Table of Contents

1 INTRODUCTION .............................................................................................................. 1
1.1 Aim .............................................................................................................................. 2
1.2 Objectives .................................................................................................................... 2
2 LITERATURE REVIEW ................................................................................................... 2
2.1 Butt weld ..................................................................................................................... 2
2.2 Strength of butt weld ................................................................................................... 2
3 METHODOLOGY ............................................................................................................. 3
3.1 Apparatus and tools used............................................................................................. 3
3.2 Experimental procedure .............................................................................................. 4
1. Marking out and filing................................................................................................. 4
2. Milling ......................................................................................................................... 4
3. Welding ....................................................................................................................... 5
4. Grinding ...................................................................................................................... 8
4 Results ................................................................................................................................ 8
4.1 Square butt................................................................................................................... 8
4.2 V-butt .......................................................................................................................... 9
5 Analysis.............................................................................................................................. 9
5.1 Single V butt joint metal ............................................................................................. 9
5.1.1 Weld metal strength ............................................................................................. 9
5.1.2 Base metal strength ............................................................................................ 11
5.2 Square butt................................................................................................................. 11
5.2.1 Weld metal strength ........................................................................................... 11
5.2.2 Base metal strength ............................................................................................ 12
6 DISCUSSION .................................................................................................................. 13
6.1 Limitations of experiment ......................................................................................... 14
6.2 Improvements ............................................................................................................ 14
6.3 Safety measures undertaken during experiment........................................................ 14
7 CONCLUSION ................................................................................................................ 15
8 REFERENCES ................................................................................................................ 16

i
LIST OF FIGURES
Figure 1: Manual shielded arc welding operation...................................................................... 1
Figure 2: Square butt welded joint ............................................................................................. 2
Figure 3: Single v butt welded joint ........................................................................................... 2
Figure 4: Tensile loading in single v groove butt weld. ............................................................ 3
Figure 5: Shear loading in single v groove butt weld. ............................................................... 3
Figure 6 : Marking out ............................................................................................................... 4
Figure 7: Filing of work piece ................................................................................................... 4
Figure 8: Milling ........................................................................................................................ 5
Figure 9: Welding ...................................................................................................................... 6
Figure 10: After welding V-groove specimen ........................................................................... 7
Figure 11: Square butt ................................................................................................................ 8
Figure 12: V-butt cut perpendicular to weld .............................................................................. 9
Figure 8: V-butt cut along weld ................................................................................................. 9
Figure 9: Comparison of strengths between square butt and V-butt joint ............................... 13

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LIST OD TABLES
Table 1: Type of loading and their permissible stress ............................................................. 10

iii
INTRODUCTION
Welding is a fabrication process of joining together two or more metal parts. The process of
welding doesn't simply bond the two pieces together as in brazing and soldering, but, through
the use of extreme heat and sometimes the addition of other metals or gases, causes the metallic
structures of the two pieces to join together and become one. (brighthubengineering.com/,
2009).

There are many types of welding techniques used to join metals. The welding processes differ
in the manner in which temperature and pressure are combined and achieved. The welding
process is divided into two major categories: Plastic/Pressure Welding and Fusion/Non-
Pressure Welding. Welding process can be classified as: arc welding, resistance welding,
oxyfuel welding, laser welding, diffusion welding, friction welding and ultrasonic welding
(shodhganga.inflibnet.ac.in/, 2017).

In this practical, only shielded metal arc welding process is used to connect two set of metal
samples into square butt joints and single v butt joints. During SMAW, a metal electrode is
used to carry an electrical current (alternating or direct). The current creates an arc that jumps
a gap from the end of electrode to the workpiece. Enough amount of heat is generated by the
electric arc to melt the electrode and the base metal. Molten metal from the electrode travels
across the arc to the molten pool of metal of base metal where they mix together. As the arc
moves away, the mixture of molten pool of base metal solidifies and become one piece.

Figure 1: Manual shielded arc welding operation

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 Figure 2: Square butt welded joint Figure 3: Single v butt welded joint

1.1 Aim
 To study the welded butt joints and comment on their expected mechanical properties.

1.2 Objectives
 To perform milling process on one set of metal sample to chamfer the edges at 45°.
 To weld two sets of metal samples into square butt joints and single v butt joints.
 To determine which of the two welded joints has higher weld strength.

2 LITERATURE REVIEW
2.1 Butt weld
Butt welds can be described as welds whereby two pieces of metals are joined in the same
plane (Henderson, G, 2008). These types of welds require only some kind of preparation and
are used with thin sheet metals that can be welded with a single pass. Common issues that can
weaken a butt weld are the entrapment of slag, excessive porosity, or cracking. For strong
welds, the goal is to use the least amount of welding material possible. The two common types
of butt welds are square butt weld and single v groove butt weld.

The square-groove is a butt welding joint with the two pieces being flat and parallel to each
other. This joint is simple to prepare, economical to use, and provides satisfactory strength, but
is limited by joint thickness. With a single-V joint, stress tends to warp the piece in one
direction when the V-joint is filled. In a butt weld joint it is assumed that the weld can sustain
the full working stresses in tension, compression and shear (Funk, E. 2015).

2.2 Strength of butt weld

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

2
holding or, sometimes, because of the order of welding. Usually these residual stresses are not
of considerable amounts. In some cases, a light heat treatment after welding has been found
helpful in relieving them. When the parts to be welded are thick, a preheating will also be of
benefit.

Figure 4: Tensile loading in single v groove butt weld. Figure 5: Shear loading in single v groove butt weld.

For either tension or compression loading, average normal stress is

𝐹
𝜎= ℎ𝑙

where h is the weld throat and l is the length of the weld. The value of h does not include
reinforcement.

The average stress in a butt weld due to shear loading as shown in Figure 5 is

𝐹
𝜏= ℎ𝑙

And the shear strength is F = 𝜏ℎ𝑙

3 METHODOLOGY
3.1 Apparatus and tools used
This section contains the apparatus and tools used throughout the practical.
1. Two mild steel work pieces.
2. Milling machine.
3. Wire brush.
4. Bench vice.
5. Flat file.
6. Manual arc welding set up.
7. Face shield.
8. Heat resistant gloves.
9. Leather apron.

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 10. S6013 Electrode (2.6mm).
11. Polishing machine of 80, 320 and 500 grit silicon carbide paper.

3.2 Experimental procedure

The experiment was carried out under the guidance of the lab attendant.

The procedures of the practical consists of 4 parts:

1. Marking out and filing
 The 2 sets of work pieces are cut into 4 equal parts using a band saw before being handed
out.
 The 4 pieces are placed on a surface table top and are marked out into 90 degrees corners
using a scriber and an engineer’s square.
 The sides are also marked out into true and flat edges using the surface table top as a datum.
 Then 4 parts are then clamp into a bench vice and then filed down using a wasp file.
 The flat surface is then checked using the engineer’s square before further work is done.
 The 2 pieces for the butt joint is set aside as no more marking out is necessary.

Figure 7: Filing of work piece Figure 6 : Marking out

 For the V-shape joint, the inclination on the 2 work pieces need to be 45 degrees.
 So, it was decided that the 45 degrees cut would be 3 mm on each side.
 The marking out of the 3 mm mark is done using a surface gauge placed on the surface
table top.
2. Milling
The two metal pieces for the single V-groove butt joint is to be chamfered at an angle of 45o
using a milling machine.
 The metal pieces being 5mm thick implies that at least 3mm thickness need to be removed
to obtain a chamfer of 45o.
 One plate of the work pieces are clamped on the bench top of the milling machine.
 Parallel bars are used to level the work piece for milling.
 The clamp is rotated 45 degrees for the V-shaped cut.

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 The cutting bit is lowered at the surface the work piece and is moved away from the work
piece.
 The cutting bit is further lowered by 2 mm and the machine is switched on. The lubrication
fluid is set running to prevent overheating. The cutting bit is slowly and steady fed into the
work piece.
 Several passes are done until the mark is reached.
 Those processes are repeated to the other plate.

Figure 8: Milling

3. Welding
For single V-butt joint
 The specimens were placed on the welding bench with the 45° surfaces together.
 Welding face shield, gloves and apron were worn by the experimenter.
 Earthing connections were made to the work piece by clamping the ground clamp of the
arc welding machine directly to the table.
 An S6013 electrode was clamped into the electrode holder and the arc welding machine
was turned on at 110 A and 50V
 The electrode was held at an angle of 60°-80° with the work piece.
 The electrode was held in contact with the work and then separated at a proper distance
above to produce an arc.

5
 Figure 9: Welding

 The electrode was moved along the metal plates at constant speed while making
downstream feed. The weld bead was shaped by moving the arc back and forth in a zig zag
motion.
 When the end of the plates was reached, the electrode holder was taken out to break the
arc.
 The supply current was switched off.
 The slag formation was removed using a chipping hammer and the work was allowed to
cool down.

NOTE: Welding is done on one side only.

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 Figure 10: After welding V-groove specimen

For square butt joint

 The specimens were placed on the welding bench with the horizontal surfaces.
 Welding face shield, gloves and apron were worn by the experimenter.
 Earthing connections were made to the work piece by clamping the ground clamp
of the arc welding machine directly to the table.
 An S6013 electrode was clamped into the electrode holder and the arc welding
machine was turned on at 110 A and 50V
 The electrode was held at an angle of 60°-80° with the work piece.
 The electrode was held in contact with the work and then separated at a proper
distance above to produce an arc.
 The electrode was moved along the metal plates at constant speed while making
downward feed. The weld bead was shaped by moving the arc back and forth in a
zig zag motion.
 When the end of the plates was reached, the electrode holder was taken out to break
the arc.
 The supply current was switched off.
 The slag formation was removed using a chipping hammer and the work was
allowed to cool down.

NOTE: Welding needs to be done on both sides.

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4. Grinding
A piece of metal was cut perpendicular for both the square and V-groove butt joints. In
additional for the V-groove was cut along the weld. These were done using a circular
band saw.
1. The sample was washed using liquid soap and brought to a grinding machine with
rotating wheel of silicon carbide 80 grit.
2. The machine was switched on and the sample was ground to obtain a flat surface.
3. Upon obtaining a surface of unidirectional scratches, steps 1 and 2 were repeated
for grit 320, 500 respectively while rotating the sample 90° about its vertical axis
for grinding between each stage.
4. The specimen was washed and dried properly.
5. Photos and scans of the polished metal pieces were taken to be further analysed.

4 RESULTS
The dimension of the throat thickness (t) and the leg length (h) is measured using a Vernier
calliper.

4.1 Square butt

Figure 11: Square butt

x h

Throat thickness (h) = 1.89 mm

Leg length (x) = 4.41 mm

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4.2 V-butt

Figure 12: V-butt cut perpendicular to weld

x h

Throat thickness (h) = 2.08 mm

Leg length (x) = 3.25 mm

Impurities in welding

Figure 13: V-butt cut along weld

5 ANALYSIS
The measurements of throat thickness and leg length are used to find the weld strength of the
square and V-butt joints.

5.1 Single V butt joint metal

5.1.1 Weld metal strength
Taking reference from the table below:

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 Table 1: Type of loading and their permissible stress

Shear stress is given by:

𝜏𝑎𝑙𝑙 = 0.3𝑆𝑢𝑡
Tensile/compressive stress is given by:
𝜎𝑎𝑙𝑙 = 0.6𝑆𝑦

The ultimate strength (Sut) of the S6013 electrode is found to be 488MPa and the yield
strength (Sy) is 439 MPa.
𝜏𝑎𝑙𝑙 = 0.3 × 488 = 146.4 𝑀𝑃𝑎
𝜎𝑎𝑙𝑙 = 0.6 × 439 = 263.4 𝑀𝑃𝑎
For the weld to be satisfactory and no failure to occur,
𝜏𝑎𝑙𝑙 ≥ 𝜏
𝜎𝑎𝑙𝑙 ≥ 𝜎
𝐴 = 2𝑡𝑙
𝐴𝑟𝑒𝑎, 𝐴 = (1.89 × 10−3 ) × (5 × 10−2 ) × 2 = 1.89 × 10−4 𝑚2
The forces required for shear stress is given by:
𝐹
𝜏=
𝐴
𝐹 = 𝜏 × 𝐴 = 146.4 × 106 × 1.89 × 10−4 = 27 670 𝑁

The forces required for tensile/compressive stress is given by:

𝐹
𝜎=
𝐴
𝐹 = 𝜎 × 𝐴 = 263.4 × 106 × 1.89 × 10−4 = 49 783 𝑁

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5.1.2 Base metal strength
The base metal used was steel A36
Taking reference from Table 1;
Shear stress is given by:
𝜏𝑎𝑙𝑙 = 0.4𝑆𝑦

Tensile/Compressive stress is given by:

𝜎𝑎𝑙𝑙 = 0.6𝑆𝑦

𝑆𝑦 𝑜𝑓 𝑠𝑡𝑒𝑒𝑙 𝐴36 = 250 𝑀𝑃𝑎

𝜏𝑎𝑙𝑙 = 0.4 × 250 × 106 = 100 𝑀𝑃𝑎

𝜎𝑎𝑙𝑙 = 0.6 × 250 × 106 = 150 𝑀𝑃𝑎

For no failure,
𝜏𝑎𝑙𝑙 ≥ 𝜏
𝜎𝑎𝑙𝑙 ≥ 𝜎
𝐴𝑟𝑒𝑎, 𝐴 = 4.41 × 10−3 × 5 × 10−2 × 2 = 4.41 × 10−4 𝑚2

The forces required for shear stress is given by

𝐹 = 𝜏 × 𝐴 = 100 × 106 × 4.41 × 10−4 = 44 100 𝑁
The forces required for tensile/compressive stress is given by
𝐹 = 𝜎 × 𝐴 = 150 × 106 × 4.41 × 10−4 = 66 150 𝑁

5.2 Square butt

5.2.1 Weld metal strength
From Table 1,
Shear stress is given by:
𝜏𝑎𝑙𝑙 = 0.3𝑆𝑢𝑡
Tensile/compressive stress is given by:
𝜎𝑎𝑙𝑙 = 0.6𝑆𝑦

The ultimate strength (Sut) of the S6013 electrode is found to be 488MPa and the yield
strength (Sy) is 439 MPa.
𝜏𝑎𝑙𝑙 = 0.3 × 488 = 146.4 𝑀𝑃𝑎
𝜎𝑎𝑙𝑙 = 0.6 × 439 = 263.4 𝑀𝑃𝑎

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For the weld to be satisfactory and no failure to occur,
𝜏𝑎𝑙𝑙 ≥ 𝜏
𝜎𝑎𝑙𝑙 ≥ 𝜎
𝐴 = 𝑡𝑙
𝐴𝑟𝑒𝑎, 𝐴 = (2.08 × 10−3 ) × (5 × 10−2 ) = 1.04 × 10−4 𝑚2
The forces required for shear stress is given by:
𝐹
𝜏=
𝐴
𝐹 = 𝜏 × 𝐴 = 146.4 × 106 × 1.04 × 10−4 = 15 226 𝑁

The forces required for tensile/compressive stress is given by:

𝐹
𝜎=
𝐴
𝐹 = 𝜎 × 𝐴 = 263.4 × 106 × 1.04 × 10−4 = 27 394 𝑁
5.2.2 Base metal strength
The base metal used was steel A36
Taking reference from Table 1;
Shear stress is given by:
𝜏𝑎𝑙𝑙 = 0.4𝑆𝑦

Tensile/Compressive stress is given by:

𝜎𝑎𝑙𝑙 = 0.6𝑆𝑦

𝑆𝑦 𝑜𝑓 𝑠𝑡𝑒𝑒𝑙 𝐴36 = 250 𝑀𝑃𝑎

𝜏𝑎𝑙𝑙 = 0.4 × 250 × 106 = 100 𝑀𝑃𝑎

𝜎𝑎𝑙𝑙 = 0.6 × 250 × 106 = 150 𝑀𝑃𝑎

For no failure,
𝜏𝑎𝑙𝑙 ≥ 𝜏
𝜎𝑎𝑙𝑙 ≥ 𝜎

𝐴𝑟𝑒𝑎, 𝐴 = 3.25 × 10−3 × 5 × 10−2 = 1.63 × 10−4 𝑚2

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The forces required for shear stress is given by
𝐹 = 𝜏 × 𝐴 = 100 × 106 × 1.63 × 10−4 = 16 250 𝑁

6 DISCUSSION
One of the methods of stress relieving is hand peening. In this experiment, while the joint was
hot, the weld was hammered with a peen hammer along the length of the weld. This will in
turn reduces residual stresses and induces residual compressive stresses on the surfaces. As a
result, the fatigue strength of the joint is improved.

However, since there are impurities present in the weld metal, this can cause the stress
concentration to vary thus affecting weld strength and strength of parent metal.

To compare the strength of the square butt joint and V butt joint, a bar chart is created to depict
the strengths diagrammatically.

Comparison between square butt and V-butt joint

70000
60000
50000
Force/N

40000
30000
20000
10000
0
Maximum Shear Maximum Tensile Maximum Shear Maximum Tensile
force/N force/N force/N force/N
Weld metal strength Base metal strength

Single-V
Square butt joint Square
Single V-buttbutt
joint

Figure 14: Comparison of strengths between square butt and V-butt joint

As deduced from Figure 14, the maximum shear force and maximum tensile force for the single
V-butt is greater than the square butt joint. The single V-butt joint is thus stronger than the
square butt joint. In addition, the base metal strength for both square butt and V butt are greater
than their respective weld metal strength. Therefore for failure not to occur, the maximum shear
force and maximum tensile force for the weld metal strength should not be exceeded.

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The square butt joint is reasonably strong, but its use is not recommended when the metals are
subject to fatigue or impact loads. Even though, V butt joint requires more filler material than
the square joint, it is stronger than the square butt joint. As with the square joint, V joint is not
recommended when subjected to bending at the root of the weld.

6.1 Limitations of experiment

 The shielded metal arc welding process was discontinuous due to limited length of the
electrodes.
 The welding process contained slag inclusion. Furthermore, welding was not maintained
constantly along the length of the metal piece. There are places where the reinforcement of
the weld is greater. This may affect the strength of the weld.
 Fumes make difficult the process control.
 Since the parent metal and the electrode were probably made up of the same material, it
was difficult to measure the throat thickness and leg size of the weld.

6.2 Improvements
 Digital Vernier callipers or more accurate instruments could be used to measure throat
thickness.
 Dying could have be used to know exact throat thickness and leg length.
 Observation under microscope could have been used to find any impurities in weld and
whether weld was done properly.
 Grinding could be done using diamond polishing to obtain clearer surface and have a
clearer definition of the throat thickness
 During milling each pass must be done slowly and not used to ensure proper facing.
 Welding should be done slowly so as to obtain same reinforcement and ensure a good weld.

6.3 Safety measures undertaken during experiment

 Wear protective apron and ensure it is tightly adjusted to the body.
 Protective gloves are worn
 A face weld shield is worn to prevent sparks coming into contact with the face as well as
to prevent excessive strain on the eye.
 Pliers are used while handling hot work piece after welding
 The electrode is placed far from table connected to power supply when not welding to
prevent sparks.

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 Safeguards of the machine are used accordingly.

7 CONCLUSION
The aim and objectives of this experiment was met. Comparison in terms of strength of the two
welded joints: square butt and single v butt joint was calculated and discussed. In this
experiment, the strength of single V butt welded joint was found to be greater than the square
butt welded joint. This is in correlation to the mechanical properties of the two types of welded
joint. In general, this experiment was very helpful to consolidate on the theory of welding
process.

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8 REFERENCES
 Budynas Richard G & Nisbett Keith J. (2015). Mechanical Engineering Design, 10th
edition. McGraw-Hill Education.
 Brighthubengineering.com. 2019. Introduction to welding. [Online]. Available at:
https://www.brighthubengineering.com/manufacturing-technology/90440-an-
introduction-to-welding/. Accessed on 21 November 2019.
 Nguyen O. (2017). Different Types of Arc Welding [Online]. Available at:
https://www.weldingschool.com/blog/welding/different-types-of-arc-welding/
[Accessed: 24th November 2019]

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