Welding Special Applications Handout

Special Welding Applications
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Welding - Special
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through the Chat feature on the left portion of your screen. written and presented by
Duane K. Miller, Sc. D., P.E.

Manager, Engineering Services,
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American Institute of Steel Construction 1

Chapter 12
Listen to the Steel!
Special Welding
Applications
Special Welding
Applications
5 6
Special Welding Applications Special Welding Applications
•Extending Anchor Rod •Welding HSS

•Welding Anchor Rod to Base Plates •Welding AESS
•Welding on Coated Steels •Welding on Existing Structures
•Welding Heavy Sections •Field Welding
•Welding Under High Restraint •Heat Shrinking
7 8

•Extending Anchor Rod

•Welding Anchor Rod to Base Plates
•Welding on Coated Steels
•Welding Heavy Sections
•Welding Under High Restraint
9 10
•Extending Anchor Rod •Extending Anchor Rod

•Investigate Mechanical Options •Investigate Mechanical Options
•Investigate “Weldability” •Investigate “Weldability”
•Use Appropriate Detail •Use Appropriate Detail
11 12

AWS Standard Terms & Definitions ASTM A6/A6M, Section X3

(A3.0-94)
Weldability:
Weldability:
“A term that usually refers to the
“The capacity of a material to be
welded under the imposed fabrication relative ease with which a metal can
conditions into a specific, suitably be welded using conventional

designed structure, and to perform practice.”
satisfactorily in the intended service.”
13 14
Weldability Concerns With Anchor

Weldability
Rod Specifications
• Based on composition • High Carbon
• Driven by carbon content • High Alloy
• Compounded by alloy content • Undefined Carbon, Alloy
• Related to “hardenability” • Heat Treatment (Q&T)
• “Hot cracking” concerns as well (S,
Ph, others)
15 16

ASTM F1554 ASTM F1554

Grade 36
• Three Grades: 36, 55, 105 – Chemistry like that of ASTM A36
–
– Footnote: for rod diameters of up to
¾ in., the manganese content is
“optional with the manufacturer, but
shall be compatible with weldable
steel.”
– Grade 55 substituted for Grade 36
(“only Grade 55 is made today”)
–
17 18

Grade 36:
Grade 55, 105: – Chemistry indicates it should be readily
– Controls only on S and P weldable, but…..
– Grade 55 can be ordered to Supplement – Confusion exists (mechanical properties or
S1 with limits on C, Mn, Si, P, S mechanicals plus composition)
– Also, two CE equations (“carbon” steel, – “Weldability only assured if Grade 55 is
“alloy” steel) ordered in accordance with Supplement S1”
– Grade 55 supplied for Grade 36
–
19 20


Grade 36:
– Chemistry indicates it should be readily Grade 55:
weldable, but….. – Essentially no limits on chemistry
– Confusion exists (mechanical properties or indicate it may not be readily weldable
mechanicals plus composition) – “Weldability only assured if ordered in
– “Weldability only assured if Grade 55 is accordance with Supplement S1”
ordered in accordance with Supplement S1”
– Grade 55 supplied for Grade 36
Therefore, investigate on a case-by-case
basis 21 22
Grade 55: Grade 55:

– Essentially no limits on chemistry – Essentially no limits on chemistry
indicate it may not be readily weldable indicate it may not be readily weldable
– “Weldability only assured if ordered in – “Weldability only assured if ordered in
accordance with Supplement S1” accordance with Supplement S1”

basis 23 24

Grade 55:
Grade 55 with Supplement S1:
– Essentially no limits on chemistry
indicate it may not be readily weldable
– “Weldability only assured if ordered in
accordance with Supplement S1”

basis 25 26
Grade 55 with Supplement S1: Grade 105:

– Essentially no chemistry control
– High strength
Good weldability should be assured.

27 28


ASTM F1554
Grade 105: •Extending Anchor Rod

– Essentially no chemistry control •Investigate Mechanical Options
– High strength
•Investigate “Weldability”
•Use Appropriate Detail
Weldability likely to be poor.

29 30
31 32

Note:
chisel-point,
not pencil-point
33 34
35 36

37 38
39 40

41 42
43 44

Plug weld to
end of rod
45 46

Plug weld nut
to end of rod

47
•Welding Under High Restraint 48


•Investigate Mechanical Options
49 50
51 52

Special Welding Applications Fit of rod to

base plate
likely poor
•Welding Anchor Rod to Base
Plates
•Investigate Mechanical Options
53 54
55 56

•Extending Anchor Rod Welding on Coated Steels

•Welding Anchor Rod to Base Plates Galvanized
•Welding on Coated Steels Painted
•Welding Under High Restraint 57 58
Specification for Structural Steel Buildings

13th Edition
ANSI/AISC 360-
360-05
An American National Standard
M3. SHOP PAINTING
SPECIFICATION
5. Surfaces Adjacent to Field Welds
Unless otherwise specified in the design

documents, surfaces within 2 in. (50 mm) of
For Structural
Steel Buildings
any field weld location shall be free of
materials that would prevent proper welding
March 9, 2005 or produce objectionable fumes during
welding.
59 60

Specification for Structural Steel Buildings

AWS D1.1/D1.1M:2004
13th Edition An American National Standard
M4. ERECTION Structural

Welding Code--
Steel
5. Field Welding
Shop paint on surfaces adjacent to joints to

be field welded shall be wire brushed if
necessary to assure weld quality.
American Welding Society ANSI
61 62
AWS D1.1
Structural Welding Code—Steel Common Elements
5.15 Preparation of Base Metal • Concern about fumes

Surfaces to be welded, and surfaces
• Concerns about inhibiting
adjacent to a weld, shall also be free
from loose or thick scale, slag, rust, “proper welding”
moisture, grease, and other foreign • “Materials” broadly defined
material that would prevent proper
welding or produce objectionable • Outcome-based requirements
fumes.
63 64

Welding Safety
•See ANSI Z49.1 Safety in Welding, Cutting

Chapter 15 and Allied Processes
Welding Safety
•Available by free download from AWS
www.aws.org/technical/facts
•“Fact Sheets” from AWS, also available as
free download
65 66
67 68

Safety and Health Fact Sheet No. 25

Metal Fume Fever
• Overview
• Effects of Overexposure
• Permissible Exposure Limit (PEL)
• How to Avoid the Hazard
• Respirators
• Monitoring and Measuremetnt Procedures
• Information Sources
• Summary
69 70
71 72

Galvanized
Quality Concerns Steel
–Fusion
–Porosity
–Cracking
73 74
Fusion Porosity in
problems weld made
occur when on
weld does galvanized
not fuse to steel
steel.
75 76

AWS D19.0-72 Welding Zinc-Coated Steel

Centerline
crack in Factors affecting cracking tendencies on
weld made galvanized steel
on – The silicon content of the weld metal
galvanized – The degree of penetration of the weld beyond
steel the root
– The thickness of the base metal (which affects
restraint)
– The coating weight of the zinc (a function of
the coating thickness)
– The microstructure of the zinc coating, which
is related to the base metal composition and
77
the silicon content in particular 78

For critical applications
• Qualify WPS by test •Extending Anchor Rod

• Limitations of Table 4.5 may not be
adequate •Welding Anchor Rod to Base Plates
• Closely replicate field conditions
• Test thickest coating condition
79

81 82
W14x730
5”
22” 3”
18”
83 84

W14x730 Heavier Sections

5”
ns”
tio
c Larger Welds
22” Se 3”
bo
u m
“J More Shrinkage
18”
85
Increased Stress 86
Heavier Sections Heavier Sections
More Restraint Less Rolling
More Triaxiality Slower Cooling
Less Ductiliy 87
Lower Toughness 88

89 90
Greater Cracking Tendencies
Heavier Sections
91 92

Fracture Fracture
Toughness Toughness
Stress Crack Stress Crack

Size Size
93 94
W14x730
5”
22” 3”
18”
95 96

97 98
99 100

101 102
Compression Tension
103 104

ASTM A6, Supplementary Requirement S30

Charpy V-Notch Impact Tests for Structural
Shapes—Alternate Core Location
CL
20 ft-lbs (27J) @
tf /4
+70 oF (+21 oC)
105 106
ASTM A6, Supplementary Requirement S5

Charpy V-Notch Impact Test J3.6 Filler Metal Requirements
20 ft-lbs (27J) @
+40 oF (+4 oC)
20 ft-lbs (27J) @
+70 oF (+21 oC)
107 108

Fracture
Toughness
Stress Crack
Size
109 110
111 112

Longitudinal STRENGTH OF METALS

shrinkage of Longitudinal UNDER COMBINED STRESSES
web weld shrinkage of
flange welds
Transverse
shrinkage of
welds
113 114
“This is an important concept and

needs to be emphasized: no shear
stress, no plastic deformation or
flow.”
Maxwell Gensamer
1941
115 116

SHEAR SHEAR
TENSILE TENSILE
σ1 σ2 σ1
117 118
SHEAR SHEAR
τ1-2
TENSILE TENSILE
σ3 σ2 σ1 σ2 σ1
σ1−σ2
119 120

SHEAR SHEAR
τ1-3
τ2-3
TENSILE TENSILE
σ3 σ1 σ3 σ2 σ2−σ3
σ1−σ3
121 122
SHEAR SHEAR
τ1-2, τ1-3
τ1-2, τ1-3
σ2 - σ3
τ2-3 τ2-3
TENSILE TENSILE
σ3 σ2 σ1 σ3 σ2 σ1
σ1 - σ2 , σ1 - σ3
123 124

SHEAR SHEAR
τ1-2, τ1-3 τ1-2, τ1-3
Critical Shear Critical Shear

Strength τ2-3 Strength τ2-3
TENSILE TENSILE
σ3 σ2 σ1 σ3 σ2 σ1
σyield σyield
τ1-2 125 τ1-2 126
SHEAR SHEAR
τ1-2, τ1-3 τ1-2, τ1-3
Critical Shear Critical Shear

Strength τ2-3 Strength τ2-3
TENSILE TENSILE
σ3 σ2 σ1 σ3 σ2 σ1
σyield σyield
τ1-2 127 τ1-3 128

SHEAR SHEAR
τ1-2, τ1-3 τ1-2, τ1-3
Critical Shear
Strength τ2-3 τ2-3
TENSILE TENSILE
σ3 σ2 σ1 σ3 σ2 σ1
σyield Ductility σyield
τ1-3 129 130
SHEAR SHEAR
τ1-2, τ1-3 τ1-2, τ1-3
τ2-3 τ2-3
σ3 σ2 σ1 σ3 σ2 σ1
σyield σtensile Fracture σyield σtensile
131 132

SHEAR SHEAR
σ2
TENSILE TENSILE
σ1 σ1
σyield σtensile σyield σtensile
133 134
SHEAR SHEAR
τ1-2
τ1-3, τ2-3
σ2 σ2
TENSILE TENSILE
σ3 σ1 σ3 σ1
135 136

SHEAR SHEAR
τ1-2 τ1-2
τ1-3, τ2-3 τ1-3, τ2-3

σ2 σ2
TENSILE TENSILE
σ3 σ1 σ3 σ1
137 138
SHEAR τ1-2 SHEAR
τ1-3, τ2-3
σ2
TENSILE
σ3 σ1 σ1,
139 140

SHEAR SHEAR
TENSILE TENSILE
σ1, σ2, σ1, σ2, σ3,
141 142
SHEAR SHEAR
τ1-2, τ1-3, τ2-3

TENSILE TENSILE
σ1, σ2, σ3, σ1, σ2, σ3,
143 144

SHEAR
τ1-2, τ1-3, τ2-3
σ1, σ2, σ3
σyield σtensile
145 146
SHEAR
σ2 τ1-2, τ1-3, τ2-3
σ3
σ1, σ2, σ3,
σyield
147 148

SHEAR τ1-2
τ1-3, τ2-3 hminimum* = 1.5 tw

> 1 in. (25 mm)
(need not exceed 2 in. (50 mm)
σ2
h
σ3 σ1
σyield
149
L Lminimum = 1.5 tw
150
W 14x730 W 14x730
4.5”
4.5” 2.9” 15”
15”
151 152

153 154
Reduce Weld
Metal Volume
to Reduce Fracture
Shrinkage Toughness
Stresses
Stress Crack
Size
155 156

Control
Placement of
Final Weld Fracture
Passes Toughness
Stress Crack
Size
157 158
159 160

161 162
Fracture
Toughness
Stress Crack
Size
163 164

165 166
Preheat to 150o F before

thermal cutting Alternate Method of Making
Weld Access Holes
Grind after thermal

cutting
Inspect with PT or MT
167 168

Drilled Hole
169 170
Extend Cut for Access Hole Cut Bevel

From Drilled Hole
171 172

No Need to Grind Curved

Portion of Access Hole
173 174
Catenary Truss
164 ft.
W14x500 W14x245
Tension
175
W14x370, 397 176

177 178
179 180

181 182
183 184


185
Welding Under High Restraint Welding Under High Restraint
• Increase Fracture Resistance

Increase Fracture Resistance – Avoid cracks and notches
• Smooth transitions
Reduce Shrinkage Stresses • Ground flame cut and rough surfaces
Reduce Restraint • Ream punched holes
– Use materials with defined notch
toughness
– Increase preheat levels
187 188


Reduce Shrinkage Stresses Reduce Shrinkage Stresses (continued)
– Specify the smallest weld size possible – Use filler metal with the lowest strength level possible
– For a given weld size, select details that will require – In general, but not always, use higher levels of
the least amount of weld metal preheat, and heat a greater volume of weld metal
– Control fitup – Limit weld penetration
– Don’t overweld – Complete highly restrained weldments without
– Limit weld reinforcement interruption
– For a given weld size, make the weld in the fewest – When around-the-clock welding is impossible,
number of weld passes maintain around-the-clock interpass temperature
– For double-sided joints requiring backgouging, limit control
the backgouging to only that which is required – Plan the welding to ensure the assembly will need to
189 be welded only once 190
• Reduce Restraint • Reduce Restraint (continued)

– When possible, fabricate small subassemblies, – For individual joints, balance shrinkage on opposite sides of
and then join subassemblies into the final the member, when possible
assembly – Slight gaps of 1/32–1/16 in. help accommodate shrinkage.
– Weld components expected to have the greatest Soft steel spacer wires in between members can help in this
shrinkage first, then weld the members with less regard
anticipated shrinkage – Increasing the preheat, and increasing the volume of
material preheated, can sometimes assist, particularly when
– Weld the most rigid components first, saving the transverse cracking is being experienced and the joint can
more flexible components for welding later be expanded thermally before welding
– When possible, sequence the welding of various – Preset members before welding and allow them to move
joints so that the shrinkage movement of the parts during welding
is all toward a relatively fixed central location
191 192

•Welding HSS
•Welding HSS
•Connections and HSS member
•Welding AESS
size
•Welding on Existing Structures
•Field Welding
•Heat Shrinking 193 194
Special Welding Applications Matched Connection
•Welding HSS
size
•Overall configuration
195 196

197 198
199 200

201 202
Stepped
Connection Overlapped
203 204

Overlapped Gapped
205 Preferred 206

Provide Access for Welding
and Inspection
•Welding HSS
Ψ size
•Overall configuration
•Cutting and preparing HSS
Ψ = 30o minimum 207 208

Box HSS Box HSS
209 210
Box HSS Gapped
211 212

Box HSS Box HSS
213 214
Overlapped Round HSS
215 216

Round HSS Box HSS
217 218
Box HSS Box HSS
219 220

Round HSS Round HSS
Cannot insert
this member
221 222
Round HSS Round HSS
223 224

Round HSS Round HSS
225 226
•Welding HSS
•Welding AESS
•Field Welding

229 230
231 232

Welding AESS
•Use of Mock-ups
•Visual Inspection from the
observer’s distance and
perspective
•Note requirements on drawings
233 •Technical issues 234
Required for strength May be required for AESS
235 236

May be required for AESS

Code required practice
Cost
Distortion
237 238
Code required practice

May be AESS specified practice
Workmanship Concerns
Inspection Concerns 239 240

May be AESS specified practice May be AESS specified practice
How can flange CJP groove weld be made?

241 242
May be AESS specified practice Acceptable D1.1 distortion
Will splice crack when insert is welded?
243 244

May be AESS Specified

Tolerance
245 246
Free
Download
from AISC
http://www.aisc.org/store/p-
1500-architecturally-exposed-
structural-steel.aspx
247 248

•Welding HSS Welding on Existing Structures

•Welding AESS • Historic Steels
•Welding on Existing Structures • Welding Under Load
•Field Welding • Fire
•Heat Shrinking 249
• Cold Worked/Strain Aging 250
Chapter 4 Metallurgical Issues

Welding on Existing Structures
• Historic
(Obsolete) • Check weldability of steel
Steels (especially if riveted)
–ASTM A9
–ASTM A7
–ASTM A373
–ASTM A242
251 252


• Historic Steels
• Welding Under Load
• Fire
• Cold Worked/Strain Aging 253 254
255 256

257 258
259 260

261 262
50 1.0
ASTM A36 ASTM A441
From ASM “High-Temperature Property From ASM “High-Temperature Property
40 Data: Ferrous Alloys” 0.8 Data: Ferrous Alloys”
Strength (ratio)
Strength (ksi)
30 0.6
20 Yield 0.4 Yield

Tensile Tensile
10 0.2
0 200 400 600 800 1000 1200 1400 0 200 400 600 800 1000 1200 1400 1600 1800
263 264
Temperature (oF) Temperature (oF)

50
Welding on members under ASTM A36
From ASM “High-Temperature Property
load 40 Data: Ferrous Alloys”
• The amount of material at temperatures >650
Strength (ksi)
oF is negligible (Blodgett) 30
• Only a very small percentage of the cross
section experiences reduced properties 20
(Tide)
• The impact of the weld orientation Yield
(longitudinal versus transverse) is typically 10
inconsequential (Ricker) Tensile
• Each situation should be checked
0 200 400 600 800 1000 1200 1400
265 266
Temperature (oF)
1.0
ASTM A441 Special Welding Applications
From ASM “High-Temperature Property
0.8 Data: Ferrous Alloys”
Strength (ratio)
0.6 Welding on Existing Structures
0.4 Yield • Historic Steels

Tensile • Welding Under Load
0.2
• Fire
0 200 400 600 800 1000 1200 1400 1600
267
1800 • Cold Worked/Strain Aging 268
Temperature (oF)


General precaution: Fire! Welding on Existing Structures

–From combustibles
• Historic Steels
–From unintended work circuits
• Welding Under Load
• Fire
269
• Cold Worked/Strain Aging 270
Effects of cold working Effects of cold working
yield tensile elongation notch yield tensile elongation notch

toughness271 toughness272

Strain Aging Effects of strain aging

• Occurs when steel is heated to 400-
700o F
• Yield, tensile increase
• Ductility, notch toughness decrease
• Aggravated by presence of “free”
nitrogen
yield tensile elongation notch
273
toughness274
Welding on plastically
Strain Aging
deformed members
• Stress relief helps, but… • Reduced notch toughness make
– Typically impractical sure material is crack and notch free
– Depending on alloy, may experience • Reduced ductility minimize
cracking (Cr, Mo, V, B) practices that increase ductility demand
275 276

•Welding HSS
•Welding AESS
•Field Welding
Shop versus Field Welding
• Primarily an issue of cost

• Some environmental factors
• Position of welding
• Easier to control project in shop
279 280

MYTHS
• Can’t get quality weld out-of-position

• Can’t get quality in the field
• No codes apply
• Welders aren’t “certified”
• WPSs aren’t used
• No audit program for field contractors
• No contractor supplied inspectors
281 282
•Welding HSS
•Welding AESS
•Field Welding

Heated region
285 286
287 288

289 290
Heat Shrinking Heat Shrinking
• 1200 oF temperature limit for hot rolled • For new steel being curved
steels – No change in modulus of elasticity (E)
• 1100 oF temperature limit for quenched – Slight increase in yield and tensile strength
and tempered steels – 10-25% increase in ductility
• Pre-stress of up to 50% of room • For bent steel being straightened
temperature yield (Avent) – Yield strength increases 10%
– Tensile strength increases 4-6%
291 292

293 294
295 296

297 298
299 300


301
•Welding HSS Listen to the Steel!

•Welding AESS
•Welding on Existing Structures Special Welding
Applications
•Field Welding

www.aisc.org/seminars • Design Steel Your Way • Practical Connection

II – Efficient Analysis for Design for Economical
Steel Design Using the Steel Structures
2005 AISC Specification De-mystify connection
behavior and design
• Seismic Connections/
Manual – Practical • Listen to the Steel –
Applications of the 2005 Duane Miller on Welding
Seismic Provisions
For more information, go to www.aisc.org/seminars
305 306
• Over 50 total hours of free education • Introduction to Seismic Steel Design and the
AISC Seismic Provisions
• Twenty new courses added so far in 2009 December 10, 2009
• On-line testing for completion if desired Presented by Thomas A. Sabol
• CEU/PDH certificates for a fee
For more information, go to www.aisc.org/webinars
For more information, go to www.aisc.org/elearning
307 308

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309 310
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311 312

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Special Welding Applications

Need Help? Call ReadyTalk Support: 800.843.9166

Today’s AISC Live Webinar

Duane K. Miller, Sc. D., P.E.

American Institute of Steel Construction 1

Special Welding Applications Special Welding Applications

•Extending Anchor Rod •Welding HSS

American Institute of Steel Construction 2

Special Welding Applications

•Extending Anchor Rod

Special Welding Applications Special Welding Applications

•Extending Anchor Rod •Extending Anchor Rod

American Institute of Steel Construction 3

AWS Standard Terms & Definitions ASTM A6/A6M, Section X3

conditions into a specific, suitably be welded using conventional

Weldability Concerns With Anchor

American Institute of Steel Construction 4

ASTM F1554 ASTM F1554

ASTM F1554 ASTM F1554

American Institute of Steel Construction 5

ASTM F1554 ASTM F1554

ASTM F1554 ASTM F1554

Grade 55: Grade 55:

Therefore, investigate on a case-by-case

American Institute of Steel Construction 6

ASTM F1554 ASTM F1554

Therefore, investigate on a case-by-case

ASTM F1554 ASTM F1554

Grade 55 with Supplement S1: Grade 105:

Good weldability should be assured.

American Institute of Steel Construction 7

Special Welding Applications

Grade 105: •Extending Anchor Rod

Weldability likely to be poor.

American Institute of Steel Construction 8

American Institute of Steel Construction 9

American Institute of Steel Construction 10

American Institute of Steel Construction 11

Special Welding Applications

•Extending Anchor Rod

American Institute of Steel Construction 12

Special Welding Applications

•Welding Anchor Rod to Base Plates

American Institute of Steel Construction 13

Special Welding Applications Fit of rod to

American Institute of Steel Construction 14

Special Welding Applications Special Welding Applications

•Extending Anchor Rod Welding on Coated Steels

Specification for Structural Steel Buildings

Unless otherwise specified in the design

American Institute of Steel Construction 15

Specification for Structural Steel Buildings

13th Edition An American National Standard

M4. ERECTION Structural

Shop paint on surfaces adjacent to joints to

5.15 Preparation of Base Metal • Concern about fumes

American Institute of Steel Construction 16

•See ANSI Z49.1 Safety in Welding, Cutting

American Institute of Steel Construction 17

Safety and Health Fact Sheet No. 25

American Institute of Steel Construction 18

American Institute of Steel Construction 19

AWS D19.0-72 Welding Zinc-Coated Steel

Special Welding Applications