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Fillet welds have similar features.

toes
face

fusion boundary

root HAZ

The shape of a fillet in cross-section is described in three terms.

Mitre fillet Convex fillet Concave fillet

A convex fillet has a poor toe blend - greater notch effect and sharper angle at toe, not used in
fatigue situations. A concave fillet has a better toe blend for fatigue situations, however a reduced
throat. The concave weld may be made by welding alone or by subsequent grinding.

SIZE OF WELDS

Full Penetration Butt Welds.

The general rules are: design throat thickness = thickness of the thinner part joined.
cap width = prep width + 10% either side (for open prep, not specified in BS 499)

Partial Penetration Butt Welds.

The term partial penetration strictly implies butt welds that are designed to have less than full
penetration. Failure to achieve full penetration when it is wanted should be listed as the defect
incomplete penetration.
The design throat thickness of a partial penetration weld is t1 and the actual throat thickness is t2.
With a partial penetration weld made from both sides, the design throat thickness is t1 + t1 and the
actual throat thickness is t2 + t2. Note that the degree of penetration must be known.

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t1 t2
t2
t1
t1 t2
t1 t2

t1 t2

t1
t2

Fillet Welds.

Fillet weld sizes are calculated by reference to allowable shear stress on the throat area, i.e.
throat area = design throat thickness x length of weld.
The size required is specified on drawings in terms of leg length (l).
For fillet welds with equal leg lengths l = 1.4 t1. This does not apply to concave fillet welds.

l t1 = t2 t1 t1 t1 t1
t2 t2

If an asymmetrical weld is required, both leg lengths are specified and t1 is taken as the minimum
throat dimension.

l1

l2
t1

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Deep penetration fillet weld.

With high current density processes, e.g. submerged arc and MIG (spray), penetration along the
joint line can be produced. This gives an increase in throat thickness with no change in leg length.

t1 t1

THE DUTIES OF THE WELDING INSPECTOR

VISUAL INSPECTION

At any point in the course of welding, i.e. tacking, root pass, filler pass or capping pass, but
particularly for the root and cap, a detailed inspection may be required. British Standard 5289: 1976
gives guidance on tools and responsibilities together with sketches of typical defects.
The inspector at this point must -
a) observe, identify and perhaps record (measure) the features of the weld.
b) decide whether the weld is acceptable in terms of the particular levels that are permitted;
defect levels may be ‘in-house’ or national codes of practice.
When the defect size is in excess of the permitted level then either a concession must be applied for
(from a competent person), or the weld rejected.

AIDS OF VISUAL INSPECTION

Illumination: Good lighting is essential.

Inspection Lenses: The magnification should not exceed 2 - 2.5 diameters. If higher
magnification is required use a binocular microscope.
Optical viewing can progressively develop from eyesight, to use of a hand torch and mirror, to the
addition of a magnifier and light source.
In order to achieve accessibility, remote probe units are available which must have the following
properties.
a) Large field of vision
b) Freedom from distortion of image
c) Accurate preservation of colour values
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