A. General Information SEARI - DESIGN OF WELDED CONNECTIONS B. Weld Strength Calculations C. Weld Symbols D. Quiz (Discussion) E.

Moment Connections CJP Welds (If Time) F Shear F. Sh C Connections ti (U lik l ) (Unlikely)
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G. Weld Procedures(Unlikely)
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Welding Codes

Structural Welding
D1.1 Structural Welding Code Steel one of the most consulted codes in the world, is produced by The American Welding Society (AWS) a nonprofit organization with a goal to advance the science, technology and application of welding and related joining disciplines

A. General

D1.5 and D1.8

AISC 360 - The Steel Specification (Ch J and Ch N New to 2010) AISC 358 - Prequalified Connections for SMF and IMF AISC 341 Seismic Provisions (App Q and W)
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Weld Types 1 Fillet

Most Common Weld Types 1 Fillet

85% of All Welds

2.1 CJP 2 Groove 2.2 PJP 2 Groove

2.1 CJP
10% of All Welds

2.1a Single Bevel 2.1b 2 1b S Square Etc 2.2a Single Bevel 2.1b Double Bevel 2.2c Flare Bevel Etc

2.2 PJP
5% of All Welds

3 Plug/Slot

3 Plug/Slot
<1% of All Welds

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Fillet Welds

Groove Welds (CJP/PJP)

Symbolic Profiles

Actual Profiles The most commonly used weld is the fillet weld Fillet welds are theoretically triangular in cross-section Fillet welds join two surfaces at approximately right angles to each other in lap, tee, and corner joints (AISC & NISD 2000)
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Groove welds are specified when a fillet weld is not appropriate

The configuration of the pieces may not permit fillet welding A strength greater than that provided by a fillet weld is required

Groove welds are made in the space or groove between the two pieces being welded
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CJP

Full Penetration Groove Welds

PJP

Partial Penetration Groove Welds

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Length of Welds

Welding Terminology

Multi Pass Welds

Weld Size

Tack Weld (above left) - A temporary weld used to hold parts in place while more extensive, t i fi l welds final ld are made d Continuous Weld - A weld which extends continuously from one end of a joint to the other Stitch Weld (above right) - A series of welds of a specified length that are spaced a specified distance from each other
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Larger weld sizes may require multiple passes to meet the size requirement Common single pass welds include fillet welds up to and including 5/16 inch and thin plate butt welds with no preparation Common multiple pass welds include single bevel full penetration groove welds, single bevel partial penetration groove welds, and fillet welds over 5/16 inch
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Welding Positions

B. Weld Strength Calculations

There are four recognized welding positions:

Flat The face of the weld is approximately horizontal and welding is performed from above the joint Horizontal The axis of the weld is horizontal Vertical The axis is approximately vertical or in the upright position Overhead Welding is performed from below the joint

The flat position is preferred because it is easier and more efficient to weld in this position
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Weld Capacity
Weld Capacity = Strength x Area

Weld Capacity
Weld Capacity = Strength x Area ASD: R/ = F/ x A where = 2.0 20

R=FxA
where F = Strength of Weld or Base Metal A = Area (Effective Throat x Width)

R=FxA
LRFD: R= F x A where = 0.75 where F = Strength of Weld or Base Metal See J2.5 F = 0.6 x 70ksi = 42 ksi for 70ksi Weld (21 ksi for ASD and 31.5 ksi for LRFD) A = Effective Throat x Width

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Weld Capacity
Weld Capacity = Strength x Area ASD: LRFD: R/ = F/ x A where = 2.0 20 R = F x A where = 0.75

Fillet Weld Nomenclature

where F = Strength of Weld or Base Metal See J2.5 A = Effective Throat x Width For Fillet = Leg x 0.707 For PJP = Leg 1/8 (or see Tables J2.1, J2.2) For CJP = Thickness of Thinner Material For Plug/Slot, Area = Area
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Strength of Fillet Weld

Fillet Weld Strength in Shear (Parallel)

Throat Dimension = 0.707 (Leg Dim) for strength calculations Check 1/4 fillet (10 long) LRFD
Phi Rn = 0.75 x 0.6 x 70ksi x = 0.75(0.6)(70ksi)(0.25 0 75(0 6)(70ksi)(0 25)(0 )(0.707)(10 707)(10)(2sides) )(2sides) = 111 kips or = 1.392 x 4 x 10 x 2 sides = 111 kips

(For LRFD you can use .75 x .6 x 70 x 0.707/16 = 1.392 k/in per 1/16 fillet) (For ASD you can use .6 x 70 x 0.707/(16 x 2) = 0.928 k/in per 1/16 fillet)

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Fillet Weld Strength

Fillet Weld Strength in Shear (Perpendicular)

50% Increase for Tension Welds Check 1/4 fillet (20 long) LRFD
Phi Rn = 0.75 x 0.6 x 70ksi x Ae = 0.75(0.6)(70ksi)(0.25)(0.707)(20) x 1.5 = 166 kips

(For LRFD you can use .75 x .6 x 70 x 0.707/16 x 1.5 = 1.392 k/in per 1/16 fillet) x 1.5 (For ASD you can use .6 x 70 x 0.707/(16 x 2) x 1.5 = 0.928 k/in per 1/16 fillet) x 1.5

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Comparison (ASD)
Fillet Capacity (Shear) = 0.6 (70ksi) / 2.0 = 21.0 ksi x 0.707 Leg Fillet Capacity (Tension) = 0.6 (70ksi) / 2.0 x 1.5 = 31.5 ksi x 0.707 Leg Technically there is no such thin as tension in a fillet weld, but I am using this word to describe the load orientation is perpendicular to the weld Fillet Weld Tension = 31.5 ksi x 0.707 Leg = 22.3 ksi x LEG Plate in Tension = Fy y /1.67 = 21.5 ksi x LEG = Fu /2 = 29.0 ksi x LEG So instead of a 1.5 multiplier, you could justify 1.45 max for A36

Strength of PJP

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Strength of PJP has Changed

If Base Metal is 50ksi, PJP capacity = 50/1.67 = 30 ksi (2005 ASD) If Base Metal is 50ksi, PJP capacity = 65/2 = 32.5 ksi (2010 ASD)

Effective Throat of PJP

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Effective Throat of PJP

Weld Size 1/8 = Effective Throat

PJP - Flare Bevel Detail

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Strength of CJP

(Part of Table J2.5 AISC 2005)

Comparison Weld in Shear

ASDShearStrength(36ksiBaseMetal)
E70XX Fillet PJP CJP ASDStrength inksi 0.6(70ksi)/2 0.6(70ksi)/2 0.6(36ksi)/1.5 0.6(36ksi)/1.5 Controlling Capacity 21.0ksi 14.4ksi 14.4ksi What Controls? Weld Base Base Effective ASDShear Throat Strengthk/in 0.707Leg 14.8ksi Leg1/8 PLThick Varies 14.4ksi

ASDShearStrength(50ksiBaseMetal)
E70XX Fillet PJP CJP ASDStrengthin Controlling What Effective ASDShear ksi Capacity Controls? Throat Strengthk/in 0.6(70ksi)/2 21.0ksi Weld 0.707Leg 14.8ksi 0.6(70ksi)/2 20.0ksi Base Leg1/8 Varies 0.6(50ksi)/1.5 0.6(50ksi)/1.5 20.0ksi Base PLThick 20.0ksi

ASDShearStrength(36ksiBaseMetal)
Size 1/16 1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 Fillet 0.928k/in 1.856k/in 2.784k/in 3.712k/in 4.640k/in 5.568k/in 6.496k/in 7.424k/in 8.351k/in 9.279k/in 10.207k/in 11.135k/in 12.063k/in 12.991k/in 13.919k/in 14.847k/in PJP 0.900k/in 1.800k/in 2.700k/in 3.600k/in 4.500k/in 5.400k/in 6.300k/in 7.200k/in 8.100k/in 9.000k/in 9.900k/in 10.800k/in 11.700k/in 12.600k/in CJP 0.900k/in 1.800k/in 2.700k/in 3.600k/in 4.500k/in 5.400k/in 6.300k/in 7.200k/in 8.100k/in 9.000k/in 9.900k/in 10.800k/in 11.700k/in 12.600k/in 13.500k/in 14.400k/in

ASDShearStrength(50ksiBaseMetal)
Size 1/16 1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 Fillet 0.928k/in 1.856k/in 2.784k/in 3.712k/in 4.640k/in 5.568k/in 6.496k/in 7.424k/in 8.351k/in 9.279k/in 10.207k/in 11.135k/in 12.063k/in 12.991k/in 13.919k/in 14.847k/in PJP 1.250k/in 2.500k/in 3.750k/in 5.000k/in 6.250k/in 7.500k/in 8.750k/in 10.000k/in 11.250k/in 12.500k/in 13.750k/in 15.000k/in 16.250k/in 17.500k/in CJP 1.250k/in 2.500k/in 3.750k/in 5.000k/in 6.250k/in 7.500k/in 8.750k/in 10.000k/in 11.250k/in 12.500k/in 13.750k/in 15.000k/in 16.250k/in 17.500k/in 18.750k/in 20.000k/in

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Comparison Weld in Tension

ASDTensionStrength(36ksiBase Metal)
E70XX Fillet PJP CJP ASDStrengthin Controlling What Effective ASDTension ksi Capacity Controls? Throat Strengthk/in 1.5x0.6(70ksi)/2 31.5ksi Weld 0.707Leg 22.3ksi 0.6(70ksi)/1.88 22.3ksi Base Leg1/8 Varies (58ksi)/2 (36ksi)/1.67 ksi)/1 67 21 6ksi 21.6 Base PLThick 21 6ksi 21.6

ASDTensionStrength(50ksiBaseMetal)
E70XX Fillet PJP CJP ASDStrengthin Controlling What Effective ASDTension ksi Capacity Controls? Throat Strengthk/in 1.5x0.6(70ksi)/2 31.5ksi Weld 0.707Leg 22.3ksi 0.6(70ksi)/1.88 22.3ksi Weld Leg1/8 Varies (65ksi)/2 (50ksi)/1.67 ksi)/1 67 29 9ksi 29.9 Base PLThick 29 9ksi 29.9

ASDTensionStrength(36ksiBase Metal)
Size 1/16 1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 Fillet 1.392k/in 2.784k/in 4.176k/in 5.568k/in 6.960k/in 8.351k/in 9.743k/in 11.135k/in 12.527k/in 13.919k/in 15 311k/in 15.311 16.703k/in 18.095k/in 19.487k/in 20.879k/in 22.271k/in PJP 1.396k/in 2.793k/in 4.189k/in 5.585k/in 6.981k/in 8.378k/in 9.774k/in 11.170k/in 12 566k/in 12.566 13.963k/in 15.359k/in 16.755k/in 18.152k/in 19.548k/in CJP 1.347k/in 2.695k/in 4.042k/in 5.389k/in 6.737k/in 8.084k/in 9.431k/in 10.778k/in 12.126k/in 13.473k/in 14 820k/in 14.820 16.168k/in 17.515k/in 18.862k/in 20.210k/in 21.557k/in

ASDTensionStrength(50ksiBaseMetal)
Size 1/16 1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16 1 Fillet 1.392k/in 2.784k/in 4.176k/in 5.568k/in 6.960k/in 8.351k/in 9.743k/in 11.135k/in 12.527k/in 13.919k/in 15 311k/in 15.311 16.703k/in 18.095k/in 19.487k/in 20.879k/in 22.271k/in PJP 1.396k/in 2.793k/in 4.189k/in 5.585k/in 6.981k/in 8.378k/in 9.774k/in 11.170k/in 12 566k/in 12.566 13.963k/in 15.359k/in 16.755k/in 18.152k/in 19.548k/in CJP 1.871k/in 3.743k/in 5.614k/in 7.485k/in 9.356k/in 11.228k/in 13.099k/in 14.970k/in 16.841k/in 18.713k/in 20 584k/in 20.584 22.455k/in 24.326k/in 26.198k/in 28.069k/in 29.940k/in

C. Weld Symbols

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Groove Weld Nomenclature

Groove Weld Nomenclature

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Symbols

Symbols

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Symbols

Fillet Symbols

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CJP Symbol B-L1a

CJP Symbol B-U4a

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CJP Symbol TC-U4a

PJP Symbol BTC-P4

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PJP Symbol BTC-P10

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Erik Nelson, PE Structures Workshop

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C. Quiz

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Quiz #1: Which Weld Symbol is Shown Wrong?

#1 Examples Wrong Faying Surface on HSS

OK

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Quiz #2: Which weld(s) is shown wrong?

Quiz #3: What is very problematic with this detail?

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#3 Examples of Welds and Bolts Sharing Shear Plane

#3 Examples of Welds and Bolts Sharing Shear Plane

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Quiz #4: Which weld is shown wrong?

#4 Examples of Mirrored Welds

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Quiz #5 Which weld is shown wrong?

#5 Examples of All Around Shown Wrong

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Quiz #6: What is wrong here?

Quiz #7: What is wrong here?

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Quiz #8: What is wrong here?

Quiz #8 Info on Plug Welds

Why nor greater?

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Quiz #9

#9 Examples of Wrong Use of Butt Welds

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#9 Examples of Wrong Welds Shown

Quiz #10 Prequalified?

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Quiz #11: Anything Missing Here?

Quiz #13 Anything wrong here?

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Quiz #14 Plan

Quiz #14 Comments?

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Quiz #14 Comments?

Quiz #15: Min fillet. Anything Change Here?

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Quiz #16: Fillet Max Thickness for Lap Joint

16 Max Fillet to Develop Steel Capacity

Dmax = Fu (t) / 6.19 6 19 So 1/2 PL, use 5/16 Weld

Is there a max fillet weld for a T or L joint?

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Dmax = Fu (t) / 3.09 So 1/2 PL, use 5/8 Weld

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Quiz #17: Does Reinforcing Fillet Increase Capacity?

Quiz #18: How should an Engineer Specify a CJP?

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Quiz #19: How do you know what is more expensive?

Quiz #20: Which is preferred weld for Backing bar?

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Quiz #21: Length of Runoff Tabs?

Quiz #22: Corner Detailing (To Avoid Laminar Tearing)

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Quiz #23: Is a longer 5/16 weld better than a shorter 3/8 weld?

23: Two Small Triangles better than One

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Quiz #23: Does increasing thickness of A36 help?

Quiz #24: Problem?

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Quiz #25: How much should EOR show?

Quiz #26: What is a shelf bar?

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Quiz #26: What is a shelf bar?

Quiz #27: When to use PJP instead of Fillet?

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4 Moment Connections (If there is time!)

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AWS 5.17 Weld Access Holes

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Good Notes on MC Connections

MC Connection

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Strategies for Improved Performance of Moment Connections:

Improved practices for backing bars and weld tabs Remove bottom flange backing bar Seal weld top flange backing bar Remove weld tabs at top and bottom flange welds Greater emphasis on quality and quality control (AISC Seismic Provisions - Appendix Q and W)

Bottom Flange

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Top Flange

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MC Connections - Comments

5 Sh Shear C Connections ti (If th there i is ti time!) !)

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Welding Procedure Specifications

WPS contain welding parameters in AWS D1.1 2010 Table 3.8 (for prequalified welding processes)

6W Weld ld P Procedures d (If th there i is ti time!) !)

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SMAW

Elements of SMAW

Shielded Metal Arc Welding (SMAW) is also known as manual, stick, or hand welding An electric arc is produced between the end of a coated metal electrode and the steel components to be welded The electrode is a filler metal covered with a coating The electrodes coating has two purposes: It forms a gas shield to prevent impurities in the atmosphere from getting into the weld It contains a flux that purifies the molten metal
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GMAW

FCAW

FCAW Welding

Gas Metal Arc Welding (GMAW) is also known as MIG welding It is fast and economical - A continuous wire is fed into the welding gun The wire melts and combines with the base metal to form the weld The molten metal is protected from the atmosphere by a gas shield which is fed through a conduit to the tip of the welding gun This process may be automated
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Flux Cored Arc Welding (FCAW) is similar to the GMAW process The difference is that the filler wire has a center core which contains flux With this process it is possible to weld with or without a shielding gas This makes it useful for exposed conditions where a shielding gas may be affected by the wind
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SAW

SAW Welding

Welding Equipment

Submerged Arc Welding (SAW) is only performed by automatic or semiautomatic methods Uses a continuously fed filler metal electrode The weld pool is protected from the surrounding atmosphere by a blanket of granular flux fed at the welding gun Results in a deeper weld penetration than the other process Only flat or horizontal positions may be used
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Equipment used for welding will vary depending on the welding process and whether the welding is being done in the shop or in the field A Flux Cored Arc Welding machine for shop welding is pictured above left A Shielded Metal Arc Welding machine for field welding is pictured above right
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Weather Impacts

on Welding

Weld Inspections

In addition to the erectors quality control program, tests and inspections are specified by the Engineer of Record and/or the local building authority

Welding in the field is avoided if possible due to welding condition requirements Field welding is not to be performed while it is raining, snowing, or below 0 F In certain ambient temperatures preheating of the material to be welded is required AWS Code D1.1 (2004b) specifies minimum preheat and interpass temperatures, which are designed to prevent cracking
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A local building inspector may request that tests in addition to those specified by the Engineer of Record be performed Some problems that can be found in welds include: There are several weld tests and inspections that are commonly used

Lack of fusion Porosity

Cracks Insufficient penetration

Wrong size Poor workmanship

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Visual Inspection

Dye Penetrant Test

Visual inspection is the most frequently used inspection and is the only inspection required unless the specification calls for a more stringent inspection method Inspection is done by the welder before, during, and after welding When outside inspection is required it should also be done before, during, and after welding Minor problems can be identified and corrected before the weld is complete (AISC & NISD 2000)
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Dye penetrant testing locates minute surface cracks and porosity Dye types that may be used include: Color contrast dye - which shows up under ordinary light Fluorescent dye which shows up under black light The dye is normally applied by spraying it directly on the weld (AISC & NISD 2000)
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Magnetic Particle Inspection

Ultrasonic Inspection

Ultrasonic inspection can be used to detect flaws inside welds Magnetic particle inspection uses powdered magnetic particles to indicate defects in magnetic materials A magnetic field is induced in the part The magnetic powder is attracted to and outlines cracks within the material
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High frequency sound waves are directed into the metal with a probe held at a specific angle The flaws reflect some energy back to the probe Flaws show up as indications on a screen (above) and are subject to interpretation by an inspector

Radiographic Inspection

Cost

Fillet weld is less expensive than groove weld

No special preparation, preparation no backing required, required less volume of weld
Radiographic inspection, or X-ray, can also be used to detect flaws inside welds Invisible rays penetrate the metal and reveal flaws on an x-ray film or fluorescent screen (above) This is the most costly of the inspection methods
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Partial penetration groove weld is less expensive than full penetration groove weld Labor represents the majority of the cost associated with welding

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