Chapter (4) Welding 4.1 BASIC PROCESS Welding is the process of joining materials (usually metals) by heating them ot suitable temperatures such that the materials coalesce into one material. There may or may not be pres- sure, and there may or may not be filler material applied. Arc welding is the genral term for the many processes that use electrical energy in the form of an electric arc to generate the heat necessary for welding ‘There are many welding processes that have special uses for particular metals and for vari- ‘ous thickness. Shielded Metal Arc Welding (SMAW) The SMAW process is often referred to as the manual stick electrode process. The coated electrode is consumed as the metal is transferred from the electrode to the base meterial during the welding process. The welding circuit is shown in Fig, 5.2.1. coating 00 Welding machine ieetoge Electrade wire Metal being welded Gretna Eletroe eable (4) Are weleing cout (0) Shielded ae weling Figure 4.1.1 Shielded metal arc welding (SMAW) The electrode material is specified under various American Welding Society specifications that are lifted in AWS (2.24) Table 3.1.1, The designations such as E60XX or E70XX indicate 60 ksi and 70 ksi, respectively, for tensile strength. The X's refer to factors such as the suitable welding positions, recomended power supply, type of coating and type of arc characteristics. Table 5.13.1 indicates which coated electrodes should be used with each particular structural steel “1.Sho Te metal jure 4.1.2 Submerged arc welding (SAW) Submerged Arc Welding (SAW) In the SAW process the arc is not visible because it is covered by a blanket of granular, fusible material, as shown in Fig. 4.1.2. The bare metal electrode is consumable in that it is deposited as filler material. The end of the electrode is kept continuously shielded by the molten flux over which is deposited a layer of unfused flux in its granular condition Gas Metal Arc Welding (GMAW) In the GMAW process the electrode is a continuous wire that is fed from a coil through the electrode holder, a gun-shaped device as shown in Fig. 4.1.3 Eleetrose Figure 4.1.3 Gas metal are welding (GMAW) 4.2! ABILITY OF STRUCTURAL STEEL To select the proper electrode to join a particular grade of steel and a summary of the "matchin; electrodes and the base steel is given in Table 5.13.1 The weldability of a steel is a measure of the ease of producing a crack-free and sound structural joint. ‘Any variation in chemical content above the ideal values may be evaluated and special weld- ing procedures be set up to insure a properly welded joint. -1-4.3 TYPES OF JOINTS The type of joint depends on factors such as the size and shape of the members coming into the joint, the type of loading, the amount of joint area available for welding, and the relative costs for various types of welds. Butt Joints The butt joint is used mainly to join the ends of flat plates of the same or nearly the same thicknesses. The principal advantage of this type of joint is to eliminate the eccentricity devel- oped in single lap joints as shown in Fig.4.3.1b. Their principal disadvantage lies in the fact that the edges to be connected must usually be specially prepared (beveled, or ground flat) and very carefully aligned prior to welding. Little adjustment is possible and the pieces must be carefully detailed and fabricated SSF a (@) Butt joint (b) Lap joint (© Tee joint (@) Corner joint (6) Eage joint Figure 4.3.1 Basic types of welded joints. Lap Joints The lap joint, shown in Fig, 4.3.2, is the most common type. It has two principal advantages 1, Ease of fitting 2, Ease of jointing. -B-ai ° Sas @ & Figure 4.3.2 Examples of lap joints. Tee Joints This type of joint is used to fabricate built-up sections such as tees, I-shapes, plate girders, bearing stiffeners, hangers, brackets, and in general, pieces framing in at right angles as shown in Fig, 4.3 1c. It permits s¢ tions to be built up of flat plates that can be jointed by either fillet or groove welds. Corner Joints Corner joints are used principally to form built-up rectangular box sections such as used for columns and for beams required to resist high torsional forces. Edge Joints Edge joints are generally not structual but are most frequently used to keep two or more plates in a given plane or to maintain initial alignment. As the reader can infer form the previous discussions, the variations and combinations of the five basic types of welds are virtually infinite. -14-4.4 TYPES OF WELDS ‘The four types of welds are the groove, fillet, slot, and plug welds as shown in Fig. 4.4.1, Each type of weld has specific advantages that determine the extent of its usage. Roughly, the four types represent the following percentages of welded construction. groove welds, 15%, fillet welds, 80% the remaining 5% are made up of the slot, plug, and other special welds. A > (2) Groove weld Section AA aay (@) Slot weld Cl () Fillet welds penn Ends shall be ‘semicircular for have corners rounded to a radius not less than thickness A of part containing sot Section AA (@) Plog weld Figure 4.4.1 Types of welds. ir3 53 fee (@) Dowble-U (e) Dost bee (9 Singe-U 0) Single-5 ( Double-s Figure 4.4.2 Types of groove welds. -15-i U Figure 4.4.3 Use of groove welds in tee joints iss os} ‘ (a) Lapped plates (©) Stites plates (6) Stoned connection (@) Tee connection (e) Brackets (0 Beam bering () Column base plates (h) Pipe connection (0 Beam brackets IT Figure 4.4.4 Typical uses of fillet welds. Hi 6) Buittup sections a6"or LAFO and ASO23.0 Figure 4.4.5 Slot andplug welds in combination with fillet welds. 4.5 WELDING SYMBOLS The need for a simple and yet accurate method for communicating between the designer and fabricator gave rise to the use of shorthand symbols that characterize the type and size of weld The American Welding Society standard symbols, shown in Fig. 4.5.1, indicate the type, size, length, and location of weld, as well as any special instructions. aieBASIC WELD SYMBOLS a Grae oO ack | euer | “on or foousre] voce | uv | 4 |ranev| Beet aiNoluVviyivie nic ‘SUPPLEMENTARY WELD SYMBOLS WELD ALL Kobi sackine | spacer | WEOAR Jrieto wen For other basic and supplementary weld olol|z|)-|>- mnt s A286 STANDARD LOCATION OF ELEMENTS OF A WELDING SYMBOL rush | CONVEX Fish symbol Groove angle oF neludes tange of countersink Contour symbol — for pug weles Root opening, depth Length of weld un snches of fling for lug nd slot welds pact ; ie (6. 19€ $pBCIR Eftctive teat 3 fol welds inches Depth of preparation S forage in inehes \ Feld wed symbol Speciation, process tne reterence Tau (omttes whan felerence fs not used) ‘Arrow connects reference inet arrow side joint, Ure break as at Aor B tony Basie weld symbol that arrow s pointing tothe grooved ordeal reference member in bevel or -erooved joints, = cessed gn tense mengrnninetoo tet rotg arte he sr prnoenre ems erat ae ‘The pependicuas fag of T.. . H. U~ waid symbols must be att errno eae ee ven Si anLToRE ES yar Peommetearemras me pnts ETE Tepe yn omit tame ne ETE TE, ete omen warm ei te ea ne (chm itera) GS on to ue web or unt ul The abatg ual hd coped Pe OMe, oer Sang tha amc atoal aonetgrtocefsmanoe’ ona ara a wet exon oa Boe, eR nie te near ana be cupeats on for ee. Figure 4.5.1 Standard welding symbols. (From LRFD Manual [1.17] and AWS A2.4 1539) -B-Filet welds ‘Groove welds rl Seana re Fest indicating eg aed rom bow Shown oy on one weld Shenton der arte : Ba Single beve wa ‘on upper piece, and 4 Dacong weld uses Incieates 240. tong 1 taggerad on ain contrs Singe-V welded rom ‘ne sige having 1:0 Footopening and 20° angle Figure 4.5.2 Common uses of welding symbols -19-4.6 SIZE AND LENGTH LIMITATIONS FOR FILLET WELDS TABLE 4.6.1 MINIMIUM SIZE FILLET WELD AND MINIMUM EFFECTIVE THROAT Minimum effective Base metal throat (t,) for thickness (T) partial joint of thicker part Minimum size penetration joined of fillet weld groove weld (in) (mm) (in) (mm) (in) (mm) W8Aosphy MOT, savowsynbos eau pjom sefonoys pue Beyso29[9 3) 02 295 "BET 1G SMV 298, sou pam pofodsp 24) “PoeDas S11 90} 218 SPIER LOA, 1 vot axh 0} ay geadde stuauraunbas anbeuyra 2 01 129%qn8 34 eye HatF0030 waHosphy- AO] orpkimoy dnost Wwa!ghp Jo slaw 35eq FuIAonu NWO! UT, (G2pon purus 2 eoxtta sores poos-xtta wxxorta ‘8001 PUR QOL PED OLY _S@SVSKV BESSA tcsv sav ssv SMV ‘Gapun pur ws 42) PIS HLSW a cary fo) sLxOr, ssoorwa. poo x01 pocoor ROOT PEE 001 S9PEID 6OLV orsvSMY —_avS¥ SMV ESV SAV SS¥SMV ju! fz eo) pISV WAS a xe ‘sore Rerent pxONE SO mE 0 PED orsvsmVY _avsv SMV __“esvsmv_ SSvSAV Cusv WIS _ G0: “OS PEE OF OPED 6OLV "r1deo1) sis XuXea x-souwa XXNEXL wexocd 05 pur ze s9pHI0 TiS _AVSVSAY —_CUSVIOLISVSMY _SSWOTSV SHY ULV WISY ue 9 97D 6OLY 40019) X-LXL (5 Pur ‘spor BHO OLS pu XIXTE X-SOLYI—_XXNG-XLAIO XE XXOLT2O KOBE “easW 105 ‘O05 OPSVSMY —-BISVSMVY —-EZSVIOLISYSMY —SSVIOTSYSANY 2pun (Sv CW ASV 1 nwo) awnio) nv) Gans) uoneoyioads 015 noi Suppiom Supiam Bupiom upon oseg weparoa%ms Sy OWSED ve pablawans —_ ave eI DapIORS {880001 BupIom (eez)] Pr ATAVL “SMV GILdVGV) SININGUINOTY TVLAW YATTHA ONTHOLVIAT L$ AAV -83-4.8 LOAD AND RESISTANCE FACTOR DESIGN - WELDS ‘The general philosophy of Load and Resistance Factor Design (LRFD) was described as fol- lows. oR, 2 Ey Q as) where @ = resistance factor (strength reduction factor), values of which for welds are given in Table 4.8.1 R, = nominal resistance (strength) = Ry for welds = overload factors (LRFD-A4.1) Q; = service loads Equation 4.8.1 requires the dsign strength R, to equal or exceed the summation of factored loads, or specifically for welds, Eq. 4.8.1 becomes Raw 2 Ry (482) where @ = resistance factor (for welds the @ factor is the same as for the material it connects; that is, 0.90 for the yielding limit state and 0.75 for the fracture limit state) Ryw = the nominal strength per unit length of weld, but not to exceed the nominal strength per unit length of adjacent base material = factored load per unit length of weld 84TABLE 4.8.1 DESIGN STENGTH OF WELDS (FROMLRFD MANUAL [1.17], TABLE J2.3) Resis- | Nominal | Required Wold tance | strength ‘tt Matoriat | Factor ¢ | Fou OF Fe lever ‘Complete Penetration Groove Weld “Tension normal to “Matching” weld fective area — oe Fr | must bo used. ‘Compression normal to Weld metal with a otlectve area Base 0.90 strength level 0 or ess, “Tension or compression than "matching parallal to axis of wold may be used. ‘Shoar on otfectve area Base 090 | -060F, Weld electrode | 0.80 | 0.80Fexx Partial Penetration Groove Welds Compression normal to Wold metal with a fective area nth tov Base hr “Tension or compression “matching” weld Parallel to axis of wold? ‘etal may be used. ‘Shoar parallel to wis | Base" of weld Weld electrode | 0.75 | 0.60Fexx Tension normal 10 Base 0.90 F effective area Wold Electrode | 0.80 | 0.60Fee Flot Welds ‘Sttss on ettecive | Baset Weld metal with a area Weld electrode | 0.75 | 0.60Fexx | stongth level equal to orless than “Tension or compression | Base 090 r parellel to axis of wold? Plug or Slot Welds ‘Shear parallel to faying | Base” surtaces (on effecive | Wold Electrode’ | 0.75 | 0.60Fexx roa) metal mey be used. ‘*For definition of ettective area, see Sect. J2. For “matching” weld metal, S00 Table 4.1.1, AWS D1.1 Weld metal one strength level stronger than “maiching” wld metal wil be permited. Filet welds and partia-penetration groove welds joining component elements of bull-up _mombers, such as flange-to-wob connections, may be designed without regard to the tensile oF compressive stress in theso elements parallel tothe axis of the welds ‘Tho design of connected material is gavemed by Sect. 4 f Groove Welds ‘The design strength (LRFD-J2.1.) per unit length of complete penetration groove welds de- pends on the type of stress that is applied 1. Tension and compression normal to effective area, and tension and compression parallel -85-to axis of weld: OR ORyy = 0.90t,F yy, weld metal (4.8.4) 0.90t,F, base material (4.8.3) where F, and Fyy are the yield streses of the base and weld metals, respectively. When "match ing” welds indicated in Table 4.7.1 are used, Fyy is taken as the yield stress of the base material 2. Shear on effective area*: Ry = 0.90t, Ty base metal = 0.90t, (0.60F,) (4.8.5) ORyy = 0.80t,(0.60F_xx) weld metal. (4.8.6) Note that in the above, the shear yield stress is taken approximately as 0.6F, for the base metal an 0.6 of the electrode tensile strength for the weld metal; thus, the lower $ factor 0.80 is used for the weld metal Partial penetration groove welds are similarly treated and the summary of design strengths is given in Table 4.8.1 Fillet Welds ‘The design strength (LRFD-J2.2.) per unit length ofa fillet weld is based on the shear resistance through the throat of the weld, as follows: aR, .75t,(0.60F pxx) _ fillet weld (4.8.7) but not less than the shear rupture strength (LRED-J4.) of the adjacent base metal. ORyw = 0.75t(0.60F,) base metal (4.8.8) where t, = effective throat dimension Fixx. ~ tensile strength of electrode material t_=thickness of base material along which weld is placed tensile strength of base metal Note that the limit state for fillet welds is fracture through the throat of the fillet, thus, the factor is 0.75, Values of (Ryy based on Eq. 4.8.7 for various electrode strengths are given in Table 4.8.2 for shielded metal arc welding (SMAW) and in Table 4.8.3 for submerged arc weld- ing (SAW). -86-TABLE 4.8.2 DESIGN SHEAR STRENGTH OF FILLET WELD, ©R,,, (kips/in.) (SHIELDED METAL ARC WELDING) Nominal Eflectne _ Misra ans songt of wld (43) (ey) SCSC«SCSCO 1/8 RY 238277347358 3.96 436 36 0433338 AA S37 39756, a OAT? 477587 63671678585 ss 0597695 79S«BNS 984 1094 3/0285 716835984 107489132 76 0308835, 97K LAE 28S B92 1S 120384954 LAS «127B 1432911750, 5/6 0398 ©1074-1283. 143261790 19.69, s/® 0482 «193.1392 1591 1790 t9ak 2187 16 0486 «131215311750 1969 21.87 2406 3/4 053014321670 1909 2148 2385 2625 %, = 0.707 times leg size a = 0.707 (1/8) = 0.088 in. bgt, (0.60F gy) = 0.75 (0.707a)(0.60 times tensile strength) = 0.75 (0.707)(1/8)(0.60)(60) = 2.38 kips/in. TABLE 4.8.3 DESIGN SHEAR STRENGTH OF FILLET WELD, ©R,,, (kips/in.) (SUBMERGED ARC WELDING) Maver tens songth of wat (8) f) @) OS Te 1/8 O12S* 33 38h 450 S065 68 3/6 OLB 506 S81 678789 Bak 928 1/0280" 6.78 T8R_ 90003 as 1238 SAS O31 844 9811258 1266 14051847 3/8 O37S* 1013813801819 16.8 RSE TAs oat 132 HAL 1510 698 187 2076, 1/2 046312511460 1869877 BH 2294 9/6 0808 13711599 182B 2056 28S 2513 5/8 038214901738 19T 7235 DAs 27D 1/16 05% 1609 18TH 1456 2414264822951 3/4 0680 172920172308 2593 BR H.68 44, = a = leg size for sizes < 3/8 in. bt, = 0.707a + 0.11 for sizes > 3/8 in, Gt, (0.60F xx) = 0.75 (0.707a)(0.60 times tensile strength) = 0.75 (1/8)(0.60)(60) = 3.38 kips/in -87-EXAMPLE 4.8.1 Determine the effective throat dimension of 7/;,-in. fillet weld made by (a) shielded metal arc welding (SMAW), and (b) submerged are welding (SAW), in accordance with the AISC Speci- fications (1.5, 1.15] SOLUTION (a) t, =0.707a = 0,707 (0.4375) = 0.309 in. (b) t= 0.707a + 0.11 = 0.707(0.4375) + 0.11 = 0.419 in ‘These values are in agreement with those given in Tables 4.8.2 (for SMAW) and 4.8.3 (for SAW). EXAMPLE 4.8.2 Determine the design shear strength @R,,, of a ¥/g -in. fillet weld produced by (a) shielded metal arc welding, and (b) submerged arc welding. Assume E70 electrodes having minimum tensile strength Frxx of 70 ksi are used, according to AISC LRED Specification, SOLUTION (a) SMAW process. t, 07a = 0.707(0,375 0.265 in. According to Eq. 4.8.7 Ruy = bt, (0.60 Fx) = 0.75(0.265)(0.60)70 = 8.35 kips/ in, (b) SAW process . t, Raw ‘These values agree with those in Tables 4.8.2 and 4.8.3 = 0.375 in, t, ( 0.60F Ex) = 0.75 (0.375) (0.60)70 = 11.81 kipsfin. EXAMPLE 4.8.3 Determine the design shear strength @R,, for a %-in. -diam plug weld using E70 electrode mate- rial. Use AISC LRFD Specification. SOLUTION: Assuming the weld diameter D satisfies the limitations of LRFD-J2.3.b relating to the di- mension of the piece in which th eplug weld is made, R, = 0.75 (area of faying surface, nD7/4) (0.60 Fxx) =0.75 (0.4418) (0.60) 70 = 13.9 kips = 88-Maximum Effective Fillet Weld Size Consider the two lines of fillet weld transmitting the shear V across section a-a of Fig 4.8.1a, The design strength Ray of the fillet weld is given by Eq. 4.8.7. The design shear rupture strength FAs of the base material is 0.75 (0.6F,) (net area in base mateial subject to shear) according to LRFD-J4. Equating the capacity per inch of the weld metal to the shear capacity per inch in the base material gives for shielded metal arc welding, ORyw Oveld) = GR, (base metal) 2pa(0.707) (0.60F xx) = ~—-(0.6F,) ty (4.8.9) 0.60 F,t, Fyty Ama eff == 0.707 -—_ (48 10) 2(0.707)0.60 Fry, Fexx where t= thickness of base material F,, = tensile strength of base material Fexx = tensile strength of electrode material (70 ksi for E70 electrodes) Figure 4.8.1 Critical sections for possible overstressing of base material. Sections b-b and c-c will not be critical since two lines of weld transfer load across two sections, as shown in the equation for maximum effective weld size across those sections, 4a(0.707) (0. 60F exx) = 6(0.6F, ty sib Fy EXX -89-Considering the four fillet welds of Fig. 4.8.1b, sections d-dand e-e are thesameas section $ a-a; therefore, Eq. 4.8.10 applies. On sections f-f and g-g four fillet welds transfer load across two sections. Thus, $4a(0.707) (0.60F gx 62(0.6F,)t, (4.8.13) and again Eq, 4.8.10 is the result. Even when fillet welds connect members that are in tension, the transfer of load by means of the weld is a shear transfer to the base pieces when the fillet welds are parallel to the direction of the load. For such cases, the maximum effective weld size concept still applies. EXAMPLE 4.8.4 Determine the design shear strength @R,y, to be used for the flange to web connection in Fig. 4.8.2 The plates are A36 steel and electrodes having Fy.xx = 70 ksi are to be used with (a) shielded metal arc welding (SMAW) and (b) submerged arc welding (SAW) Jb sty Figure 4.8.2 Example 4.8.4 SOLUTION Minimum weld size = agin = °/yg in. (LRFD- Table J2.5) (a) SMAW Process Equation 48. 10applies, Fyty S8t amex eff = 0.707 —— = 0.707 —=0.59 EXX 70 = 0.59 (0.3125) = 0.183 in. Ray = 0.75 (0.183) (0.707) (0.60) (70) = 4.08 kips! in, or, for two fillets, the design strength is 2(4.08) = 9.16 kips/in. Thus, even though a °/;,-in. fillet ‘weld must be placed, its strength in design may not exceed the strength assuming a = 0.183 in -90-(b) SAW process. Here the effective throat dimension equals the weld size. Equating the weld strength to the plate strength gives 2a (0.60) 70 = 0.60 (58)t = 0.414 t= 0.414 (5/16) = 0.129 in. Amex eff Raw 75 (0.129) (0.60) 70 = 4.08 kips/ in. or, 9.16 kips/ in. for two fillets. Again the same result is obtained as in (a) because 9.16 kips/in. is the design strength based on the 5/;, -in. web plate, which is well below the strength of the weld metal -91-