LECTURE III
WELDED JOINTS
INTRODUCTION
❑ A welded joint is a permanent joint which is
obtained by the fusion of the edges of the two
parts to be joined together, with or without the
application of pressure and a filler material
❑ The heat required for the fusion of the material
may be obtained by burning of gas (in case of gas
welding) or by an electric arc (in case of electric
arc welding)
❑ The latter method is extensively used because of
greater speed of welding
INTRODUCTION
❑ Welding is extensively used in fabrication as an
alternative method for casting or forging and as a
replacement for bolted and riveted joints
❑ It is also used as a repair medium e.g. to reunite
metal at a crack, to build up a small part that has
broken off such as gear tooth or to repair a worn
surface such as a bearing surface
ADVANTAGES OF WELDED OF
WELDED JOINTS OVER RIVETED
JOINTS
❑ 1. The welded structures are usually lighter than
riveted structures. This is due to the reason, that
in welding, gussets or other connecting
components are not used
❑ 2. The welded joints provide maximum efficiency
(may be 100%) which is not possible in case of
riveted joints.
ADVANTAGES OF WELDED OF
WELDED JOINTS OVER RIVETED
JOINTS
❑ 3. Alterations and additions can be easily made
in the existing structures.
❑ 4. As the welded structure is smooth in
appearance, therefore it looks pleasing.
❑ 5. In welded connections, the tension members
are not weakened as in the case of riveted joints.
❑ 6. A welded joint has a great strength. Often a
welded joint has the strength of the parent metal
itself.
ADVANTAGES OF WELDED OF
WELDED JOINTS OVER RIVETED
JOINTS
❑ 7. Sometimes, the members are of such a shape
(i.e. circular steel pipes) that they afford difficulty
for riveting. But they can be easily welded
❑ 8. The welding provides very rigid joints. This is in
line with the modern trend of providing rigid
frames.
ADVANTAGES OF WELDED OF
WELDED JOINTS OVER RIVETED
JOINTS
❑ 9. It is possible to weld any part of a structure at
any point. But riveting requires enough clearance
❑ 10. The process of welding takes less time than
the riveting
DISADVANTAGES OF WELDED OF
WELDED JOINTS OVER RIVETED
JOINTS
❑ 1. Since there is an uneven heating and cooling
during fabrication, therefore the members may
get distorted or additional stresses may develop
❑ 2. It requires a highly skilled labour and
supervision
DISADVANTAGES OF WELDED OF
WELDED JOINTS OVER RIVETED
JOINTS
❑ 3. Since no provision is kept for expansion and
contraction in the frame, therefore there is a
possibility of cracks developing in it
❑ 4. The inspection of welding work is more
difficult than riveting work
WELDING PROCESSES
❑ The welding processes may be broadly classified
into the following two groups:
1. Welding processes that use heat alone e.g. fusion
welding
2. Welding processes that use a combination of
heat and pressure e.g. forge welding
FUSION WELDING
❑ In case of fusion welding, the parts to be jointed
are held in position while the molten metal is
supplied to the joint
❑ The molten metal may come from the parts
themselves (i.e. parent metal) or filler metal
which normally have the composition of the
parent metal
FUSION WELDING
❑ The joint surface become plastic or even molten
because of the heat from the molten filler metal
or other source
❑ Thus, when the molten metal solidifies or fuses,
the joint is formed
FUSION WELDING
❑ The fusion welding, according to the method of
heat generated, may be classified as:
1. Thermit welding
2. Gas welding
3. Electric arc welding
THERMIT WELDING
❑ In thermit welding, a mixture of iron oxide and
aluminum called thermit is ignited and the iron
oxide is reduced to molten iron
❑ The molten iron is poured into a mold made
around the joint and fuses with the parts to be
welded
❑ A major advantage of the thermit welding is that
all parts of weld section are molten at the same
time and the weld cools almost uniformly
THERMIT WELDING
❑ This results in a minimum problem with residual
stresses. It is fundamentally a melting and
casting process.
❑ The thermit welding is often used in joining iron
and steel parts that are too large to be
manufactured in one piece, such as rails, truck
frames, locomotive frames, other large sections
used on steam and rail roads, for stern frames,
rudder frames etc.
GAS WELDING
❑ A gas welding is made by applying the flame of
an oxy-acetylene or hydrogen gas from a welding
torch upon the surfaces of the prepared joint
❑ The intense heat at the white cone of the flame
heats up the local surfaces to fusion point while
the operator manipulates a welding rod to
supply the metal for the weld
GAS WELDING
❑ A flux is being used to remove the slag
❑ Since the heating rate in gas welding is slow,
therefore it can be used on thinner materials
ELECTRIC ARC WELDING
❑ In electric arc welding, the work is prepared in
the same manner as for gas welding
❑ In this case the filler metal is supplied by metal
welding electrode
❑ The operator, with his eyes and face protected,
strikes an arc by touching the work of base metal
with the electrode
ELECTRIC ARC WELDING
❑ The base metal in the path of the arc stream is
melted, forming a pool of molten metal, which
seems to be forced out of the pool by the blast
from the arc
❑ A small depression is formed in the base metal
and the molten metal is deposited around the
edge of this depression, which is called the arc
crater
❑ The slag is brushed off after the joint has cooled
ELECTRIC ARC WELDING
❑ The arc welding does not require the metal to be
preheated and since the temperature of the arc
is quite high, therefore the fusion of the metal is
almost instantaneous.
❑ There are two kinds of arc welding depending
upon the type of electrode.
❑ 1. Un-shielded arc welding, and
❑ 2. Shielded arc welding.
ELECTRIC ARC WELDING
❑ The arc welding does not require the metal to be
preheated and since the temperature of the arc
is quite high, therefore the fusion of the metal is
almost instantaneous
FORGE WELDING
❑ In forge welding, the parts to be joined are first
heated to a proper temperature in a furnace or
forge and then hammered
❑ This method of welding is rarely used now-a-days
❑ An electric-resistance welding is an example of
forge welding
FORGE WELDING
❑ In this case, the parts to be joined are pressed
together and an electric current is passed from
one part to the other until the metal is heated to
the fusion temperature of the joint
❑ The principle of applying heat and pressure,
either sequentially or simultaneously, is widely
used in the processes known as *spot, seam,
projection, upset and flash welding
TYPES OF WELDED JOINTS
❑ Following two types of welded joints are
important from the subject point of view:
1. Lap joint or fillet joint
2. Butt joint
LAP JOINTS
❑ The lap joint or the fillet joint is obtained by
overlapping the plates and then welding the
edges of the plates
❑ The cross-section of the fillet is approximately
triangular.
❑ The fillet joints may be
1. Single transverse fillet
2. Double transverse fillet
3. Parallel fillet joints
Single transverse fillet
❑ A single transverse fillet joint has the
disadvantage that the edge of the plate which is
not welded can buckle or warp out of shape.
Double transverse fillet
Parallel fillet joints
BUTT JOINTS
❑ The butt joint is obtained by placing the plates
edge to edge
❑ In butt welds, the plate edges do not require
bevelling if the thickness of plate is less than 5
mm
❑ On the other hand, if the plate thickness is 5 mm
to 12.5 mm, the edges should be bevelled to V or
U-groove on both sides
BUTT JOINTS
BUTT JOINTS
OTHER TYPE OF WELDED JOINTS
CONSIDERATIONS INVOLVED IN
THE SELECTION OF WELD TYPE
❑ 1. The shape of the welded component required
❑ 2. The thickness of the plates to be welded
❑ 3. The direction of the forces applied
Strength of Transverse Fillet
Welded Joints
❑ We have already discussed that the fillet or lap
joint is obtained by overlapping the plates and
then welding the edges of the plates
❑ The transverse fillet welds are designed for
tensile strength
Strength of Transverse Fillet
Welded Joints
❑ Let us consider a single and double transverse
fillet welds as shown below
Strength of Transverse Fillet
Welded Joints
If 𝜎𝑡 is the allowable tensile stress for the weld
metal, then the tensile strength of the joint for
single fillet weld,
P = 0.707s × 𝑙 × 𝜎𝑡
❑ tensile strength of the joint for double fillet
weld,
P = 2 × 0.707s × 𝑙 × 𝜎𝑡
Strength of Transverse Fillet
Welded Joints
❑ If 𝜎𝑡 is the allowable tensile stress for the weld
metal, then the tensile strength of the joint for
single fillet weld,
P = 0.707s × 𝑙 × 𝜎𝑡
❑ tensile strength of the joint for double fillet
weld,
P = 2 × 0.707s × 𝑙 × 𝜎𝑡
Strength of Parallel Fillet Welded
Joints
The parallel fillet welded joints are designed for shear strength
Consider a double parallel fillet welded joint as shown below
Strength of Parallel Fillet Welded
Joints
If 𝜏 is the allowable shear stress for the weld metal,
then the shear strength of the joint for single
parallel fillet weld,
P = 0.707 × s × 𝑙 × 𝜏
❑ tensile strength of the joint for double fillet weld,
P = 2 × 0.707 × s × 𝑙 × 𝜏
Note the following
❑ If there is a combination of single transverse and
double parallel fillet welds as shown in below
Note the following
❑ The strength of the joint is given by the sum of strengths of
single transverse and double parallel fillet welds
❑ Mathematically,
where l1 is normally the width of the plate.
❑ In order to allow for starting and stopping of the bead, 12.5
mm should be added to the length of each weld obtained by
the above expression
❑ For reinforced fillet welds, the throat dimension may be taken
as 0.85 t
Stress Concentration Factor for
Welded Joints
❑ The reinforcement provided to the weld produces stress
concentration at the junction of the weld and the parent
metal
❑ When the parts are subjected to fatigue loading, the stress
concentration factor as given in the following table should be
taken into account
Stress Concentration Factor for
Welded Joints
EXAMPLES
❑ A plate 100 mm wide and 10 mm thick is to be
welded to another plate by means of double
parallel fillets. The plates are subjected to a static
load of 80 kN. Find the length of weld if the
permissible shear stress in the weld does not
exceed 55 MPa.
EXAMPLES
EXAMPLES
❑ A plate 100 mm wide and 12.5 mm thick is to be
welded to another plate by means of double
parallel fillet welds. The plates are subjected to a
load of 50 kN. Find the length of the weld so that
the maximum stress does not exceed 56 MPa.
Consider the joint first under static loading and
under fatigue loading.
EXAMPLES
EXAMPLES
