Budynas−Nisbett: Shigley’s III. Design of Mechanical 9.

Welding, Bonding, and © The McGraw−Hill 469

Mechanical Engineering Elements the Design of Permanent Companies, 2008
Design, Eighth Edition Joints

466 Mechanical Engineering Design

in which Ju is found by conventional methods for an area having unit width. The trans-
fer formula for Ju must be employed when the welds occur in groups, as in Fig. 9–12.
Table 9–1 lists the throat areas and the unit second polar moments of area for the most
common fillet welds encountered. The example that follows is typical of the calcula-
tions normally made.

Table 9–1

Torsional Properties of Fillet Welds*

Unit Second Polar

Weld Throat Area Location of G Moment of Area

A 0.70 hd x̄ 0 Ju d 3 /12
G
d
ȳ = d/2
y

b d(3b2 + d 2 )
A 1.41 hd x̄ = b/2 Ju =
6
ȳ = d/2
G d
y

b b2 (b + d )4 − 6b 2 d 2
A 0.707h(2b d) x̄ = Ju =
2(b + d) 12(b + d )
d2
d ȳ =
2(b + d )
G
y

b b2 8b3 + 6bd 2 + d 3 b4
A 0.707h(2b d) x̄ = Ju = −
2b + d 12 2b + d
G d ȳ = d/2
y

b (b + d)3
A 1.414h(b d) x̄ = b/2 Ju =
6
ȳ = d/2
G d
y

A 1.414 πhr Ju 2π r3
G
r

*G is centroid of weld group; h is weld size; plane of torque couple is in the plane of the paper; all welds are of unit width.
 Budynas−Nisbett: Shigley’s III. Design of Mechanical 9. Welding, Bonding, and © The McGraw−Hill 473
Mechanical Engineering Elements the Design of Permanent Companies, 2008
Design, Eighth Edition Joints

470 Mechanical Engineering Design

Table 9–2
Bending Properties of Fillet Welds*

Weld Throat Area Location of G Unit Second Moment of Area

d3
A 0.707hd x̄ 0 Iu =
G
d 12
y
ȳ d/2

b d3
A 1.414hd x̄ b/2 Iu =
6
ȳ d/2
G d
y

b bd 2
A 1.414hd x̄ b/2 Iu =
2
ȳ d/2
G d
y

b b2 d2
A 0.707h(2b d) x̄ = Iu = (6b + d )
2b + d 12
G d ȳ d/2
y

b 2d 3
A 0.707h(b 2d ) x̄ b/2 Iu = − 2d 2 ȳ + (b + 2d )ȳ 2
y 3
G d2
d ȳ =
b + 2d

b d2
A 1.414h(b d) x̄ b/2 Iu = (3b + d )
6
ȳ d/2
G d
y

b 2d 3
A 0.707h(b 2d) x̄ b/2 Iu = − 2d 2 ȳ + (b + 2d )ȳ 2
3
y
d2
G d ȳ =
b + 2d

x
 Budynas−Nisbett: Shigley’s III. Design of Mechanical 9. Welding, Bonding, and © The McGraw−Hill 475
Mechanical Engineering Elements the Design of Permanent Companies, 2008
Design, Eighth Edition Joints

472 Mechanical Engineering Design

Table 9–3 AWS Electrode Tensile Strength Yield Strength, Percent

Number* kpsi (MPa) kpsi (MPa) Elongation
Minimum Weld-Metal
Properties E60xx 62 (427) 50 (345) 17–25
E70xx 70 (482) 57 (393) 22
E80xx 80 (551) 67 (462) 19
E90xx 90 (620) 77 (531) 14–17
E100xx 100 (689) 87 (600) 13–16
E120xx 120 (827) 107 (737) 14

*The American Welding Society (AWS) specification code numbering system for electrodes. This system uses an E prefixed to a four-
or five-digit numbering system in which the first two or three digits designate the approximate tensile strength. The last digit includes
variables in the welding technique, such as current supply. The next-to-last digit indicates the welding position, as, for example, flat,
or vertical, or overhead. The complete set of specifications may be obtained from the AWS upon request.

Table 9–4 Type of Loading Type of Weld Permissible Stress n*

Stresses Permitted by the Tension Butt 0.60Sy 1.67
AISC Code for Weld Bearing Butt 0.90Sy 1.11
Metal Bending Butt 0.60–0.66Sy 1.52–1.67
Simple compression Butt 0.60Sy 1.67
Shear Butt or fillet 0.30S†ut

*The factor of safety n has been computed by using the distortion-energy theory.
†
Shear stress on base metal should not exceed 0.40Sy of base metal.

a welded cold-drawn bar has its cold-drawn properties replaced with the hot-rolled
properties in the vicinity of the weld. Finally, remembering that the weld metal is usu-
ally the strongest, do check the stresses in the parent metals.
The AISC code, as well as the AWS code, for bridges includes permissible stresses
when fatigue loading is present. The designer will have no difficulty in using these
codes, but their empirical nature tends to obscure the fact that they have been estab-
lished by means of the same knowledge of fatigue failure already discussed in Chap. 6.
Of course, for structures covered by these codes, the actual stresses cannot exceed the
permissible stresses; otherwise the designer is legally liable. But in general, codes tend
to conceal the actual margin of safety involved.
The fatigue stress-concentration factors listed in Table 9–5 are suggested for
use. These factors should be used for the parent metal as well as for the weld metal.
Table 9–6 gives steady-load information and minimum fillet sizes.

Table 9–5 Type of Weld Kfs

Fatigue Reinforced butt weld 1.2
Stress-Concentration Toe of transverse fillet weld 1.5
Factors, Kfs End of parallel fillet weld 2.7
T-butt joint with sharp corners 2.0
 476

Table 9–6

Allowable Steady Loads and Minimum Fillet Weld Sizes

Schedule A: Allowable Load for Various Sizes of Fillet Welds Schedule B: Minimum Fillet Weld Size, h
Design, Eighth Edition

Strength Level of Weld Metal (EXX)

Mechanical Engineering
Budynas−Nisbett: Shigley’s

60* 70* 80 90* 100 110* 120

Allowable shear stress on throat, ksi (1000 psi) of fillet weld

Elements

or partial penetration groove weld

τ= 18.0 21.0 24.0 27.0 30.0 33.0 36.0

Allowable Unit Force on Fillet Weld, kip/linear in

III. Design of Mechanical

Material Thickness of Weld Size,

Thicker Part Joined, in in
†
f= 12.73h 14.85h 16.97h 19.09h 21.21h 23.33h 25.45h
1 1
*To 4
incl. 8
Joints

Leg Allowable Unit Force for Various Sizes of Fillet Welds 1 1 3

Over 4
To 2 16
Size h, in kip/linear in
1 3 1
Over 2
To 4 4
1 12.73 14.85 16.97 19.09 21.21 23.33 25.45 † 3 5
Over 4
To 1 12 16
the Design of Permanent
9. Welding, Bonding, and

7/8 11.14 12.99 14.85 16.70 18.57 20.41 22.27 3

Over 1 21 To 2 14 8
3/4 9.55 11.14 12.73 14.32 15.92 17.50 19.09
1
5/8 7.96 9.28 10.61 11.93 13.27 14.58 15.91 Over 2 14 To 6 2
5
1/2 6.37 7.42 8.48 9.54 10.61 11.67 12.73 Over 6 8
7/16 5.57 6.50 7.42 8.35 9.28 10.21 11.14
Not to exceed the thickness of the thinner part.
3/8 4.77 5.57 6.36 7.16 7.95 8.75 9.54 3
*Minimum size for bridge application does not go below 16 in.
5/16 3.98 4.64 5.30 5.97 6.63 7.29 7.95 † 5
For minimum fillet weld size, schedule does not go above 16 in fillet weld for every
1/4 3.18 3.71 4.24 4.77 5.30 5.83 6.36 3
4
in material.
3/16 2.39 2.78 3.18 3.58 3.98 4.38 4.77
1/8 1.59 1.86 2.12 2.39 2.65 2.92 3.18
1/16 0.795 0.930 1.06 1.19 1.33 1.46 1.59
Companies, 2008
© The McGraw−Hill

*Fillet welds actually tested by the joint AISC-AWS Task Committee.

†
f 0.707h τ all.

Source: From Omer W. Blodgett (ed.), Stress Allowables Affect Weldment Design, D412, The James F. Lincoln Arc Welding Foundation, Cleveland, May 1991, p. 3. Reprinted by
permission of Lincoln Electric Company.

473
 Budynas−Nisbett: Shigley’s III. Design of Mechanical 9. Welding, Bonding, and © The McGraw−Hill 485
Mechanical Engineering Elements the Design of Permanent Companies, 2008
Design, Eighth Edition Joints

482 Mechanical Engineering Design

failure would be less critical) and nonstructural applications (of headliners, etc., for aes-
thetic purposes) are also of significant interest to the design engineer, providing cost-
effective means required for assembly of finished products. These include contact
adhesives, where a solution or emulsion containing an elastomeric adhesive is coated onto
both adherends, the solvent is allowed to evaporate, and then the two adherends are
brought into contact. Examples include rubber cement and adhesives used to bond lami-
nates to countertops. Pressure-sensitive adhesives are very low modulus elastomers that
deform easily under small pressures, permitting them to wet surfaces. When the substrate
and adhesive are brought into intimate contact, van der Waals forces are sufficient to main-
tain the contact and provide relatively durable bonds. Pressure-sensitive adhesives are nor-
mally purchased as tapes or labels for nonstructural applications, although there are also
double-sided foam tapes that can be used in semistructural applications. As the name
implies, hot melts become liquid when heated, wetting the surfaces and then cooling into
a solid polymer. These materials are increasingly applied in a wide array of engineering
applications by more sophisticated versions of the glue guns in popular use. Anaerobic
adhesives cure within narrow spaces deprived of oxygen; such materials have been wide-
ly used in mechanical engineering applications to lock bolts or bearings in place. Cure in
other adhesives may be induced by exposure to ultraviolet light or electron beams, or it
may be catalyzed by certain materials that are ubiquitous on many surfaces, such as water.
Table 9–7 presents important strength properties of commonly used adhesives.

Table 9–7
Mechanical Performance of Various Types of Adhesives Source: From A. V. Pocius, Adhesion and Adhesives
Technology, Hanser Publishers, Munich, 2002. Reprinted by permission.

Room Temperature Peel Strength

Adhesive Chemistry Lap-Shear Strength, Per Unit Width,
or Type MPa (psi) kN/m (lbf/in)

Pressure-sensitive 0.01–0.07 (2–10) 0.18–0.88 (1–5)

Starch-based 0.07–0.7 (10–100) 0.18–0.88 (1–5)
Cellosics 0.35–3.5 (50–500) 0.18–1.8 (1–10)
Rubber-based 0.35–3.5 (50–500) 1.8–7 (10–40)
Formulated hot melt 0.35–4.8 (50–700) 0.88–3.5 (5–20)
Synthetically designed hot melt 0.7–6.9 (100–1000) 0.88–3.5 (5–20)
PVAc emulsion (white glue) 1.4–6.9 (200–1000) 0.88–1.8 (5–10)
Cyanoacrylate 6.9–13.8 (1000–2000) 0.18–3.5 (1–20)
Protein-based 6.9–13.8 (1000–2000) 0.18–1.8 (1–10)
Anaerobic acrylic 6.9–13.8 (1000–2000) 0.18–1.8 (1–10)
Urethane 6.9–17.2 (1000–2500) 1.8–8.8 (10–50)
Rubber-modified acrylic 13.8–24.1 (2000–3500) 1.8–8.8 (10–50)
Modified phenolic 13.8–27.6 (2000–4000) 3.6–7 (20–40)
Unmodified epoxy 10.3–27.6 (1500–4000) 0.35–1.8 (2–10)
Bis-maleimide 13.8–27.6 (2000–4000) 0.18–3.5 (1–20)
Polyimide 13.8–27.6 (2000–4000) 0.18–0.88 (1–5)
Rubber-modified epoxy 20.7–41.4 (3000–6000) 4.4–14 (25–80)