On welding designing, the following items should be

taken into consideration on a weldment:

-Purposes and conditions of use, economical

factors, work period.
-Stress computation.
-Determination of shape and size of welding joints.
-Selection of materials.
-Determination of welding procedures.
-Determination of heat treatment and inspection
procedures after welding.
The welding design engineer must

• Known the limitations and specific requirements of the

processes as well as the equipment available on the shop floor.
• Have a good working knowledge of the shop problems of
shrinkage and distortion.
• Have accurate knowledge not only of suitability but also of
availability of materials or the costs of extras.
• Be able to calculate stresses, strengths and determine weld
sizes.
• Be able to make design practical production and practical in the
economic sense, as well as workable in service.
• Always bear in mind that welding costs money and it should be
used only, where it gives benefit in terms of cost as well as
quality. Once the design is established the costs are fairly well
predestined.
There are two fundamental welding design related
considerations requiring individual and knowledgeable
engineering attention:

First - for the welds to fulfill the exact design function

assigned to them in the structure or the product and to
reliably maintain their integrity under the anticipated
handling, shipping and ultimately service loads.

Second - for the welded joints to fully satisfy the

requirements of optimum economy in their execution
and optimum access for inspection.
 FACTORS AFFECTING WELDING DESIGN

•Materials for Welding

•Welding Processes
•Welding Joints and Groove
•Welding Residual Stresses and Distortion
•Fixtures and Positioners
•Joint Strength and Efficiency
•Welding Cost
FACTORS AFFECTING WELDING DESIGN

•Materials for Welding

•Welding Processes
•Welding Joints and Groove
•Welding Residual Stresses and Distortion
•Fixtures and Positioners
•Joint Strength and Efficiency
•Welding Cost
MATERIALS FOR WELDING

(a) Welded Materials

(Base Metal)

(b) Welding Material

(Filler Metal)
(a) Welded Materials

• The materials used for welded structures are steels in general,

and mostly mild steels.

• High tensile strength steels are often used for making products
lighter, or atmospheric corrosion resisting steels for longer life
utilizing rust-resistance feature, and low alloy steels for heat-
resisting or low-temperature services.

• Also, for preventing corrosion by chemicals or for that resistance,

or for low-temperature services, stainless steels or high-nickel
alloys are used.

• Further cast iron, copper alloys, etc. are may be related to

designing for special applications.

• Therefore welding designer is expected to look into specifications

of materials for welding, and to know their properties, e.g.
chemical composition, mechanical strength, available sizes, etc.
(b) Welding Material

• For welding the same materials, a welding consumable of nearly

similar composition or mechanical properties to the base metal will
be used in general.
• For welding dissimilar metals, a welding consumable matching the
base metal of higher alloy side, or lower strength side is used
considering the combination of dissimilar metals or requirements.
• For example, welding between mild steel and an austenitic
stainless steel is conducted with a high Cr-Ni welding electrode
because of metallurgical reasons.
• Anyhow, welding consumables fitting to the base metals to be
jointed should be selected taking account of technological and
economical factors.
FACTORS AFFECTING WELDING DESIGN

•Materials for Welding

•Welding Processes
•Welding Joints and Groove
•Welding Residual Stresses and Distortion
•Fixtures and Positioners
•Joint Strength and Efficiency
•Welding Cost
WELDING PROCESSES

•Selection of welding process shall be made in the light of

the fabrication plant size, and its equipment capacity as
well as the efficiency improvement and cost lowering
measures for fabrication.

•Since welding consumables and welding procedures are

daily progressing, designers of welded structures should
adopt the most suitable method by keeping good contact
with welding engineers and by fully examining various
methods.
FACTORS AFFECTING WELDING DESIGN

•Materials for Welding

•Welding Processes
•Welding Joints and Groove
•Welding Residual Stresses and Distortion
•Fixtures and Positioners
•Joint Strength and Efficiency
•Welding Cost
WELDING JOINTS AND GROOVE

(A) Groove Weld

(B) Fillet Weld

(A) Groove Weld
Single Side
(A) Groove Weld
Double Side
A complete joint penetration groove weld (CJPG) is a
weld which has an effective size equal to the
thickness of the material.

Their amplification is expressed in the following:

- if welded from one side, steel backing must be

used and full fusion into it obtained

- if welded from both sides, back gouging to sound

metal is required before welding to second side.
 Welded from one side
with steel backing

Weld on first Back gouging to sound Completion of weld

(prepared) side metal from other side from second side
In recognizing the special importance of these type of grooves
and the full development of the total cross-sectional area of the
joint, the use of extension bars or run-off plates is stipulated,
when satisfactory termination at the ends by other means cannot
be obtained.
Partial Joint Penetration Groove welds in plates PJPG

PJPG is one having penetration less than complete.

The following conditions are additionally recognized in
the governing welding design standards (AWS D1.1) as
also defining PJPG welds:

- joints welded from one side without steel backing

- joints welded from both sides without back gouging

with few exceptions related to either their thickness or
a deep penetrating welding process
Penetration less Welded from one side Welded from both sides
than complete without steel backing without back gouging
Definition and detail selection for complete joint penetration pre-
qualified tubular joints for simple T, Y or k connections
Welds in tubular construction designated as CJPG welds -
Details A and B
Welds in tubular construction designated as CJPG welds - Details
C and D
This special consideration for tubular construction is based
on the proven contention that:

- Since welds are circumferential, the effect of the resulting

eccentricity with respect to the line of action of axial loads in
the walls of circular or rectangular profiles has a negligible
effect on the strength capacity of the weld.

- The flexibility of the connection and the resulting non-

uniform distribution of stresses around the joint tend to force
the failure to occur in the adjacent base metal (localized
excessive deformation, buckling, punching shear - general
ovalizing plastic failure of cylindrical shells).
The effective size of PJPG welds,
other than flare groove types,
was made a function of the angle
at the root of the joint and the
root opening.

- 60 degrees or greater the size

is designated as equal to the
depth of preparation

- less than 60 degrees, but not

less than 45 degrees, the size is
designated as the depth of
preparation minus 3mm (1/8
inch), when in both cases the
root opening is zero.

Obviously with root openings greater than zero, deeper penetration is

obtainable for the grooves with smaller angles at the root although at the
cost of additional weld metal.
Effective sizes of flare groove welds on solid bars

The normally achievable effective size of those welds is made a

function of their radii. When flush with their surface these sizes
are:
- for flare-bevel groove welds = 0.3R
- for flare-Vee groove welds = 0.5R
 Flare groove weld on hollow structural section
The following figure shows the current status on effective sizes
for certain types of groove welds encountered in rectangular
profile fabrication according to AWS provisions for welds
between rectangular sections of equal width.

However, because of its being an elusive relationship, varying with

hot and cold forming, no conclusive recommendations have as yet
emerged.
 (B) FILLET WELDS

Fillet welds can be said to be the most universally used

types of welds. Almost all of the flexible types of
connections, which are really a combination of lap and
tee joints, and a variety of standardized structural detail
material rely on their strength and economy.
A typical fillet weld is normally described as a weld of
approximately triangular cross-section joining two surfaces at
about right angles to each other in a lap, Tee, or corner joint.
Although the reference in the basic definition is to surfaces at
about right angles, the governing design specifications consider
welds in skewed joints with acute angles not less than 60° and
obtuse angles not greater than 120° as fillet welds.

It has been established that the ultimate strength of fillet welds

varies with the direction of applied load. Failures are always in
shear, but they occur in different rupture planes depending on the
orientation of the load. Research results have shown that
transverse fillet welds have a strength up to 1.82 times that of
longitudinal fillet welds.
It should be noted that although the basic strength of fillet welds
is derived from their effective cross-section area

1- Effective sizes of specified equal legged fillet welds

The effective of an equal-legged fillet weld is represented by

the biggest isosceles triangle that can be inscribed into its
profile.
 2- Effective size of specified unequal legged fillet weld

In the case of unequal-legged fillet welds any inscribed

triangle is used for the determination of effective throats and
effective leg sizes.
Since for any type of fillet weld the quantities entering the
calculation of their strength are the "throat area of the weld" (A w) and
the "area of fusion into the base metal" (A m), the clear understanding
of the constituents making up these quantities is very important:

Aw = effective length x effective throat

= l x teff
Am = effective length x effective leg size
=lxs

where:
- the effective length "l" is the length of the full size weld
- the effective throat "teff" is the shortest distance from the root to the
diagrammatic face of the weld
- the effective size - "s" - is the leg size corresponding to the
effective throat, which for equal-legged fillet welds is:
s = 1.414teff
For unequal-legged fillets, the leg sizes must be established by
measurement.
 Effective size of fillet weld for submerged arc welding process

The deeper penetration characteristic of the process permits the outside

measured fillet size to be increased to the next metric size (or by 1/16 inch
in imperial sizes) when certain conditions are met.
Maximum fillet sizes

There are a number of

limitations that are
imposed on maximum
sizes of fillet welds either
by considerations of
good welding practice or
balanced design. They
are shown in the
following diagrams.
Minimum fillet sizes

On the other hand the

minimum sizes of fillet
welds are governed
primarily by strength but
additionally by thickness of
material considerations.
Residual stresses
Residual stresses are said to result from
the inability of the material to return to
an unstressed condition after some
plastic deformation. In rolled shapes
these deformations always occur during
the process of cooling from the rolling
temperature to ambient air
temperature.
The principal characteristic to
recognize is that for elements under a
temperature gradient the part to cool
last will usually be in the state of tensile
residual stress. Hence, all rolled and
welded "H" sections will show the
presence of residual compressive
stresses towards the toes of flanges and
in the center part of the web as the
elements that cool faster.
The presence of residual stresses and specifically their
nature (tensile or compressive) has an influence on the

SE S
behavior of welded joints in service. While in some
S
circumstances they are known to enhance the
E
ST R
performance, in others they have a detrimental effect.

A L
I DU
The differential cooling following an application of heat

S
to a part of material gives rise to shrinkage, which in
RE
turn causes distortion. In the case of welding this
distortion may be longitudinal, transverse, or angular.
Its magnitude is a function of many factors.
Generally the control of distortion rests with the
fabricators who have several means at their disposal
with which to minimize it and hence indirectly keep
down the cost of any corrective action. However, in
recognition of the difficulties in controlling distortion,
especially in cases of complexity, concentration of
welds, and thinner materials, the designer may see fit
to apply some latitude in setting tolerance acceptance
criteria that more realistically reflect the achievable
workmanship and the actual service requirements.
There are two different approaches to structural design:

- The Allowable Stress Design (ASD) which is the

conventional design method based on the actual loads
and the working stress

- The Limit States Design (LSD) which is the relatively

new evolution of the design method based on the
factored loads and factored resistance.
The allowable stress design method is based on the actual stress under
the actual loading. The maximum actual stress allowed in a structural
member is specified as a certain fraction of the material’s yield stress.
For structural steel design:

allowable axial compression stress

Fa = 0.60Fy
allowable bending stress
Fb = 0.66Fy
allowable shear stress
Fv = 0.40Fy

Other conditions such as compact or non-compact sections and lateral

support conditions must also be checked. Under certain conditions
higher or lower design stress may be allowed.
Example 1: Allowable Stress Design

Given: applied loads and dimensions as shown

Find: fillet size and gusset plate thickness

(I)Conventional Elastic Analysis: based on vectorial sum

 Solution: Fillet Size
Shear along A-A is 291 kN
fv = 291 x 1000 / ( 2 x 500 D )
= 291 / D MPa

Section Modulus of 2 fillets

S = 2 x D x 5002 / 6
= 83333 x D mm3

Moment about A-A is

291 x 150 = 43650 kNmm

The bending stress is

fb = 43650 x 1000 / ( 83333 x D )
= 524 / D MPa
The resultant stress is:
fT = SQRT ( (291/ D)2 + (524 / D)2 )
= 599 / D = 101 N / mm / mm
thus D = 6 mm
 Gusset Plate Thickness

fv = 291 x 1000 / 500 t

= 582 / t MPa

fb = 43650 x 1000 / ( 41700 t )

= 1047 / t MPa

S = 5002 x t / 6
= 41700 x t mm3

fT = SQRT ( (582/D)2 + (1047/D)2 )

= 1198 / t MPa

For G40.21 - 300W, Fb = 0.6 x 300 = 180 Mpa

t = 1198 / 180 = 6.65 mm

therefore, use an 8mm plate.

Welding and Fabrication Related
Design Considerations
 Access for Welding and Edge Distances

One of the prerequisites of sound and economic welding design

is the consideration of good access and ease of execution of
welding.

Of equal importance is the due recognition of reasonable open

access to welded joints for inspection and especially to those of
more critical nature targeted for special attention with
designated examination methods.
In the case of manual shielded metal arc welding (SMAW)
the minimum electrode angle for fillet welds should not be
less than about 30 degrees. This is illustrated in the
following diagrams showing two rather common structural
details:
·an angle in the web of a column,
·a header angle connection in the web of a beam.

In both cases the specified leg sizes of fillets and the

corresponding fusion to both elements - the toe or side of
the angle and the web of the supporting elements - is only
possible for a certain minimum access angle theta.
Of direct concern are primarily fillet welded

· lap joints, such as cover or moment plates on flexural members,

reinforcing plates on column flanges

· corner joints encountered, say, in box-section elements.

The amount of edge distance will be affected by:

- the length of the moment plate: - the longer the lap joint on a flange
the greater should be the edge distance for side fillets.

- the size of the side fillet weld: - the greater the size the greater
should be the edge distance. Any existing gap greater than 1mm (1/6
inch) requires a correspondingly increased fillet size to maintain the
specified effective size. This will necessitate still greater edge
distances.
Stress Concentration in Welded Joints
In the case of groove welds in double welded butt joints the stress
concentration factor depends on the height of the reinforcement but
more so on the angle included between the surface of the plate and the
tangent to the face of the weld at its toe. The smaller the angle, the
higher the stress concentration.
The justification for chamfering, in cases of splices of material of different
thickness, is evident in the reduction of the maximum stresses, this
reduction being a function of the slope of the chamfer .

Similar gradual transition through sloping of the wider plate is

required for splices of material of different width.
In lap and Tee joints using fillet welds the stress distribution is markedly
non-uniform due to the sharp change in the direction of stress flow. The
typical distribution in lap joints is shown in the following figure:
The beneficial effects of using fillet welds to reinforce groove welds in
Tee joints subject to tension (mandatory in governing design codes) is
well illustrated in the following figure.
The advantage offered by the use of the combined welds
over the fillet welded joint is very evident. The use of
deep penetration welding processes - say, the SAW
process - for fillet welding of both the lap and Tee joint
results in some reduction of the stress concentration
because the additional fusion into the base material
reduces the sharpness in the change of the direction of
stress.
It is important to note that in welding attachments to
structural members: ·even non-load carrying joints cause
stress concentrations.
Tapering of ends of load carrying
details will tend to reduce the
stress concentration at the terminal
ends of the welds.
In conclusion, an effort has been made to
illustrate the detrimental effect - mainly
because of stress concentrations resulting in
greater potential for failure - of some welded
details on performance bearing directly on the
appropriate degradation of these details
especially in the fatigue design provisions of
governing welding standards.
 Component design

Component design is the method frequently used for machine design

where various elements perform independent functions, then are
assembled or joined together to make an end product.

Design by components would naturally be the approach for designing

elements of a machine or other mechanical projects; however, that
approach is not necessarily limited to design of small parts,
mechanical elements or machines. For example, the design of large
structural members, tanks, ships, bins, and almost anything
manufactured may make use of the component method to facilitate
the manufacture or fabrication of the end product.
The following is a partial list of options for consideration when
designing components or component segments:

- design for properties of material available;

- select materials best suited for the intended use, element

function, and service conditions, e.g., replaceable Q&T wear
plates; aluminum contact material to prevent sparking; high
strength material to reduce component size; strength
requirements at high or low temperatures; etc.;

- material selected for weldability and electrode compatibility;

- electrode selected to be compatible with the base material, and

both being compatible with the service environment, e.g., an
acid mist atmosphere;
- castings may substitute for weldments, especially for large quantities
of small complicated weldments, or when welding access is difficult;

- components subject to fatigue can be given special consideration for

design, e.g., weld locations that will allow access for weld dressing;

- severe through thickness stresses may be accommodated by use of

castings;

- components can be designed as an overload protective device;

- size or weight of assembly can be controlled by component

design, e.g., PWHT oven size; crane capacities; on-site restrictions
such as limited access to a mining operation; etc.;

- economic advantage by machining sub-assemblies;

- overall shrinkage due to welding is minimized by component design.

Rod Anchor Component
Example 1: Anchor assembly

Section Modulus of Weld Group

S = {2 x (1 x b) x (d/2)2} / (d / 2) + {2 x (1 x d)2} / 6
= {b x d} + {d2 / 3} = {20 x 200} + {2002 / 3}
= 17,333 mm3

Forces

P = 100 kN; PH = 100 x COS 30 = 86.6 kN;

PV = 100 x SIN 30 = 50.0 kN

Stresses

MV = (50 x 100 X 1000) / 17,333 = 289 MPa

MH = (86.6 x 35 X 1000) / 17.333 = 175 MPa
PH = (86.6 x 1000) / 440 = 197 MPa
PV = (50.0 x 1000) / 440 = 114 MPa

MV = 289 MPa MH = 175 MPa

PH = 197 MPa PV = 114 MPa
Resultant stress on weld across the bottom of weld group

R = {(289 - 175 + 197)2 + 1142} = 331 MPa

Capacity of 1 mm weld size = 0.707 x (0.30 x 480 MPa)

= 102 MPa

Fillet size required = (331 / 102) = 3.25 mm.

> > Make 6 mm fillet welds to meet the "minimum fillet size" code requirement for 20
mm thick plates.
Example 2

Anchor assembly - Example 2

Required to solve for the allowable load P

Eelectrode = E480XX Classification

Section Modulus of Weld Group

Forces

P = (P)kN;
PH = Pcos50 = .643PkN;
PV = Psin50 = .766PkN

Stresses

MV = .737P MPa MH = .216P MPa

PH = .244P MPa PV = .29P MPa
Resultant stress on weld 2 across the bottom of weld group
Example 3 Shaft design

Find the circumferential weld size

to transmit a shaft torque of
1,000,000kN-mm.

Weld shear value = t

t = 0.707 (0.3 x 480)
= 101 MPa / mm weld size

* The shear value is reduced by .707 for the weld throat size. The
shear value of the electrode =.3 x Min. ultimate electrode tensile
strength

Weld resistance to torque = (2 p r) / sT

S = Torque / (2 p r) / sT
= 1000000 / (2 p x 250 x 101)
=6.3 mm
Use a fillet size = 7mm.
Notes:

•For large diameter shafts, the weld diameter may be taken

as the shaft diameter.

•For small diameter shafts, one may want to check the ratio
of the true weld diameter to the weld diameter used in the
design.

•The 7mm weld size may have to be increased to meet the

minimum size requirements of the governing code or
standard.

•Other criteria such as, whether the shaft is tubular or solid,

thickness of materials adjacent to the weld, dynamic loading,
etc may be needed to be incorporated into the weld design.
Example 4: Assembly 4
Table to calculate Ixx and Iyy
Moment of Inertia
Ixx = I0 + A(k)2 = 562,500 + 2,250,000 =2,812,500 mm3

Iyy = I0 + A(k)2 = 140,625 + 482,142 = 622,767 mm3

Izz = (Ixx) + (Iyy) = 2,812,500 + 622,767 = 3,435,267 mm3

Distance D = ((75)2 + (26.79)2)1/2 = 79.64 mm

sm = (M x D) / Izz = (27 x 1000 x(600 + 26.79) x 79.64) / 3,435,267 = 392.33 N/mm

Horizontal Component of sm = (75 / 79.64) x 392.33 = 369 N/mm

Vertical Component of sm= (26.79 / 79.64) x 392.33 = 132 N/mm

(Directed downward)

sv = V / A = (27 x 1000) / 300 = 90 N/mm

<< Note: Assumed all vertical shear taken by vertical welds (most severe) >>

Resultant stress at distance D from N/A = ((369)2 + (132 +90)2)1/2 = 431 N/mm
Use E70XX Classification Electrode:

Value of 1 mm fillet weld = 480 MPa x 0.3 x 0.707 = 101 Mpa on Throat Area.

Therefore required fillet weld size = R / 101 = 431 / 101 = 4.27 mm >> Make 5 mm Fillet
Weld

Check Weld at radius "E":

Distance E = ((75)2 + (75 - 26.79)2)1/2 = 89.16 mm

sm= (M x E) / Izz = (27 x 1000 x(600 + 26.79) x89.16) / 3,435,267 = 439.23 N/mm

Horizontal Component of sm= (75 / 89.16) x 439.23 = 369 N/mm

Vertical Component of sm = ((75 - 26.79) / 89.16) x 439.23 = 237 N/mm (Directed

upwards)

sv= V / A = (27 x 1000) / 700 = 39 N/mm

<< Note: Assumed vertical shear is distributed to all welds >>

Resultant stress at distance E from N/A = ((369)2 + (237 - 39)2)1/2= 419 N/mm

Resultant 419 N/mm at Distance E From N/A Is Less Than 431 N/mm at Distance D
From N/A
Comments:

- The above analysis is for the described weld only.

Codes and Standards may require that the fillet welds be
interrupted at the corners, and calculation adjustments
will have to be done.

- Codes and Standards may allow the vertical shear to

be distributed to all the welds.

- The final analysis must be checked for minimum

allowable weld size and expected fit-up tolerance. The
strength of the materials on either side of the welded
connection must be investigated for load carrying
capacities.