Steel

Connections -II
Welding

Design of Steel Structures

Durgesh C. Rai
Department of Civil Engineering, IIT Kanpur

Basics
Field welded truss

Basics

Welds seem simpler, but

Large welding required at each connection
Need for following a predetermined weld sequence

Basics

Types of welded joints

Butt

Lap

Tee
4

Edge

Corner

Basics

Types of welds

Basics

Types of Groove Welds

Basics

Types of Fillet welds

Basics

Types of welding technology

Shielded metal arc welding (SMAW)

Electrical
Electricalcircuit
circuit
8

Basics

Types of welding technology

Submerged arc welding (SAW)

Basics

Types of welding technology

Gas Metal Arc Welding (GMAW)
Metal Inert Gas (MIG) Welding

10

Basics

Types of welding technology

Gas Tungsten Arc Welding (GTAW)
Tungsten Inert Gas (TIG) Welding

11

Basics

Welding machines
Manual to Fully Automatic Equipment

12

Basics

Choosing an Electrode

13

Basics

Positions of welding electrode

14

Basics

Welding Symbols

15

Basics

Welding Symbols

150

150

8
12

150
150

16

150

Process OF Welding
Edge preparations for groove welds

17

Quality of WeldING
Possible weld defects

18

Quality OF Welding

Preferred weld profile

For better flow of forces

Poor
Poor

19

Good
Good

Quality OF Welding

Weld profile
Fillet
FilletWeld
Weld

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Groove
GrooveWeld
Weld

Quality OF Welding

Weld profile

1.5-2mm

21

Quality OF Welding

Weld profile

22

Quality OF Welding

Weld problems

23

Quality OF Welding

Checking size of fillet welds

Weld inspection gauge

Tolerance
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Problems of welding
Heat affected zone
Material properties are changed

Base metal

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Fusion zone

Heat affected zone

Problems of welding

Distortion and dimensional changes

Unsymmetric welds

Angular distortion

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Process OF Welding

Distortion due to welding

Curvature
Curvaturedeveloped
developedafter
afterwelding
welding

Sequence of intermittent welds

to avoid weld-induced curvature

or

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or

Problems of welding

Distortion and dimensional changes

Unsymmetric welds

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Problems of welding

Internal stresses
Weld restraints

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Problems of welding

Internal stresses
Weld restraints

30

Problems of welding

Internal stresses
Weld restraints
One solution

31

Problems of welding

Closing welds in indeterminate structures

Weld and base metals contract on cooling
Accompanied by yielding, cracking or elongation of
members

32

Problems of welding

Avoid problems of closing welds

Use proper weld sequence
Adopt prescribed number of passes for a required
total weld size
Allow the prescribed cooling time after each weld

33

Problems of welding

Lamellar tearing due to shrinkage of welds

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Problems of welding

How to reduce lamellar tearing

35

Problems of welding

Residual stresses in welded sections

Comparable to that in hot-rolled sections

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Problems of welding

Beam bottom flange welding - a challenge

Weld access hole, cope and backup bar required
Un-fused interface at bottom of back-up bar
Potential crack initiation of CJP weld

Weld Access
Hole

Cope

Beam
Column

CJP
Weld

Detail A

Backup Bar
Un-Fused Interface
Detail A

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Problems of welding

Performance of Welds
Tri-axial state of stress at column face
Avoid high stresses in welds
Yield stress y/2 is not reached
in shear; brittle fracture

u/2
y/2
1 2 = 3 = 0

y/2
max

1 = y

1 = u

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Uni-axial
Uni-axialStresses
Stresses

Tri-axial
Tri-axialStresses
Stresses

Problems of welding

Welding is difficult in tapered sections

Only obtuse-angled small-thickness weld possible
at tapered tip
Use parallel flange sections

Cover plate
I-section
Only small thickness
weld possible

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Cover plate
I-section

Proper welds
possible

Structural welds
Design of welds
Butt
ButtWeld
Weld

Fillet
Fillet
Weld
Weld
40

Structural Design of welds

Weld sizes
Fillet Welds

Cl. 10.5.8

Max. size:
smax = t-1.5 mm for square edges of t > 6 mm
smax = t for square edges of t < 6 mm
smax = 0.75t for the rounded edges of rolled sections

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Structural Design of welds

Weld sizes
Fillet Welds
Max. size:
End fillet weld normal to
force direction
Throat thickness not less
than 0.5t

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[ Cl. 10.5.8.5 ]

Structural Design of welds

Weld sizes
Fillet Welds
Min. size:
smin = 3 mm for tmax 10 mm
smin = 5 mm for 10 mm tmax 20 mm
smin = 6 mm for 20 mm tmax 32 mm
smin = 8 mm for the first run and 10
mm for 32 mm tmax 40 mm

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[ Cl. 10.5.2.3 ]
Table 21

Structural Design of welds

Weld sizes
Butt Welds
Min. groove depths for different situations applicable

End returns: min of 2 times weld size

Min length Lmin = max (4 s, 40 mm)
Lap Joints: min. lap length Llap = 4t min or 40 mm

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Structural Design of welds

Stresses in Fillet Welds

s

s
s

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lw

Structural Design of welds

Stresses in Fillet Welds

Due to individual forces

f a = N /(lwtt )
q = Q /(lwtt )

Axial force

Shear force
Q

[ Cl. 10.5.9 ]

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s
=sK

lw

Structural Design of welds

Stresses in Fillet Welds

[ Cl. 10.5.10 ]

Due to combination of stresses

Combined normal and shear stresses

fe =

fu
f + 3q
3 mw
2
a

[ Cl. 10.5.10.1.1 ]

Fillet
Fillet Weld
Weld
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Structural Design of welds

Stresses in Butt Welds

Due to combination of stresses

[ Cl. 10.5.10 ]

Butt
ButtWeld
Weld
Combined bearing, shear and bending

fe =

f b2 + f br2 + f b f br + 3q 2
[ Cl. 10.5.10.1.1 ]

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Structural design of welds

Design of fillet weld connection

Design strength
Rwdf = (lwtt ) f wdf lw
Effective
throat area

Design stress

f wd = f wn mw

mf =
f wn
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[ Cl. 10.5.7.1.1 ]

1.25

Shop welds

1.50

Field welds

fu
=
; f u = m in( f uw , f up )
3

Structural design of welds

Design of fillet weld connection

Design strength
Rwdf = (lwtt ) f wdf lw

[ Cl. 10.5.7.3 ]

Reduction factor for long joints

lw = 1.2

50

0.2 l j
150tt

1.0

Structural design of welds

Design of butt weld connection

Design strength
Rwdb = (lwtt ) f wdb lw
Effective
throat area
With throat
thickness
equal to
tickness of
plate

[ Cl. 10.5.7.1.1 ]

Design stress

f wdb = f wnb mw

mf =

1.25

Shop welds

1.50

Field welds

f wn = f u = m in( f uw , f up )
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Structural design of welds

Design Example of fillet weld connection

Design weld on face AB and GF with no eccentricity, plate thickness is 16mm
Strength per unit length for 6 mm weld Ex50xx and E250(Fe410) plates, shop welds

Rwdf = (lwtt ) f wdf lw

Rwdf = 1 (0.7 6mm)

410 MPa
= 0.8 kN / mm
3 1.25

160 kN

Eqm. requires

FAB + FGF = 160 kN

LAB + LGF = 160 kN /0.8kN / mm = 200mm

Moment condition requires

A
0.8kN/mm LAB

FAB (75mm) = FGF (125mm)

LAB = (5 /3) LGF

75 mm 160
200 mm
125mm

Solving A and B
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LAB = 125mm , LGF = 75mm

0.8kN/mm LGF

kN

Eccentric connection
Definition
Resultant of applied forces does not pass through the c.g. of
weld group
Two types
Cause only shear in fasteners
Cause shear + tension in fasteners

M=Pe

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Shear-only Weld Group

Shear + Tension Weld Group

Eccentric connection

Shear-only weld group

P

y
tt
z
M=Pe

Resultant
at point of interest

f R t t = ( t t f m )2 + ( t t f c ) 2

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Direct Shear

Rotation Effect

P
fc =
lw t t

( Pe ) ri ( Pe ) ri ( Pe ) ri
= 2
=
fm =
J
r dA I z + I y
A

Based on shaft
torsion analogy

Eccentric connection

Shear +Tension bolt group

e P

P
c

NA

=
Resultant
at a point of interest

f R t t = ( t t f m )2 + ( t t f c )2

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Pe

Bending behaviour (elastic)

Direct Shear

Locate NA, i.e., c

P
fc =
lw t t

t x
t

wt

dx = tt x wc dx

Tensile stress at a point

( Pe )y
fm =
I na

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