MEC 3416 Design II

Welded Joints

www.eng.monash.edu
Relevant Lectures
Material Selection
Load Analysis,
Stress
Bearing I
Bearing II
Buckling
Fatigue I
Fatigue II
Welded Joints

2
 Permanent Joints

• Rivets

• Welding

• Bonding

3
Welding
• A weld is a union or fusion between metal surfaces
brought about by the localized application of heat.
• Common because it is a quick and cheap permanent
joining method. Not suitable if disassembly required
during maintenance.

Source: http://www.lincolnelectric.com.au/ 4
Welding
• Common Sources of heat
– Electric (Resistance Welding)
– Oxy-Acetylene
– Friction
• Side effects
– The heat can lead to phase change in the base metal
as a consequence of heating and cooling.
– Warping (loss of geometry) of components as a
consequence of uneven localised expansion (during
heating) and contraction (during cooling) which can
also be coupled with fixation forces (generated
through welding fixtures which are used to hold parts
together). Warping and residual stresses are more
likely to occur during the welding of parts with
varying sections or irregular shape.
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Welding
• Often lower cost by welding than casting or
forging
• Workpieces melting at common surfaces

Electrode
Flux coating

Arc
Gaseous shield
Slag
Base metal

Molten pool

Typical Electric Arc Welding 6

Welding

7
 Welding Processes

Oxyfuel gas welding (OFW) Resistance welding (RW)

Oxyacetylene welding (OAW) Resistance spot welding (RSW)

Pressure gas welding (PGW) Resistance seam welding (RSW)
Projection welding (RPW)
Arc welding (AW)
Solid state welding (SSW)

Shielded metal arc welding (SMAW) Forge welding (FOW)

Gas metal arc welding (GMAW) Cold welding (CW)
Pulsed arc (GMAW-P) Friction welding (FRW)
Short-circuit arc (GMAW-S) Ultrasonic welding (USW)
Electrogas (GMAW-EG) Explosion welding (EXW)
Spray transfer (GMAW-ST)* Roll welding (ROW)
Gas tungsten arc welding (GTAW)
Flux cored arc welding (FCAW) Unique processes
Submerged arc welding (SAW)
Thermit welding (TW)
Plasma arc welding (PAW)
Laser-beam welding (LBW)
Stud welding (SW)
Electroslag welding (ESW)
Electron-beam welding (EBW)
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DeGarmo’s Material & Processing in Manufacturing, 10th edition
Electric Arc Welding
• Very common, usually a transformer or an inverter
to convert mains power to a constant current
source. AC or DC current supplied to weld. DC is
more penetrating. Constant current to maintain
equal penetration at varying distances between
electrode and workpiece.
• Heat is obtained from an electric arc passing
between an electrode and the work piece.
• The electrode which is composed of a suitable filler
material is melted and fed into the joint as the weld
is progressively formed.

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Shielded metal arc welding

• In shielded metal arc welding, a heavy coating of flux

shields the electrode. The flux is consumed and
produces a gas shield and/or slag shield over the
molten surface
• Both electrode and flux are consumed as the rod is
melted.

Shielded metal arc welding, source: wiki 10

Shielded metal arc welding
• Note the markings on the electrode or the packet.
• For welding of mild steel, E6013 means
– E denotes electric arc welding
– First two number denote ultimate tensile strength i.e. 60 means 60
ksi. Yield ~12 ksi Lower. 70 also very common.
– Third number denote welding position, 1 – all position, 2 – flat and
horizontal only, 3 – flat position only
– last two digits together indicate the type of coating and the type of
power supply required, e.g. 10 means organic coating and DC
current with reverse polarity.
• Electrodes for welding stainless steel also very
common but $$. Electrodes for a welding a wide variety
of materials are available.

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 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.

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Gas metal arc welding
• In gas metal arc welding (or metal inert gas - MIG
welding), argon or CO2 is used instead of flux
coating to shield the weld area.
• In tungsten inert gas welding (TIG welding), CO2 is
used to shield the weld area with a nonconsumable
tungsten electrode and with a filler wire separately
fed in.
• Also very common but tanks of gases are needed.
Not so portable.
• Produces a much cleaner weld with less inclusions
and no slag.

GMAW torch nozzle cutaway image. (1) Torch

handle, (2) Molded phenolic dielectric (shown in white)
and threaded metal nut insert (yellow), (3) Shielding
gas diffuser, (4) Contact tip, (5) Nozzle output face.
(Source: wiki)

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Less common techniques
• Resistance welding. Electric current generating heat
passes through the workpieces which are clamped
firmly together. No flux or shield is used but the
process may be carried out in a vacuum or inert
gas. Filler material is not normally used.
• Gas welding. Usually performed with an
oxyacetylene torch. Filler wire is usually used.
• Laser beam welding, plasma arc welding, electron
beam welding, eletroslag welding.
• Pressure welding.

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Weldability

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 Weld Quality
• Welding in some critical applications (structures such
as bridges & buildings or pressure vessels) is also
governed by standards. Testing of welded joints may
also be necessary where applications are critical and
absolute certainty needed about weld joint strength.
• “Ideal” stress and strength analysis of weldments
considers the entire welded junction as though it were
made from a homogeneous single body.
• Some components that has been hardened by heat
treatment do not allow welding. E.g. some pressure
vessels and lorry/trailer chassis.

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• Underwater welding

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Butt Joints
• Butt Weld Joints: in static loading (not cyclic) of “full
penetration” good quality butt welds (Fig 11.6) the
“welded member strength / sold member strength is
100%” and “the weld is as strong as the plate” (a weld
efficiency of 100%) [Juvinall & Marshek, Sec 11.4, pg
452].

a) Open square butt joint

b) Single vee grove
c) Double vee grove
d) Single bevel butt joint

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Fillet Joints
• Fillet Weld Joints: can be identified geometrically
through a number of length scales
– Length of weld L
– Leg h
– Throat t

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Fillet Joints
– Length of weld L
– Leg h: both fillet weld legs are usually of one value. Leg
length is practically proportional to the weld plate thickness.
– Thin section, h>3mm for plates <6mm thick. Welds usually never less
than h=3mm.
> Thick sections, h>15mm for plates >150mm thick.
> 6mm< plate thickness <150mm, h between 3mm<h<15mm
– Throat t: “shortest distance from the intersection of the
(welded) plates to (the lesser of either)
> (1) the straight line connecting the ends of the two legs (common
case, convex weld bead) OR (2) the weld bead surface (poor quality,
concave weld beads)”
> for convex weld beads, t=0.707h

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Fillet Joints
• For stress calculations, the value tL is used as the
weld “throat” area
• For calculations on welds where some additional
(depthwise penetration/fusion of the weld joint
occurs in practice (Fig 11.7b), the throat area may
still be (conservatively) taken as tL.

Side
View

Front View
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Loading
• Parallel loading: both plates exert a shear load on
the weld
• Transverse loading: one plate exerts a shear load
and the other a tensile load

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Loading
Parallel loading Transverse loading

F F

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Incomplete length

Effective length Le ≈ L – 2h

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Throat area (red)

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Example11.1 – Parallel Loaded Fillet Weld
Determine static load F that can be carried by the
weld shown.

Plate thickness = 12 mm.

Sy = 350 MPa. F
AB = CD = 50 mm. A
D
B
Yield strength of weld metal = 350 MPa. C
Safety factor SF = 3.
Weld leg h = 6 mm.
F

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Example11.1 – Parallel Loaded Fillet Weld

F
Assume shear failure at throat area A = 0.707 x 6 x 100 =
h t
424 mm2
h
Using distortion energy theory
t = 0.707 h
F Ssy = 0.58Sy = 0.58 x 350 = 203 MPa.
Force F = Ssy x A/SF
= 203 x 424 / 3 = 28,700 N

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Example11.2 – Transverse-Loaded Fillet Weld

Determine static load F that can be carried by the

weld shown.
Plate thickness = 12 mm.
Sy = 350 MPa. F
AB = CD = 50 mm.
Yield strength of weld metal = 350 MPa.
Safety factor SF = 3.
Weld leg h = 6 mm.
F

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 Example11.2 – Transverse-Loaded Fillet Weld

Assume shear failure at throat area

F
t h A = 0.707 x 6 x 100 = 424 mm2
h

F Using distortion energy theory

t = 0.707 h
Ssy = 0.58Sy = 0.58 x 350 = 203 MPa.
Force F = Ssy x A/SF = 203 x 424 / 3 = 28,700 N

Same as parallel loaded fillet weld

Throat area is the same and considered under shear
force .

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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.
F

Given:
*Width = 100 mm;
Thickness = 10 mm;
P = 80 kN = 80 × 103 N; F
τ = 55 MPa = 55 N/mm2
Let l =Length of weld, and F
s = Size of weld (leg) =
h t
Plate thickness = 10 mm h

t = 0.707 h
F
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 F F

h t
h

t = 0.707 h
F F

We know that maximum load which the plates can carry for
double parallel fillet weld (P),
80 × 103 = 1.414 × s × l × τ
=1.414 × 10 × l × 55
= 778 l
∴ l = 80 × 103 / 778 = 103 mm

If adding 12.5 mm for starting and stopping of weld run, we

have
l = 103 + 12.5 = 115.5 mm
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Torsional Loading

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Review

• The stress vary linearly from zero at

the axis to a maximum at the outer
surface. The shear stress intensity at
any radius r is τ =Tr/J
• J is the polar moment of inertia of the
cross section

• For pure bending, the resulting

stresses are given by
σ=My/I where y is the distance from
the neutral axis

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Example. A 50 mm diameter solid shaft is welded to a flat plate by 10 mm fillet
weld as shown. Find the maximum torque that the welded joint can sustain if
the maximum shear stress intensity in the weld material is not to exceed 80
MPa.

Solution. Given : d = 50 mm ; h = 10 mm ; τmax = 80 MPa = 80 N/mm2

Let T = Maximum torque that the welded joint can sustain.

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 𝜋𝑡𝑑 3
Polar moment of inertia J of the weld section:
4

𝑇𝑟
𝜏=
𝐽
𝑇×𝑑/2 2𝑇
∴𝜏= =
𝜋𝑡𝑑 3 /4 𝜋𝑡𝑑 2

For ring shape weld segment:

2𝑇 2.83𝑇
𝜏𝑚𝑎𝑥 = =
𝜋 × 0.707ℎ × 𝑑 2 𝜋ℎ𝑑 2

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 2.83𝑇
𝜏𝑚𝑎𝑥 =
𝜋ℎ𝑑 2

𝜋ℎ𝑑 2 𝜏𝑚𝑎𝑥 𝜋 0.01 (0.05)2 80

𝑇= = = 2220 N ∙ m
2.83 2.83

FEA results show

stress higher than 80
MPa in some regions,
any thoughts?
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Frequently used weld sections Polar moment Section
of inertia J modulus Z
l

h -
tl3/12
h

h
h
b t(b+l)3/6 t(bl+b2/3)

h
h
d
πtd3/4 πtd2/4
37
Khurmi, A Textbook of Machine Design, 2005
Example 11.3D – In plane eccentric Loading

Determine the weld size using E60 welding rod (Sy = 345 MPa and
SF = 2.5)

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20 kN force at the loading point is equivalent
to a force 20 kN at G and a torque
T = 20 ×(300 - x ) kN mm

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For rectangular moment of inertia about
the axis of the weld segment X’ and Y’,

3
L/2 L t
I X '   y 2 dA  2  y (tdy ) 
2
0 12

t is assumed to be very small

IY '  0

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Then about axes X and Y through the CG of
total weld group based on Parallel Axis
Theorem:

3
L t
I X  I X '  Ab 
2
 Ltb 2
12

I Y  I Y '  Aa 2  Lta 2

J   I X  IY  for line weld segment

These formulas will be used for weld analysis

under general loading conditions
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 Problem
Back to the problem, first find the
100 mm
B A location of CG (red). By definition:
y

CG  Ai xi 100t.50  150t.0
x x   20 mm
150 mm A 100t  150t

 Ai yi 100t.0  150t.75
y   45 mm
C
A 100t  150t

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 Problem
20 80
B A

J    I X  IY 
45 y
for each weld segment
G
T
x
105
Parallel axis theorem

1503 t
C For side weld: J s   150t[202  (75  45)2 ]  476,250t
12
1003 t
For top weld: J   100t [ 452
 ( 50  20) 2
]  375,833t
t 12
J   J s  J t   852,083t mm4
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Torsional Stress

Since x = 20 mm, T = 20000x(300 - 20) =

5600 Nm
Previously J = 852,083t mm4
Taking horizontal and vertical components,
and using torsional stress (= Tr/J), we obtain
torsional stresses at points A and C as shown
above:
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Torsional Stress + Shear Stress

Direct shear stress = F/A = 20000/250t = 80/t MPa

From vector addition of torsional and direct stresses
we obtain total stresses at points A and C as shown
above:
Max stress occurs in C = 691.9/t MPa.
Equating: 692/t = 345 × 0.58/2.5 gives t = 8.65 mm
Thus since h = t/0.707, h = 8.65/0.707 = 12.23 mm
= 13 mm 45
Design of “unstealable bike” -Yerka

http://edition.cnn.com/2015/08/05/tech/yerka-unstealable-bike/

Welding usually required for constructing the bike frame,

and will be subject to various loads
46
Example 11.4 – Out of Plane Eccentric
Loading

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Equivalent Stress across AB
Resultant stress on AB is equivalent to
bending and transverse shear stresses

A M = 10 x 160 kN mm

10 kN

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 W=70
B A

Horizontal weld t

L = 120 Vertical weld

Transverse stress:
X X
t
V 10,000 26.3
   MPa
A (120  120  70  70)t t
C D
A

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 W=70
B A Area moment of inertia about X-X axis
for both vertical and horizontal welds:
Horizontal weld t
tL3 t.1203
L = 120 Vertical weld Iv    144,000 t
12 12
X X
Wt 3 L L
t Ih   Wt ( )2  0  Wt ( )2  70.t.(60)2  252,000t
12 2 2
 I X  2 I v  2 I h  792,000t

C D Bending stress:

Mc 160,000(60) 121.2
A
   MPa
Bending stress: IX 792,000t t
121.2

B 26.3 t Using distortion energy theory and SF:

t Resultant stress = 124/t 124 345(0.58)
Shear stress:  MPa gives t = 1.86 mm
t 3
Thus h = t/0.707 = 1.86/0.707 = 2.63  3 mm
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Liberty Ship Failure

• Cargo ships of mass production between 1941 to

1945.
• Welding was introduced to replaced riveting.
• About 30% (1,200) Libery ships suffered from cracks
with 3 suddenly split in two.
• Rapid crack growth in welds
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Additional considerations (Fatigue)

- Stress concentration

- Fatigue
- Weld has a rough surface, so usually reduced
surface factor CS
- Other factors same: SN= SN’CLCGCSCTCR
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