MECH1641 Machine Design II

Lecture 10: Welded Joints I Direct Shear

Welding Processes Weldments Groove Welds and Fillet Welds Welded Joints & Symbols Groove Welds and Fillet Welds Direct Shear due to Parallel & Transverse Loading
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Objectives
After this lecture and associated homework, you will be able to: Describe and distinguish between SMAW, GMAW, GTAW, FCAW, and SAW. Distinguish between the five different types of welded joints. Interpret and use basic welding symbols. Identify the important dimensions of groove and fillet welds. Calculate shear stress in loaded weldments, and use the associated concepts to design welded joints for direct shear loading.
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Arc Welding Processes

Common arc welding processes include:
SMAW (Shielded Metal Arc Welding, a.k.a. stick welding.) GMAW (Gas Metal Arc Welding, a.k.a. MIG welding.) GTAW (Gas Tungsten Arc welding, a.k.a. TIG welding.) FCAW (Flux-Cored Arc Welding, similar to MIG.) SAW (Submerged Arc Welding, similar to MIG.)
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SMAW

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SMAW

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The SMAW Welding Circuit

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GMAW

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GMAW

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GTAW

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GTAW

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FCAW

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FCAW

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SAW

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SAW

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Review
What is SMAW? Shielded Metal Arc Welding, also known as stick welding. What is GMAW? Gas Metal Arc Welding, also known as MIG welding.

What is FCAW? Flux Cored Arc Welding.

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Review
What is SAW? Submerged Arc Welding. In SAW, what is the arc submerged in? Flux. (SAW is not under-water welding.) Which arc welding processes use a wire as the welding electrode? (SMAW, GMAW, GTAW, FCAW, SAW) GMAW, FCAW, SAW. TIG filler metal is in the form of 3-ft rod for manual, and spooled wire for automated TIG. SMAW uses flux-coated rods, or electrodes, about 14 in long.
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Review
Which arc welding processes can be done by robots or other machines? (SMAW, GMAW, GTAW, FCAW, SAW) All of them except SMAW. Stick welding is virtually always manual process.

Which arc welding processes can be done with or without filler metal? GTAW. All of the others use a consumable electrode, which melts in the arc and becomes part of the solidified weld.
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Review
Which arc welding processes do not required shielding gas? (SMAW, GMAW, GTAW, FCAW, SAW) SMAW, FCAW and SAW all get their shielding from the flux. GMAW and GTAW use bottled shielding gas. Which arc welding processes is best for small precision welds of exotic metals? GTAW. Which arc welding processes is best for automated, high speed, high deposition-rate welding on a horizontal joint? SAW.
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Weldments
Welded assemblies are called weldments. Load-bearing weldments are most commonly made from carbon steel, but may also be stainless steel, aluminum, cast iron, and other alloys. Weldments used in construction, bridges and pressure vessels are subject to appropriate welding codes.

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Weldability of Common Metals

G Good. X not used. F fair.

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The Five Basic Joints

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Groove Welds

Juvinall Figure 11.6 (p. 453)

Representative butt joint groove welds: (a) open square double-groove weld, (b) single vee groove weld, (c) double vee groove weld, (d) single-bevel groove weld.
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Fillet Welds

Juvinall Figure 11.6 (p. 453)

Representative butt joint groove welds: (a) open square double-groove weld, (b) single vee groove weld, (c) double vee groove weld, (d) single-bevel groove weld.
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Identify the Weld Type

Groove Weld

Fillet Welds (all around)

Fillet Weld (all around)

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Welding Symbols: General Notes

The reference line is always horizontal. The tail is only used when supplementary process information is included. The arrow points to the joint. Items below the reference line indicate welding on the arrow side of the joint. Items above the reference line indicate welding on the other side of the joint.

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Arrow Side and Other Side

arrow side

other side

arrow side

other side

arrow side

other side

arrow side

other side

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Fillet Weld Symbol Review

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Fillet Weld Size

The size of a fillet weld means the leg. I.e., not the throat, face, or anything else.
Most commonly, the legs are equal and only one dimension is needed. If the legs are meant to be unequal, both legs must be specified. Note the fillet weld symbol always slopes to the right, regardless of the actual weld orientation.

0.5" 0.25"

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Groove Weld Symbols

Square Groove Weld Square Groove Weld

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Groove Weld Symbols

Double V Groove Weld V Groove Weld

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Weld-All-Around Symbol
1

/4

or

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Weld Length and Pitch

1

/4

2-4

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Examples: Intermittent Fillet Welds

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Examples: Intermittent Fillet Welds

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Weld Symbol Summary

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Activity Problems 1 4
Complete the weld symbols for the welds shown.

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Activity Problems 1 4 Solutions

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Fillet Weld Terminology

Toe Leg Throat Root Leg

Face

Toe

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Groove Weld Throat

Normally, the throat of a fillet weld is defined as the shortest distance from the intersection of the two plates to a line through the ends of the weld legs. Alternatively, for concave welds, the throat is the shortest distance from the intersection of the two plates to the surface of the bead.

F = hL

n =

Sy

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Fillet Weld Load Direction

Parallel Loading

Transverse Loading
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Fillet Weld Throat

Normally, the throat of a fillet weld is defined as the shortest distance from the intersection of the two plates to a line through the ends of the weld legs. Alternatively, for concave welds, t is the shortest distance from the intersection of the two plates to the surface of the bead.

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Fillet Weld Size

The size of a weld is given as the leg length h. The throat is t. The length of a weld is L.

h2 = t2 + t2 h = 2t 2 = 2 t t = h 2

t = 0.707 h
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Weld Direct Shear Stresses

Both parallel and transverse external loads are considered to be carried by shear forces on the throat area of the weld. The shear area is then the t x L rectangle where t is the weld throat and L is the weld length.

F F F = = = Ashear tL 0.707 hL
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A Closer Look
Our assumption that the external load is carried by shear forces on the throat area is true for parallel loads. It is a useful, conservative simplification for transverse loads.

F = 0.707 hL

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Welding Filler Metal Strength

Welding electrodes (filler metal) has been standardized by the AWS. The E60 and E70 series electrodes are designated E60xx and E70xx, where xx is a code for welding process details, and the 60 and 70 mean 60 and 70 ksi tensile strength of the weld metal, respectively. The yield strengths of the metals are shown below. The yield strength in shear is calculated using the Distortion energy theory, i.e. Ssy=0.577Sy. Note that in the absence of yield strength data, you can estimate that the yield strength is 12 ksi less than the tensile strength for E60 an E70 electrodes.

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Problem 6
The welded plates shown are 12 mm thick, made of steel with Sy=350 MPa. The 6-mm fillet welds are 50 mm long, were made using E6011 electrodes. What maximum load can be carried by this joint with a safety factor of 3?
Find F n= S ys given: L = 50 mm = 50 103 m; h = 6 mm = 6 103 m; S y = 345 MPa = 345 106 Pa; n = 3 = 0.577 S y

0.577 S y n F 2 0.707 h L F= 0.577 S y 2 0.707 h L n F = 28.1 kN

F 2t L

t = 0.707 h = 0.577 S y n =

Combining,

F 2 0.707 h L

0.577 345 106 N 2 0.707 6 103 m 50 103 m 1 F= 2 1 1 3 1 1 m

Ref. Juvinall, Sample Problem 11.1

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Problem 7
The welded plates shown are in thick, made of steel with Sy=120 ksi. The in fillet welds are 2.5 in mm long, and were made with E120xx electrodes. What safety factor results if the applied load is 25,000 lbf?
Find n given: L = 2.5 in; h = 0.25 in; S y = 120 ksi; F = 25,000 lb f n= S ys

0.577 S y

0.577 S y n

F = 2t L

F t = 0.707 h = 2 0.707h L 0.577 S y

0.577 S y 2 0.707 h L F Combining, = n= n F 2 0.707 h L 1 0.577 120,000 lb f 2 0.707 0.25 in 2.5 in n= n = 2.45 2 in 25,000 lb f 1 1 1 1
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Problem 8
A joint similar to the one from the previous question must carry a shear load24 kip. The welding electrode is E7018, and the two welds will be 4 in long. What size welds are required to provide a safety factor of 2 against static yielding?
Find h given L = 4 in; S y = 70 ksi; n = 2 n= S ys = 0.577 S y = 0.577 S y n F 2 0.707 h L h= Fn 0.577 S y 2 0.707 L h = 0.21 in

F 2t L

t = 0.707h = 0.577 S y n =

Combining, h=

F 2 0.707 h L

24,000 lb f 1

2 1 in 2 1 1 1 1 0.577 70,000 lb f 2 .707 4 in

Comment:Round up to a 1 " weld. 4

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Closing Notes & Homework

Read Juvinall, Sections 11.3-11.4. Do problems 11.1, 11.2, 11.6, 11.7, 11.12. Create a spreadsheet to analyze fillet weld joints, and use it to check your answers for problems 11.1, 11.2, 11.12.
I.e., calculate Ssy, t, , n given Sy, F, L, h. Make two versions of the spreadsheet, one for SI, one for US units.

Test 1 (20%) is on Friday March 7. (Rescheduled from February 22.)

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