Section 02

Terms & Definitions

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2.0 TERMS AND DEFINITIONS
Note:
The following definitions are taken from BS 499-1:1991 “Welding terms and
symbols – Glossary for welding, brazing and thermal cutting”

Welding:
An operation in which two or more parts are united by means of heat or
pressure or both, in such a way that there is continuity in the nature of the metal
between these parts.

Brazing:
A process of joining generally applied to metals in which, during or after
heating, molten filler metal is drawn into or retained in the space between closely
adjacent surfaces of the parts to be joined by capillary attraction. In general, the
melting point of the filler metal is above 450°C but always below the melting
temperature of the parent material.

Braze welding:
The joining of metals using a technique similar to fusion welding and a filler
metal with a lower melting point than the parent metal, but neither using capillary
action as in brazing nor intentionally melting the parent metal.

Weld:
A union of pieces of metal made by welding.

Joint:
A connection where the individual components, suitably prepared and
assembled, are joined by welding or brazing.

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Type of joint Sketch Definition
Butt joint A connection between the ends
or edges of two parts making an
angle to one another of 135° to
180° inclusive in the region of the
joint
T-joint A connection between the end or
edge of one part and the face of
the other part, the parts making
an angle to one another of more
than 5° up to and including 90° in
the region of the joint

Corner joint a connection between the ends or

edges of two parts making an
angle to one another of more
than 30° but less than 135° in the
region of the joint

Edge joint a connection between the edges

of two parts making an angle to
one another of 0° to 30° inclusive
in the region of the joint

Cruciform a connection in which two flat

joint plates or two bars are welded to
another flat plate at right angles
and on the same axis

Lap joint a connection between two

overlapping parts making an
angle to one another of 0° to 5°
inclusive in the region of the weld
or welds

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2.1 TYPES OF WELDS

2.1.1 FROM CONFIGURATION POINT OF VIEW

Butt weld Fillet weld

In a butt joint

Butt In a T-joint

In a corner joint

Autogenous weld:
A fusion weld made without filler metal. Can be achieved only by TIG or Oxy-
fuel gas welding.

Slot weld:
A joint between two overlapping components made by depositing a fillet weld
round the periphery of a hole in one component so as to join it to the surface of the
other component exposed through the hole.

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Plug weld:
A weld made by filling a hole in one component of a workpiece with filler metal
so as to join it to the surface of an overlapping component exposed through the hole
(the hole can be circular or oval).

2.1.2 FROM THE PENETRATION POINT OF VIEW

Full penetration weld:

A welded joint where the weld metal fully penetrates the joint with complete root
fusion. In US the preferred term is complete joint penetration weld or CJP for short
(see AWS D1.1.)

Partial penetration weld:

A welded joint without full penetration. In US the preferred term is partial joint
penetration weld or PJP for short.

2.2 TYPES OF JOINTS (SEE BS EN ISO 15607)

- homogeneous joint: welded joint in which the weld metal and parent material
have no significant differences in mechanical properties and/or chemical
composition. Example: two carbon steel plates welded with a matching carbon
steel electrode.

- heterogeneous joint: welded joint in which the weld metal and parent material
have significant differences in mechanical properties and/or chemical composition.
Example: a repair weld of a cast iron item performed with a nickel base electrode.

- dissimilar joint: welded joint in which the parent materials have significant
differences in mechanical properties and/or chemical composition. Example: a
carbon steel lifting lug welded onto an austenitic stainless steel pressure vessel.

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2.3 FEATURES OF THE COMPLETED WELD
- parent metal: metal to be joined or surfaced by welding, braze welding or brazing.

- filler metal: metal added during welding, braze welding, brazing or surfacing.

- weld metal: all metal melted during the making of a weld and retained in the weld.

- heat-affected zone (HAZ): the part of the parent metal that is metallurgically
affected by the heat of welding or thermal cutting, but not melted.

- fusion line: the boundary between the weld metal and the HAZ in a fusion weld.
This is a non-standard term for weld junction.

- weld zone: the zone containing the weld metal and the HAZ.

- weld face: the surface of a fusion weld exposed on the side from which the weld
has been made.

- root: the zone on the side of the first run farthest from the welder.

- toe: the boundary between a weld face and the parent metal or between runs. This
is a very important feature of a weld since toes are points of high stress
concentration and often they are initiation points for different types of cracks (e.g.
fatigue cracks, cold cracks). In order to reduce the stress concentration, toes must
blend smoothly into the parent metal surface.

- excess weld metal: weld metal lying outside the plane joining the toes. Other non-
standard terms for this feature: reinforcement, overfill.

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 Parent Weld
Weld
metal zone
face Toe
Parent
metal

HAZ
Weld
metal Fusion
Root Excess
line
weld metal
Excess
weld metal

Parent
metal
Excess
weld metal
Weld
zone
Toe
Fusion
line
Weld
face

Root Parent
Weld HAZ metal
metal

2.4 WELD PREPARATION

A preparation for making a connection where the individual components,
suitably prepared and assembled, are joined by welding or brazing.

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2.4.1 FEATURES OF THE WELD PREPARATION

- angle of bevel: the angle at which the edge of a component is prepared for
making a weld. In case of a V preparation for a MMA weld on carbon steel plates,
this angle is 30°. In case of a U preparation for a MMA weld on carbon steel plates,
this angle is between 8-12°. In case of a single bevel preparation for a MMA weld
on carbon steel plates, this angle is 50°. In case of a single J preparation for a
MMA weld on carbon steel plates, this angle is between 10-20°.

- included angle: the angle between the planes of the fusion faces of parts to be
welded. In case of single V, single U, double V and double U this angle is twice the
bevel angle. In case of single bevel, single J, double bevel and double J, the
included angle is equal to the bevel angle.

- root face: the portion of a fusion face at the root that is not bevelled or grooved.
It’s value depends on the welding process used, parent material to be welded and
application; for a full penetration weld on carbon steel plates, it has a value
between 1-2 mm.

- gap: the minimum distance at any cross section between edges, ends or surfaces
to be joined. Its value depends on the welding process used and application; for a
full penetration weld on carbon steel plates, it has a value between 1-4 mm.

- root radius: the radius of the curved portion of the fusion face in a component
prepared for a single J, single U, double J or double U weld. In case of MMA,
MIG/MAG and oxyfuel gas welding on carbon steel plates, the root radius has a
value of 6mm in case of single and double U preparations and 8 mm in case of
single and double J preparations.

- land: the straight portion of a fusion face between the root face and the curved
part of a J or U preparation. Can be 0. Usually present in case of weld
preparations for MIG welding of aluminium alloys.

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2.4.2 TYPES OF PREPARATION

Open square butt preparation

This preparation is used for welding thin components, either from one side or
both sides. If the root gap is zero (i.e. if components are in contact), this preparation
becomes a closed square butt preparation (unrecommended due to the lack of
penetration problems!
Included angle

Angle of
bevel

Gap Root Face

Single V preparation
The V preparation is one of the most common preparations used in welding; it
can be produced using flame or plasma cutting (cheap and fast). For thicker plates a
double V preparation is preferred since it requires less filler material to complete the
joint and the residual stresses can be balanced on both sides of the joint resulting in
lower angular distortion.

Double V preparation
The depth of preparation can be the same on both sides (symmetric double V
preparation) or the depth of preparation can be deeper on one side compared with the
opposite side (asymmetric double V preparation). Usually, in this situation the depth of
preparation is distributed as 1/3 of the thickness of the plate on one side vs. the
remaining 2/3 on the backside. This asymmetric preparation allows for a balanced

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welding sequence with root back gouging, giving lower angular distortions. Whilst
single V preparation allows welding from one side, double V preparation requires both
sides access (the same applies for all double side preparations).

Included angle
Angle of
bevel

Root
radius

Gap Root face

Land
Single U preparation
U preparation can be produced only by machining (slow and expensive).
However, tighter tolerances obtained in this case provide for a better fit-up than in the
case of V preparations. Usually it is applied for thicker plates compared with single V
preparation (requires less filler material to complete the joint and this lead to lower
residual stresses and distortions). Similar with the V preparation, in case of very thick
sections a double U preparation can be used.

Double U preparation
Usually this type of preparation does not require a land (exception: aluminium
alloys).

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Single V preparation with backing strip
The backing strip is made out of the same type of material as the parent
material. The thickness of this backing strip is minimum 6 mm. It allows the production
of full penetration welds with increased current and hence increased deposition
rates/productivity without the danger of burn-through. Usually, the backing strip is tack
welded on the backside of one component using a fillet weld. The main problems
related with this type of weld are poor fatigue resistance and the probability of crevice
corrosion between the parent metal and the backing strip. It is also difficult to examine
by NDT due to the built-in crevice at the root of the joint. Note that in this case there is
no root face!

Single bevel preparation

Double bevel preparation

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 Single J preparation

Double J preparation

All these preparations (single/double bevel and single/double J) can be used on

T joints as well. Double preparations are recommended in case of thick sections. The
main advantage of these preparations is that only one component is prepared (cheap,
can allow for small misalignments).

For further details regarding weld preparations, please refer to BS EN ISO

9692 standard.

2.5 SIZE OF BUTT WELDS

- full penetration butt weld

Actual throat Design throat

thickness thickness

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 - partial penetration butt weld

Actual throat Design throat

thickness thickness

As a general rule:

Actual throat thickness = Design throat thickness + Excess weld metal .

- full penetration butt weld ground flush

Actual throat thickness

= Design throat
thickness

- butt weld between two plates of different thickness

Actual throat thickness = Design throat thickness

Maximum thickness = Thickness of the
through the joint thinner plate

Run (pass): the metal melted or deposited during one passage of an electrode, torch
or blowpipe.

Single run weld Multi run weld

Layer: a stratum of weld metal consisting of one or more runs.

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Types of butt weld (from accessibility point of view):

Single side weld Double side weld

2.6 FILLET WELD

A fusion weld, other than a butt, edge or fusion spot weld, which is
approximately triangular in transverse cross section.

2.6.1 SIZE OF FILLET WELDS

Unlike butt welds, fillet welds can be defined using several dimensions.

- actual throat thickness: the perpendicular distance between two lines, each
parallel to a line joining the outer toes, one being a tangent at the weld face and
the other being through the furthermost point of fusion penetration

- design throat thickness: the minimum dimension of throat thickness used for
purposes of design. Also known as effective throat thickness. Symbolised on
the drawing with “a”.

- leg length: the distance from the actual or projected intersection of the fusion
faces and the toe of a fillet weld, measured across the fusion face. Symbolised
on the drawing with “z”.

Actual throat
thickness
Leg
length

Design throat
thickness
Leg
length

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2.6.2 SHAPE OF FILLET WELDS
- mitre fillet weld: a flat face fillet weld in which the leg lengths are equal within the
agreed tolerance. The cross section area of this type of weld is considered to be a
right angle isosceles triangle with a design throat thickness “a” and a leg length “z”.
The relation between design throat thickness and leg length is:

a = 0,707 × z . or z = 1,41 × a .

- convex fillet weld: a fillet weld in which the weld face is convex. The above
relation between the leg length and the design throat thickness written in case of
mitre fillet welds is also valid for this type of weld. Since there is an excess weld
metal present in this case, the actual throat thickness is bigger than the design
throat thickness.

- concave fillet weld: a fillet weld in which the weld face is concave. The above
relation between the leg length and the design throat thickness written in case of
mitre fillet welds is not anymore valid for this type of weld. Also, the design throat
thickness is equal to the actual throat thickness. Due to the smooth blending
between the weld face and the surrounding parent material, the stress
concentration effect at the toes of the weld is reduced compared with the previous
type. This is why this type of weld is highly desired in case of applications
subjected to cyclic loads where fatigue phenomena might be a major cause for
failure.

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- asymmetrical fillet weld: a fillet weld in which the vertical leg length is not equal
with the horizontal leg length. . The relation between the leg length and the design
throat thickness written in case of mitre fillet welds is not anymore valid for this
type of weld because the cross section is not anymore an isosceles triangle.

Horizontal
leg size

Vertical
leg size

Throat
size

- deep penetration fillet weld: a fillet weld with a deeper than normal penetration. It
is produced using high heat input welding processes (i.e. SAW or MAG with spray
transfer). This type of weld uses the benefits of greater arc penetration to obtain
the required throat thickness whilst reducing the amount of deposited metal
needed, thus leading to a reduction in residual stress level. In order to produce a
consistent and constant penetration, the travel speed must be kept constant, at a
high value. As a consequence, this type of weld is usually produced using
mechanised or automatic welding processes. Also, the high depth-to-width ratio
increases the probability of solidification centreline cracking. In order to
differentiate this type of welds from the previous types, the throat thickness is
symbolised with “s” instead of “a”.

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2.6.3 COMPOUND OF BUTT AND FILLET WELDS
A combination of butt and fillet welds used in case of T joints with full or partial
penetration or butt joints between two plates with different thickness. Fillet welds
added on top of the groove welds improve the blending of weld face towards parent
metal surface and reduce the stress concentration at the toes of the weld.
Bevel
weld Fillet
weld

Double bevel compound weld

2.7 WELDING POSITION, WELD SLOPE AND WELD

ROTATION
Weld position - the orientation of a weld expressed in terms of working position, weld
slope and weld rotation (for further details, please see ISO 6947).

Weld slope –the angle between root line and the positive X-axis of the horizontal
reference plane, measured in mathematically positive direction (i.e. counter-
clockwise).

Weld rotation – the angle between the centreline of the weld and the positive Z-axis
or a line parallel to the Y-axis, measured in the mathematically positive direction (i.e.
counter-clockwise) in the plane of the transverse cross section of the weld in question.

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Welding Sketch Definition
position
Flat a welding position in which
the welding is horizontal,
with the centreline of the
weld vertical. Symbol
according ISO 6947 – PA.
Horizontal- a welding position in which
vertical the welding is horizontal
(applicable in case of fillet
welds). Symbol according
ISO 6947 – PB

Horizontal a welding position in which

the welding is horizontal,
with the centreline of the
weld horizontal. Symbol
according ISO 6947 – PC

Vertical up a welding position in which

the welding is upwards.
Symbol according ISO
6947 – PF.
PF
Vertical down a welding position in which
the welding is downwards.
Symbol according ISO
PG 6947 – PG

Overhead a welding position in which

the welding is horizontal
and overhead, with the
centreline of the weld
vertical. Symbol according
ISO 6947 – PE.
Horizontal- a welding position in which
overhead the welding is horizontal
and overhead (applicable
in case of fillet welds).
Symbol according ISO
6947 – PD.

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 Tolerances for the welding positions

2.8 WEAVING
Transverse oscillation of an electrode or of a blowpipe nozzle during the deposition of
weld metal. This technique is generally used in case of vertical up welds.

Stringer bead: a run of weld metal made with little or no weaving motion.

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