82

CHAPTER 9

Welding, Bonding, and the Design of
Permanent Joints

9.1 Welding Symbols

A weldment is a fabricated by welding together a collection of metal shapes, cut to
particular configurations.

The American Welding Society (AWS) made a standard welding symbol as shown in
figure 9-1 to specify welding on working drawings






















Basic weld symbols is shown in figure 9-2

83
Some types of welds that are used frequently by designers:

1. Fillet welds: figure 9-3
a. The number indicates the leg size; the arrow should point only to one weld
when both sides are the same.
b. The symbol indicates that the welds are intermittent and staggered 60 mm
along on 200 mm centers.










2. Fillet welds: figure 9-4
The circle on the weld symbol indicates that the welding is to go all around.













3. Butt or groove welds: figure 9-5
a. Square butt-welded on both sides
b. Single V with 60o bevel and root
opening of 2 mm
c. Double V
d. Single bevel








84
4. Special groove welds: figure 9-6
a. T joint for thick plates
b. U and J welds for thick plates
c. Corner weld ( may also have a bead weld on inside for greater strength but
should not be used for heavy loads
d. Edge weld for sheet metal and high loads


















9-2 Butt and Fillet Welds

A single V-groove weld loaded by the tensile force F can be shown in figure 9-7a. Thus,
for either tension or compression loading, the average normal stress is:

hl
F
= (9-1)

Where h is the weld throat and l is the length of the weld

Note: the value of h dose not include the reinforcement.

The reinforcement can be desirable, but it varies somewhat and does produce stress
concentration at point A in the figure.

If fatigue loads exist, it is good practice to grid or machine off the reinforcement.

The average shear stress in a butt weld is:

hl
F
= (9-2)

85
a c
b
A
B
C
SinB
A
b
a sin
=











A transverse fillet weld can be shown in figure 9-8.










Take a portion of the welded joint from figure 9-8 and draw a free body diagram for it.
At angle the forces on each weldment consist of a normal force F
n
and a shear force F
s
.
Thus,

cos
sin
F F
F F
n
s
=
=


Using the law of sines for the triangle in figure 9-9, the throat length t can be found as:





( ) sin cos 45 90 sin 45 sin +
=
+
=
h
t
h t

86
The nominal stresses at the angle in the weldment, and , are

( )
( )
( )
( )

2
2
sin cos sin
sin cos sin
cos sin cos
sin cos cos
+ =
+
= =
+ =
+
= =
hl
F
hl
F
A
F
hl
F
hl
F
A
F
s
n


The Von Mises stress at angle

( ) ( ) ( ) [ ]
5 . 0
2
2
2
2
5 . 0
2 2 '
cos sin sin 3 cos sin cos 3 + + + = + =
hl
F


Plot as a function


























As we can see from the plot, the largest Von Mises stress occurs at = 62.5
o
with a value
of = 2.16F/(hl)

The corresponding values of and are = 0.623 F/(hl) = 1.19F/(hl)

0
0.5
1
1.5
2
2.5
0 15 30 45 60 75 90
(degree)
F/hl

max

87
The maximum shear stress can be found by differentiating the shear equation with respect
to and equating to zero. Hence,

max
=1.207F/(hl) and = 0.5 F/(hl) at =67.5
o



Norris constructed a model of the transverse
fillet weld of figure 9-8 and used a
photoelastic experiment to report the stress
distribution along the sides AB and BC of the
weld.

An approximate graph of the results is shown
in figure 9-10a.

The result of figure 9-10a is applied to either
the weld metal or to the parent metal.






Figure 9-10a







Salakian presents data for the stress distribution across
the throat of a fillet weld which is the throat stress that
are used in design. The result of Salakian which is
shown in figure 9-10b applies only to the weld metal.






Figure 9-10b

88
The net result of photoelastic and finite element analysis of transverse fillet weld
geometry is more like that is shown in figure 9-10 than those given by mechanics of
materials or elasticity methods.

There is also no analytical approach that predicts the existing stresses.


9-3 Stresses in Welded Joints in Torsion

When a cantilever beam of length l welded to a column by two fillet welds and subjected
to a force F as shown in figure 9-12, the support of the cantilever is subjected to reaction
consists of a shear force V and a moment M.

















The shear force produces a primary shear of:

A
V
=
'
(9-4)

Where A is the throat area of all the welds

The moment at the support produces secondary shear or torsion of the welds, and it is
given by the equation

J
Mr
=
"
(9-5)

Where
r is the distance from the centroid of the weld group to the point in the weld of interest
J is the second polar moment of area of the weld group about the centroid of the group

89
Case 1: size of the welding is known:

The shear equations can be solved to obtain the maximum shear stress
If a group of welding such as the group welding given in figure 9-13, the rectangles
represent the throat areas of the welds.

To find the primary shear equation due to the shear force V

1) Find the throat area is:

Weld (1): A
1
= b
1
d
1
= (0.707h
1
)(d
1
)
Weld (2): A
2
= b
2
d
2
= (b
2
)(0.707h
2
)

Where h
1
and h
2
are the respective weld sizes

The total welding area of the entire group
A=A
1
+A
2


2) The primary shear stress can be found using equation 9-4

To find the secondary shear stress due to the torsion M

1) find the centroid G of the weld group

A
y A y A
y
A
x A x A
x
2 2 1 1 2 2 1 1
&
+
=
+
=

2) find the distance r
1
and r
2
from G
1
and G
2
to G

( ) [ ] ( ) ( ) [ ]
2 / 1
2
2
2
2 2
2 / 1
2 2
1 1
& x x y y r y x x r + = + =

3) The polar moment of inertia for weld (1)

12 12
3
1 1
3
1 1
1 1 1
b d d b
I I J
y x G
+ = + =

4) The polar moment of inertia for weld (2)

12 12
3
2 2
3
2 2
2 2 2
b d d b
I I J
y x G
+ = + =

5) The polar moment of inertia for the entire welding area

( ) ( )
2
2 2 2
2
1 1 1
r A J r A J J
G G
+ + + =
90
d
y
G
Case 2: The allowable shear stress is given and it is required to find size of the
welding:

The usual procedure here is to estimate a probable weld size and then to use iteration.

Observation of calculating the polar moment of inertia

In the equation of J
G1
and J
G2
, the quantities
3
1
b and
3
2
d are small and can be neglected.
In this case we can write J
G1
and J
G2
as:

12 12
3
2 2
2
3
1 1
1
b d
J and
d b
J
G G
= =

These new formula of J
G1
and J
G2
are linear in the weld width.

Choose b
1
= d
1
=1, which make the filled weld as a line. This will make a new polar
moment of inertia called: a unit second polar moment of area J
u


The advantage of treating the weld size as a line is the value of J
u
is the same regardless
of the weld size.

Since the throat width of a fillet weld is 0.707h, then

J=0.707hJ
u
(9-6)

Table 9-1 lists the throat areas and the unit second polar moment of area for the most
common fillet welds encountered
Weld Throat Area Location of G
Unit Second Polar
Moment of Area




12 / 2 / 0 707 . 0
3
d J d y x hd A
u
= = = =








Example 9-1
A 50-kN load is transferred from a welded fitting into a 200-mm steel channel as
illustrated in Figure. Estimate the maximum stress in the weld.
91
d
y
G
x
b











Solution

1. Draw the free body diagram, showing the
weld geometry











From table 9-1 picture number 4:
( )
4 6 2
4 3 2 3
2
) 10 ( 07 . 7 707 . 0 1280
95 4 . 10
56 190 6
2 12
6 8
2 /
2
2 707 . 0
mm hJ J mm A
mm y mm x
mm b mm d mm h
d b
b d bd b
J
d y
d b
b
x
d b h A
u
u
= = =
= =
= = =
+

+ +
=
=
+
=
+ =


2. find the primary shear stress

MPa
A
V
5 . 19
1280
25000
'
= = =
Note: the shear force is divided by two because of two sides welding

92
3. find the secondary shear stress

Find the distance r
i
as shown in figure below













[ ]
[ ]
( )
( )
( )
( )
MPa
J
Mr
MPa
J
Mr
m N Fl M
mm r r
mm r r
D C
B A
D C
B A
3 . 37
10 07 . 7
0956 . 0 2760
41
10 07 . 7
105 . 0 2760
. 2760 ) 4 . 10 100 ( 25
6 . 95 ) 4 . 10 ( ) 2 / 190 (
105 ) 4 . 10 56 ( ) 2 / 190 (
6
" "
6
" "
2 / 1
2 2
2 / 1
2 2
= = = =
= = = =
= + = =
= + = =
= + = =

4. The total shear stress at each location are:

MPa
MPa
D C
B A
44
37
= =
= =




5. The maximum stress in the weld is

MPa
D C
44
max
= = =

93
d
y
G
9-4 Stresses in Welded Joints in Bending

When a cantilever beam of length l welded to a support by fillet welds at top and bottom
as shown in figure 9-17, the beam is subjected to a shear-force reaction V and a moment
reaction M

The shear force produces a primary shear of:
A
V
=
'

Where A is the throat area of all the welds

The moment M produces a normal bending stress in the welds:
I
Mc
=
"


By treating the two welds in figure 9-17b as lines, we find the unit second moment of
area to be
2
2
bd
I
u
=

Then, the second moment of area based on the weld throat is

2
707 . 0 707 . 0
2
bd
h hI I
u
= =

The secondary shear stress (normal stress) is now found to be:

( )
bdh
M
hbd
d M 414 . 1
2 / 707 . 0
2 /
2
"
= =

Once the stress components and have been found for welds subjected to bending, they
are solved together to find the principal stresses or the maximum shear stress. Then an
appropriate failure theory is applied to determine the possibility of failure or safety.

Table 9-2 lists the bending properties fillet welds for most shape likely to be encountered
in the analysis of welded beams.
Weld Throat Area Location of G
Unit Second
Moment of Area




12 / 2 / 0 707 . 0
3
d I d y x hd A
u
= = = =

94
9-5 The Strength of welded Joints

The properties of electrodes are very considerably. Table 9-3 lists the minimum
properties for some electrode classes.

AWS Electrode No.
Tensile Strength
kpsi (MPa)
Yield Strength
kpsi (MPa)
Percent Elongation
E60xx 62(427) 50(345) 17-25
E70xx 70(482) 57(393) 22
E80xx 80(551) 67(462) 19
E120xx 120(827) 107(737) 14

The system uses an E prefixed to a four-or five-digit numbering system.
The first two or three digits designate the approximate tensile strength.
The next-to-last digit indicates the welding positions, as for example, flat, or vertical, or
overhead.
The last digit indicates variables in the welding technique, such as current supply.

The designer can choose factors of safety or permissible working stress with more
confidence if he is a ware of the values of those used by others.

The permissible stresses are now based on the yield strength of the material instead of the
ultimate strength.

Table 9-4 lists the formulas specified by the code for calculating the permissible stresses
for various loading conditions

The factor of safety implied by this code are easily calculated

For tension n=1/0.6=1.67
For shear n=0.577/0.4=1.44 using the Von Mises as a criterion of failure.

In the present of fatigue, the actual stresses cannot exceed the permissible stresses.
The fatigue strength reduction factors listed in table 9-5.

9-6 Static Loading

A method of analyzing welds problem when it is subjected to static load.

Example
Brackets are used in mooring (fastening) small watercraft such as the one shown in figure
below. Failure of such brackets is usually caused by the bearing pressure of the mooring-
line clip against the side of the hole. To get an idea of the static margins of safety
involved, a bracket 6mm thick and made of hot-rolled AISI 1018 steel is used. Assume
that the wave action on the boot will create no greater force F than 5340N. Under these
95
57mm
6mm
F
25 mm
30
o

x
y
7mm
M
F
25 mm
30
o

x
y
d=64mm
x
z
A B G
26mm
32mm
19mm
9.5mm
F
x

F
y
F
G

6mm
A B
G O C
C
conditions, determine the factors of safety guarding against a static failure. Knowing that
the hole of the bracket has a diameter of 13mm.














Solution

The free body diagram is shown in figure

The centroid of the weld group and of the bottom of the bracket is G.
The force F
G
is the force of the weld group acting on the bracket.
F
G
and F have different lines of action, therefore, the model will have a moment M
The dimensions shown are obtained from the trigonometry of the diagram
Note: the forces and moment of the bracket acting on the welds are equal and opposite to
those shown




















96
F
y
produces tension throughout the weld
F
x
produces shear throughout the weld
M produces a bending stress in the welds with tension at A and compression at C
Therefore:
F
x
= 5340cos30 = 4624.6N
F
y
= 5340sin30 = 2670 N
M = 5340(0.0095) =50.73N.m
From Table A-20: the bracket material is: S
ut
= 400MPa, S
y
= 220MPa

1) Factor of safety guarding against static yielding in the weldment

From table 9-2 for square shape we have:
( )
( )
( ) ( )
4 4 4
4 4
2 2
2
) 10 ( 75 . 23 )) 10 ( 6 . 5 )( 6 ( 707 . 0 707 . 0
) 10 ( 6 . 5 64 6 3
6
64
3
6
88 . 593 ) 64 6 )( 6 ( 414 . 1 ) ( 414 . 1
mm hI I
mm d b
d
I
mm d b h A
u
u
= = = =
= + = + =
= + = + =

The maximum shear stress due to moment and due to F
y
are occurs at point A (both of
them are tension)
Therefore, The normal stress

MPa
I
Mc
A
F
y
33 . 11
) 10 ( 75 . 23
) 032 . 0 ( 73 . 50
) 10 ( 88 . 593
2670
8 6
1
= + = + =


The shear stress due to F
x
is
MPa
A
F
x
8 . 7
88 . 593
6 . 4624
2
= = =

Use the same properties for the weld metal even though stronger electrodes could be
used. Also because the stresses are perpendicular to each other, their resultant is:
( )
22 . 9
76 . 13
) 220 ( 577 . 0
76 . 13
5 . 0
2
2
2
1
= = =
= + =

sy
S
n
MPa


2) Factor of safety guarding against static yielding in the parent metal

The shear stress in the parent metal is:
MPa
mm bd A
A
F
yx
x
yx
04 . 12
384
6 . 4624
384 ) 64 )( 6 ( ;
2
= =
= = = =

The tensile stress at A in the parent metal is
97
MPa
mm
bd
I
mm bd A
I
Mc
A
F
y
y
y
35 . 19
) 10 ( 1 . 13
) 2 / 064 . 0 ( 73 . 50
) 10 ( 384
2670
) 10 ( 1 . 13
12
) 64 )( 6 (
12
384 ) 64 )( 6 (
8 6
4 4
3 3
2
= + =
= = =
= = =
+ =

Using von Mises theory:

( )
73 . 7
45 . 28
220
45 . 28 3
'
5 . 0
2 2 '
= = =
= + =

y
yx y
S
n
MPa


3) Factor of safety guarding against static yielding in the hole

21 . 3
46 . 68
220
46 . 68
) 13 )( 6 (
5340
= = =
= = =

y
S
n
MPa
td
F



9-7 Fatigue Loading

Note: For fatigue analysis always
Use the surface finish of (As-forget) unless specified
A load factor of k
c
=0.59 for shear welding
When the material of the electrode welding is not specified, it is required to compare the
material of the attachment and the member with the electrode materials that are given in
table 9-3

Example
For the pervious example, find the factor of safety against a fatigue failure in the weld
metal of the mooring bracket. Knowing that the bracket under repeated load.

Solution

'
e
S = 0.504S
ut
=0.504(400)=201.6MPa
Surface factor:
k
a
=a(S
ut
)
b
=272(400)
-0.995
=0.7
Size factor:
effective diameter
98
d
e
=0.808(bd)
1/2
=0.808(0.707hd)
1/2
=0.808[(0.707)(6)(64)]
1/2
=13.313mm
k
b
=1.24d
-0.107
=1.24(13.313)
-0.107
=0.94
Load factor:
k
c
=0.59 shear welding
Temperature factor:
k
d
=1
Reliability factor
k
e
=1
Miscellaneous-effects factor
k
f
=1
Endurance limit:
S
e
=(0.7)(0.94)(0.59)(1)(1)(1)(201.6)=78.27MPa

Fatigue stress concentration factor K
fs

Form table 9-5 use the welding type: end of parallel fillet weld K
fs
=2.7.
The weldment under repeated loads F
max
=5340N, F
min
=0

(F
x
)
max
= 5340cos30 = 4624.6N
(F
y
)
max
= 5340sin30 = 2670 N
M
max
= 5340(0.0095) =50.73N.m
From table 9-2 (9-3, 5
ed
) for square shape we have:
( )
( )
( ) ( )
4 4 4
4 4
2 2
2
) 10 ( 75 . 23 )) 10 ( 6 . 5 )( 6 ( 707 . 0 707 . 0
) 10 ( 6 . 5 64 6 3
6
64
3
6
88 . 593 ) 64 6 )( 6 ( 414 . 1 ) ( 414 . 1
mm hI I
mm d b
d
I
mm d b h A
u
u
= = = =
= + = + =
= + = + =

The maximum shear stress due to maximum moment and due to F
y
are occurs at point A
(both of them are tension)

MPa
I
Mc
A
F
y
33 . 11
) 10 ( 75 . 23
) 032 . 0 ( 73 . 50
) 10 ( 88 . 593
2670
8 6 max
1
= + = + =



The shear stress due to maximum F
x
is
MPa
A
F
x
8 . 7
88 . 593
6 . 4624
max
2
= = =

The resultant shear stress
( )
MPa K
MPa K
MPa
fs m
fs a
58 . 18
2
0 76 . 13
7 . 2
2
58 . 18
2
0 76 . 13
7 . 2
2
76 . 13
min max
min max
5 . 0
2
2
2
1 max
=
+
=
+
=
=

=
= + =

99
Member Attachment
In shear analysis the ultimate stress for the material is modified by 0.67 using equation 7-
56. Then use Goodman theory:
26 . 3
1
268
58 . 18
27 . 78
58 . 18 1
268 ) 400 ( 67 . 0 67 . 0
= = + = +
= = =
f
f f su
m
e
a
ut su
n
n n S S
MPa S S


Among the possible of weldment problem are the following

The attachment and the member(s) exist and only the weld specifications need to
be decided
The members exist, but both the attachment and the weldment must be designed
The attachment, member(s), and weldment must be design














Example
The attachment shown in the figure is made of 1018HR steel 13mm. The static force is
111kN. The member is 100mm wide.
Specify the weldment:
The Pattern
Electrode number
Type of weld
Length of weld
Leg size










F=111kN
100mm
230mm
38mm dia.
F=111kN
76mm dia.
1
3
m
m

100
To select the welding material we compare the weld-material of table 9-3 with the
material of the attachment and the member.

Member (A36): from table 1-1: S
y
=36(6.89)=248MPa, S
ut
=58(6.89)=400MPa
Attachment (1018HR): from table A-20: S
y
=32(6.89)=220MPa, S
ut
=58(6.89)=400MPa
From table 9-3: The member and the attachment are weak compared to the E60xx
electrode. So we can select E6010

To select the allowable stress, we select the minimum
all
from A36, 1018HR, and weld
material using the following formula:

all
=min[0.3S
ut
, 0.4S
y
]from table 9-4 for shear type of loading.

A36:
all
=min[0.3(400), 0.4(248)]=[120, 99.2]=99.2MPa
1018HR:
all
=min[0.3(400), 0.4(220)]=[120, 88]=88MPa
E6010:
all
=min[0.3(427), 0.4(345)]=[128.1, 138]=128.1MPa

Therefore the allowable shear stress will be used is:

all
=min[0.3(400), 0.4(220)]=[120, 88]=88MPa

If n is the number of beads and for static load the fillets in parallel and transverse are the
same, then:

( )
mm h mm h n
mm h mm h n
mm h mm h n
mm h mm h n
m
d
F
nh
hd n
F
nA
F
all
all
6 88 . 5 4
8 83 . 7 3
12 75 . 11 2
25 5 . 23 1
0235 . 0
)) 10 ( 88 )( 076 . 0 ( 707 . 0
111000
707 . 0 707 . 0
6
= = =
= = =
= = =
= = =
= = = = =

By using four beads n = 4, the leg size h = 6mm, which make the weld all-around

Therefore, the weldment specifications:

Pattern: All around square
Electrode: E6010
Types: Two parallel fillets
Two transverse fillets
Bead Length: (4)76 =304mm
Leg size h = 6mm