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Rule Of Thumb For Fillet Weld Size

Published on August 21, 2017 Messaging

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This article is an introductory lesson for fillet weld sizing. The methods below apply
only to the specific scenarios in which they are described. A basic understanding of
related terminology is assumed.

To develop the full strength of a plate using fillet welds, it is necessary that the leg size of
the fillet be 3/4 of the plate thickness. A fillet weld with this leg size will out-pull its plate
under any magnitude and direction of loading.

This rule of thumb assumes the following:

1. fillet weld on both sides of the plate

2. fillet weld for the full length of the plate

3. If the plates are different thicknesses, the thinner plate thickness should be used

An example t-joint is shown below with a weld size of 3/8" on 1/2" plates:
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If designing for rigidity, meaning the stress in the plate is lower than 1/3 to 1/2 of the yield
strength, a leg size of only 1/4 to 3/8 of the thickness of the plate is required. Intermittent
welds may also be used to reduce the total volume of weld for a rigidity design.

If a weld can only be made on one side of the plate, then the weld size should be doubled.

The following table gives the leg size of fillet welds for various plate thicknesses based on
the previous formula. It's easy to calculate them yourself, but this table is a useful resource Messaging

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If there is not enough welding heat input into a thick plate, a weld can cool too rapidly,
resulting in a joint with poor penetration (a weak joint). The American Welding Society
(AWS) has established minimum weld sizes for thick plates. In practicality, very thick plates
should be preheated. The AWS table is shown below:

The methods above are a quick and reliable way to size simple fillet weld joints. Complex
critical joints, however, should be treated with more care. See my other article "Weld
Sizing" for more information on how to calculate weld stress under tension, compression,
vertical shear, bending, and twisting.
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Thomas Lakas, P.E. 3 articles Follow

Mechanical Engineer at Tuff Torq
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subramanya hareyur
Project Lead Engineer

Thanks for sharing 8mo

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Vinu Shaji
Lead Engineer @ HCL Technologies

Thank for the information very useful. 7mo

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