EFFECT OF JOINT DESIGN ON MECHANICAL

PROPERTIES OF THE WELDED JOINT IN

SHIELDED METAL ARC WELDING (SMAW)

NAME: NUR LIYANA IZZATI BINTI ZAHIRUDDIN

MATRIC NUMBER: 212100084
SUPERVISOR: RUHIYUDDIN BIN MOHD ZAKI
 INTRODUCTION
Stick Welding, also known as Shielded Metal Arc Welding (SMAW), uses a flux-covered metal electrode and electric
current.
The electric current creates an arc between the electrode tip and the work, melting both.
SMAW works with AC or DC power, usually ranging from 50 to 500A and 20 to 40V.
SMAW is popular due to its affordability, flexibility, portability, and versatility.

Joint design is critical in fields like engineering, construction, and manufacturing.

A joint connects components to form a functional system.
Weld joints distribute stresses: tension, compression, bending, torsion, shear.
Joint's ability to handle forces depends on design and weld integrity. Joint design directly influences product
strength, durability, reliability.
Mechanical assemblies, welded structures, biology all consider joint design.

Choosing the optimal joint design involves considering several factors.

Considering factors individually might lead to unfeasible fabrication.
Narrower joint angles reduce filler metal, lowering welding cost.
However, an angle too small for the process prevents welding.
Weld joint design's adaptable parts: joint type, edge prep, dimensions.
PROBLEM STATEMENT
Research gap: Influence of joint design mechanical properties is
underexplored.
Study goal: To investigate joint design impact on SMAW-welded joint
properties.
Joint design factors (configuration, bevel angle, edge prep, gap) affect
weld strength, fatigue, and ductility.

Joint type selection depends on part thickness, e.g., single-V for deep
penetration and strength.
Research plan includes mechanical testing (tensile, hardness) for parameters
like tensile strength, yield strength, fracture toughness, fatigue life.
Test results will reveal connections between joint design and mechanical
properties.
 OBJECTIVES
Investigates the influence of joint design on
the mechanical properties of welded joints
produced using SMAW technique.

Determine the best joint design to weld mild

steel plate.
SCOPE OF WORKS
Joint designs Sample sizes:
300 mm x 50 mm x
tested: square joint,
6 mm for tensile
double-bevel joint
test sample.
and single-V joint 100 mm x 30 mm x
Welding technique used in this on a 6 mm 6 mm for
thickness mild steel hardness test
project: Shielded Metal Arc plates. sample.

Welding (SMAW)
Test conducted:
Tensile test & Hardness test
Electrode type:
E6013
Electrode size:
3.25 mm
 JOINT DESIGNS

Square joint Double-bevel joint

Single-V joint
Literature
Review
 Literature Review
Mild Steel
Composed of iron and carbon
Referred as ferromagnetic - high
iron content
Suitable for forging, welding, etc.
Low carbon content of 0.05-0.25%.
SMAW
Use consumable stick electrodes to conducts
welding current.
Can be done with either AC or DC power source.
Current range: 50 to 80 V
Low cost, flexible, portable and versatile.
Can be used in metal as thin as 1/16 inch (2 mm
thick) to several feet thick using the same
machine with different settings and sizes of
electrodes.
can be used to weld almost any metal alloy,
including cast iron, aluminum and nickel.
 SMAW PROCESS
Welding apparatus is
correctly assembled, the
power to the machine
must be fused, and the
welding cables should be
sufficiently long enough to
reach the work station
before the welding session
starts.
After the welding was
finished, the slag is
knocked off the metal
plate using a chipper
hammer and a metal
brush is used to clean
off the debris and dust.
The electrode holder should
be of the proper amperage
rating and in good repair for
safe welding, electrode
angle is in the correct
position and personal
protective equipment (PPE)
are worn.
As the arc moves away,
the mixture of the molten
electrodes and base
metals solidifies and
become one piece.
Molten metal from the
electrode travels
across the arc to the
molten pool on the
base metal, where they
mix.
The end of the electrode
and molten pool of the
metal is surrounded,
purified, and protected by
a gaseous cloud and a
covering of molten flux
produced as the flux
coating of the electrode
burns or vaporizes.
 Electrodes

E6013 - most widely used ELECTRODES Tests

stick welding electrodes
due to its versatility. E XXXX: The first character “E” in E6013 stands for flux covered
works well with low electrode as used in Metal Manual Arc Welding.
voltage AC equipment E60XX: The next two characters indicate the minimum tensile
and can run on AC or strength. The “60” in E6013 indicates that the weld metal will
DC welding current. have a minimum tensile strength of 62000 psi.

Tensile Hardness
Test Test

Type of Joint Used to determine the Used to to assess the

mechanical properties of resistance of a material
WELD DESIGN materials, particularly to deformation,
Square - involves creating a square or rectangular groove their tensile strength, specifically its ability to
Five kinds of welding in the edges of two workpieces to be joined. yield strength, and withstand indentation or
joints: butt, corner, lap, Double-bevel - involves preparing the edges of two elongation. scratching.
edge, and tee joints. workpieces with symmetrical bevels or grooves on both
The joint used is butt sides.
joint with 3 different Single-V - involves preparing one side of each of the two
weld design workpieces that are to be joined.

Sample
Preparation
Mild steel sample will be
utilized in two different
sizes: 100 mm x 30 mm for
hardness testing and 300
mm x 50 mm for tensile
testing.
Results
The results obtained from
the tensile tests and
hardness tests are recorded.
METHODOLOGY
Arc
Spark Analysis
Mild steels measuring 30 mm x
30 mm are prepared for arc
spark test. The function is to
ascertain the mild steel’s
composition, which is necessary
for this welding method.
Hardness Test
& Tensile Test
To determine the impact of the
welding on the heat affected
zone (HAZ) on the base metal
and weld metal, tensile tests
and hardness tests are the
carried out on the welded
samples.
Edge
Preparation
Work on edge preparation
are done using hand
grinder. to acquire the
proper angle for the bevel
to be welded, edge
preparation is done.
Welding Process
The end of one piece of metal that
has been edge-prepared is join to
the end of another piece of metal
that has been edge-prepared, and
the joint is welded together. When
welding, the travel angle and work
angle must be set to the right
value.
TENSILE TEST RESULTS (SQUARE JOINT)

Maximum Stress: 326.250 N/mm2

 TENSILE TEST RESULTS
(DOUBLE-BEVEL JOINT)

Maximum Stress: 319.792 N/mm2

TENSILE REST RESULTS
(SINGLE-V JOINT)

Maximum Stress: 261.042 N/mm2

 DISCUSSIONS
From the result, it is shown that square joint samples welded using the
Shielded Metal Arc Welding (SMAW) resulted to a higher maximum stress
compared to double-bevel joint and single-V joint which is 326.25
N/mm2. The tensile strength result for the square joint is higher
compared to double-bevel joint and single-V joint because square joint
has flat surface compared to the other two joint. Besides that, the
square joint are welded on both side that results it to have a stronger
weld. Double-bevel joint also was welded on both sides, but incorrect
welding technique might happen causing the weld bead to not reach the
weld area properly.
HARDNESS TEST RESULTS

Highest HRB Readings: 95.5 HRB (sample 3)

 DISCUSSIONS
From the result and graph that have been produced before, the
highest hardness reading that are obtained are from sample 3 single-
V joint which is 95.5 HRB. The single-V joint were joined using weaving
technique causing the weld bead able to cover the weld area thus
resulting into a strong welded joint. There are some technical issues
during the project. Mild steel are supposed to use HRC scales but
during the hardness test, no readings were recorded. This can happen
when the mild steel plates used is too soft until the hardness machine
cannot detect the readings.
 CONCLUSIONS

Main objectives are achieved.

Mechanical properties of the welded design differs depending
on the welded joints produced using SMAW technique.
Physical characteristics of metal, such as strength, toughness,
ductility, tensile, and hardness can be influenced by its joint
design.
 RECOMMENDATIONS

The steel plates used can be change into a harder steel

plate in order to get readings when performing Rockwell
hardness test to continue this project.
The weld sample is made from more thicker materials such
as thickness of 8 mm to 10 mm to make the analysis process
much easier and precise.