FnBM = nominal stress of the base metal, MPa
Fnw = nominal stress of the weld metal, MPa
The values of , , FnBM and Fnw, and limitations thereon, are given in Table J2.5.

34
1 – Strength of Groove welds :
The strength of full penetration groove weld is superior to that of
the base metal, if matching filler is selected.
The Nominal strength of weld per unit length (Rnw) is based on
yielding of base metal rather than on weld material:
Rn = te Fy (Tension or Compression) (N/mm)
Rn = te (0.6 Fy) (Shear) (N/mm)
where : te = effective thickness of weld.
Fy = yield stress of base metal.

35
2 – Strength of Fillet Welds :
The strength of fillet welds per unt length are always controlled by
shear on the weld plane or shear on the base metal. Thus:
Rnw = te (0.6 FEXX) weld metal. (N/mm) or
Rnw = t (0.6 Fu) base metal. (N/mm)
Where:
Rnw = Resistance (strength) of weld per unit length.
te = Effective throat thickness of weld.
t = Thickness of the base metal.
FEXX = Ultimate tensile strength of electrode.
Fu = Ultimate tensile strength of metal.

36
2 – Strength of Fillet Welds (continued) :
For fillet welds, the available strength is permitted to be determined
accounting for a directional strength increase of (1.0 + 0.50sin1.5θ) if
strain compatibility of the various weld elements is considered,
where
 = 0.75 (LRFD); Ω = 2.00 (ASD)
θ = angle between the line of action of the required force and the
weld longitudinal axis, degrees
(1) For a linear weld group with a uniform leg size, loaded through
the center of gravity
Rn = Fnw Awe (J2-4)
where
Fnw = 0.60FEXX(1.0 + 0.50sin1.5θ), MPa, (J2-5)
FEXX = filler metal classification strength, ksi (MPa)

37
2 – Strength of Fillet Welds (continued) :
2. For fillet weld groups concentrically loaded and consisting of elements
with a uniform leg size that are oriented both longitudinally and
transversely to the direction of applied load, the combined strength, Rn, of
the fillet weld group shall be determined as the greater of the following:
(i) Rn = Rnwl + Rnwt (J2-10a)
or
(ii) Rn = 0.85 Rnwl + 1.5 Rnwt (J2-10b)
where
Rnwl = total nominal strength of longitudinally loaded fillet welds, as
determined in accordance with AISC 360-16 Specifications, Table J2.5, N
Rnwt = total nominal strength of transversely loaded fillet welds, as
determined in accordance with AISC 360-16 Specifications, Table J2.5
without the increase in Section J2.4(b), N

38
Example 2:
Calculate the capacity of the connection shown
below, considering E70XX weld and (A-36) bare
metal?
Solution:-
1) Check weld size :-
Minimum weld size = 3mm (Table J.2.4)
Maximum weld size = 6 - 2 = 4 mm size is ok.
t e = 0.707w = 0.707 x 4 = 2.83 mm
2) Capacity of weld :-
R nw = t e (0.6 FEXX )
= 2.83 x 0.6 x 490
= 832 N/mm (controls)

39
3) Capacity of base metal :-

R n = t 𝑝 (0.6 Fu )
= 6 x 0.6 x 400
= 1440 N/mm

4) Capacity of Connection:-
Rn = ΦR nw x L
= 832x2x100 mm
= 166.4 kN.

(LRFD ASD
 =0.75  =2.0
Rn=0.75x166.4 Rn/=166.4/2
=124.8 kN =83.2 kN

40
Example 3 : Using LRFD method OF AISC, Select a plate thickness and
design a full penetration weld, A 572 Grade 50 (Fy=345 MPa) steel, SAW process?

Solution: DL = 53.4 kN

150 mm
1) Pu = 1.2  53.4 + 1.6  266.9 = 491.1 kN Pu

2) Determine required thickness of plate: LL = 266.9 kN

Pn = Fy Ag = 345  150  t = 51750t (controls)

or Pn = Fu Ae = 450  150  t = 67500t
𝑃𝑢 491100
∴ 𝑡𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = = = 10.54𝑚𝑚 𝑠𝑎𝑦 12𝑚𝑚 𝑡ℎ𝑖𝑐𝑘.
𝜑(52500) 0.90 × 51750

3) Select electrode from “matching table” F7XX-EXXX (FEXX = 70 ksi- 490 MPa)
4) No check required for groove welds.

41
Example 4: Design the size and length of Fillet weld for the lap joint
shown below, Use SMAW E 70XX process, plates are A-36 steel ?
Solution:

Factored load = 1.2 x 115 + 1.6 x 310 = 634 kN

Minimum weld size = 6 mm (AISC table J 2.4)
Maximum weld size = 16 – 2 = 14 mm
Select size (8 mm ) since you can get it in a single pass.
te = 0.707 x 8 = 5.66 mm

42
continued:
1) Weld capacity per inch = Rnw = te (0.6 FEXX)
= 5.66 x 0.6 x 490
= 1664 N/mm (controls)
2) Plate shear-rupture = Rnw = t (0.6Fu)
= 16 x 0.6 x 400
= 3840 N/mm
3) Total length of weld required:
𝑃𝑢 634000 Ω𝑃𝑎 2 × 425000
𝐿𝑤 = = = 508𝑚𝑚 𝐿𝑤 = = = 511 𝑚𝑚
𝜑𝑅𝑛𝑤 0.75 × 1664 𝑅𝑛𝑤 1664

Use weld around plate as shown. (Use three sides of 175 mm = 525 mm).

43
Angles are eccentric in carrying axial loads as their center of
gravity x, or y are denoted by their properties. But we can balance
the weld To comply with the angle center of gravity (CG).

𝑑
Σ𝑀𝐴 = 0 𝑇 ⋅ 𝑦 − 𝐹1 ⋅ 𝑑 − 𝐹2 ⋅ = 0
2
𝑇 ⋅ 𝑦 𝐹2
∴ 𝐹1 = −
𝑑 2

Since (F2) is known (Leg length x weld capacity),

Then (F1) is found, also: F3 = T – F1 – F2

44
Example 5
Design a balanced weld for the
single angle shown in the figue,
(A 572-Gr 50 steel) and SMAW
process specified
Solution:
1) Section capacity:
Pn = Fy Ay = 350 x 2330 = 815.5 kN
or Pn = Fu Ae = 450 x 0.85 x 2330 = 891.2 kN (controls).
2) Steel weld size: LRFD ASD

Minimum weld size = 5 mm (Table J2.4)  =0.75  =2.0

Maximum weld size = 9.5 mm – 2 mm =7.5 mm Rn=0.75x891.2 Rn/=891.2/2

= 668.4 kN = 445.6 kN
Use 6mm fillet weld with E 70XX electrodes (490 MPa).
te = 0.707 x 6 = 4.24 mm

45
 contd.
3) Evaluate weld capacity LRFD:
 Rnw =  te (0.6 FEXX) = 0.75 x 4.24 x 0.6 x 490
= 934.9 N/mm (controls)
or  Rnw =  t (0.6 Fu) = 0.75 x 9.5 x 0.6 x 450
= 1923.8 N/mm
4) Determine weld length required:
F2 =  Rnw Lw
= 934.9 x 152 = 142105 N
𝟖𝟗𝟏. 𝟐 × 𝟏𝟎𝟎𝟎 × 𝟒𝟗 𝟏𝟒𝟐𝟏𝟎𝟓
∴ 𝑭𝟏 = − = 𝟐𝟏𝟔𝟐𝟒𝟏𝑵
𝟏𝟓𝟐 𝟐
𝑭𝟑 = 𝝋𝑷 − 𝑭𝟏 − 𝑭𝟐
= 𝟖𝟗𝟐𝟐𝟎𝟎 − 𝟏𝟒𝟐𝟏𝟎𝟓 − 𝟐𝟏𝟔𝟐𝟒𝟏 = 𝟓𝟑𝟐𝟖𝟓𝟒𝑵
𝟐𝟏𝟔𝟐𝟒𝟏
𝑳𝒘𝟏 = 𝟗𝟑𝟒.𝟗 =2𝟑𝟏.3 mm use 240 mm
𝟓𝟑𝟐𝟖𝟓𝟒
𝑳𝒘𝟑 = = 569.9 mm use 570 mm
𝟗𝟑𝟒.𝟗

46