Welded Connections

Chapter J2

CEE 451 Design of Metal Structures

Welded Connections in Steel Frame Buildings

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 Introduction
• Welding:
– Joining of materials by heating until molten and allowing to flow together
and resolidify (with or without the addition of other molten metal)

• Advantages of Welding:
– Economic
• Eliminate a large percentage of the gusset and splice plates for bolted structures
• Eliminate of bolt heads
– Much wider range of application
• Steel pipe column and the difficulties of connecting it to other member by bolt
– More rigid
• Members often are welded directly to each other
• Frequently, the connection for bolted structures are made through intermediate
connection angles or plates that deform due to load transfer, making the entire
structure more flexible
– Welding is silence
• NEAR HOSPITAL

CEE 451 Design of Metal Structures

Welding Process
– Electric Arc Welding (most common in structural steel)
– Electric Resistance Welding
– Oxyacetylene Welding
– Thermit Welding
– Laser Beam Welding
– Electron Beam Welding

CEE 451 Design of Metal Structures

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• Electric Arc Welding Processes:

– Shielded Metal Arc Welding (SMAW)

– Submerged Arc Welding (SAW)
• http://www.youtube.com/watch?v=lzyIV5XRAf4&feature=related
– Flux cored Arc Welding (FCAW)
• http://www.youtube.com/watch?v=kI7GOVrB33c&feature=related
– Gas Metal Arc Welding (GMAW) (SMAW)
• http://www.youtube.com/watch?v=pGczSAb57Ps

(FCAW) (SAW)
(GMAW)

CEE 451 Design of Metal Structures

• Electric Arc Welding:

• Electrical Arc generates the needed heat to melt metal

– Basic features common to Electric Arc Welding

• Electric Arc
– Provide heat to melt base metal and electrode
– Transfer droplets of molten metal from tip of electrode to the base metal
• Electrode (a short rod or wire)
– Provides filler metal for
the joint
• Shielding
– Protects molten metal from
reacting with air (prevents
brittle welds)
– Stabilizes and control arc

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• Method of shielding:
– Flux shielding:
• Flux is a granular material that is placed as a coating on outside of an electrode.
• When subjected to the heat of the electric arc, portions of the flux vaporize, forming a
gas that surrounds the arc and molten metal, protecting it from contact with the
atmosphere.
• Flux also typically contains various alloying and purifying elements that mix with the
molten metal. The purifying elements will rise to the top of the molten metal and form a
slag coating. After cooling, the slag should be removed.

– Gas Shielding
• The arc and molten metal are surrounded by an externally supplied gas.
– Typical shielding gases:
» Argon
» Helium
» Carbon dioxide

Type of Weld
Welds can be classified according to the type of Weld:
• Fillet Welds
– Are those made where parts lap over each other or tee joints
– Most common type of structural weld (about 80%)
– The most economic one
• Little preparation of the parts to be connected
• Groove Welds
– Are used when the members to be connected are lined up in the same plane
– The members have to fit almost perfectly
– They are quite common (15% of structural weld)
• Column splices
• Butting of beam flange to column
– Complete-penetration welds
– Partial penetration welds
• Slot Welds
• Plug Welds

CEE 451 Design of Metal Structures

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 Different Position for Welding
• Welds can be classified according to the position:
– Flat
– Horizontal
– Vertical more expensive
– Overhead

CEE 451 Design of Metal Structures

Type of Joint
• Welds can be classified according to the type of joint used:
– Butt
– Lap
– Tee
– Edge
– Corner

CEE 451 Design of Metal Structures

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 Welding Symbols
AISC Manual: Table 8-2, page 8-35

Size of Weld

Length Weld

CEE 451 Design of Metal Structures

Fillet Welds
• Tests have shown that fillet welds are stronger in tension and compression than they
are in shear.
– The controlling fillet weld stress is shear stress
– The fillet welds seem to fail by shear at angles of about 45 through the throat.

– The fillet weld strength = the design shearing stress X the theoretical throat area of the weld.
• Throat area= Theoretical throat distance X the length of the weld
– Root: the point at which the faces of the original metal pieces intersected
– Theoretical throat: the shortest distance from the root of the weld to its
diagrammatic face
– For the 45 or equal leg fillet, the throat = 0.707 X the leg of the weld

CEE 451 Design of Metal Structures

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 Strength of Welds
• The stress in a fillet weld is usually equal the load divided by the effective
throat are of the weld, with no consideration given to the direction of load.
– Transverse fillet welds are stronger
– It is common for designers to determine the strength of all fillet welds by
assuming that the loads are applied in the longitudinal direction.

CEE 451 Design of Metal Structures

Strength of Welds
• The applied load produces shear stress on the effective area of welds A and B.
– The stress at fracture of welds A and B = shear strength of weld metal = 0.6 FEXX

• The applied load produced both shear and tensile stress on the effective are of weld C.
– shear strength of weld metal (0.6 FEXX ) <
The stress at fracture of welds C <
Tensile strength of weld metal (FEXX )

CEE 451 Design of Metal Structures

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 Design Strength of Fillet Welds
• Failure of a Weld = Fracture of weld metal
• Strength of a Weld = Effective throat area of weld X stress at fracture
– Effective throat area = effective throat thickness/distance (t) X length of the weld (Lw)
• t= 0.707 w (leg of the weld)
• t= w1w2 / √w12 +W 22

w
t w2 t
w w1

• All loads on fillet welds are assumed to be carried as pure shear stress on the effective area of
the weld.
– Failure of a fillet weld as shear fracture through the effective throat of the weld
– Shear fracture of the weld metal is assumed to occur at a shear stress of 0.6 FEXX
• FEXX is the specified ultimate strength of the weld metal

CEE 451 Design of Metal Structures

Design Strength of Fillet Welds

• ΦRn= Φ Fnw Awe (equation J2-3 page 16.1-115)
– Φ = 0.75
– Fnw = nominal stress of the weld metal, Ksi
– Awe= effective area of the weld, in2

• ΦRn= 0.75 t Lw (0.6 FEXX )

– Φ = 0.75
– t= effective throat distance (0.707 W), in
– Lw= Length of Weld, in
– FEXX = ultimate tensile strength of weld metal, Ksi
– The same strength is used regardless of the direction of loading

The filler metal electrodes for shielded arc welding are listed as E60XX, E70 XX, etc.

The letter E represents an electrode

The first set of digits (60, 70, 80) indicates the minimum tensile strength of the weld

The last digits may be used to specify the type of coating

CEE 451 Design of Metal Structures

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 AISC Requirements
– The minimum length of fillet weld (Lw) may not be less than four times the
nominal leg size of the weld (w).

– The minimum permissible size of fillet welds of the AISC specification are
given in Table J2.4 (Depend on thinner of the two parts being joined)

CEE 451 Design of Metal Structures

AISC Requirements
• The maximum size of a fillet weld along edges of material less than ¼ in
thick equals the material thickness.

• The maximum size of a fillet weld along edges of material thicker than ¼ in
thick, it may not bigger than the material thickness less 1/16 in, unless the
weld is specially built out to give a full throat thickness.

• If the actual length of the weld (Lw) be greater than 100 times its leg size
(w), the AISC states due to stress variations along the weld, it is necessary
to determine a smaller or effective length for strength determination.
– This will be done by multiplying Lw by the term β
• β =1.2-0.002(Lw/ w) ≤ 1

CEE 451 Design of Metal Structures

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• Example 1 :
• Determine the design strength of a 1-in, 20-in and 30-in length of a ¼ -in fillet weld
formed by the shielded metal arc process (SMAW) and E70 electrodes (FEXX=70 ksi)

• a: Lw= 1in
– ΦRn= 0.75 t Lw (0.6 FEXX )
– ΦRn= 0.75 (0.707x1/4in) (1in) (0.6 x70ksi ) = 5.56 k/in

• b: Lw= 20in
– Lw/ w = 20 / (1/4) = 80 <100 → β =1
– ΦRn= 0.75 t Lw (0.6 FEXX )
– ΦRn= 0.75 (0.707x1/4in) (20in) (0.6 x70ksi ) = 111.3 k or
» ΦRn Lw = (5.56)(20) =111.2 k

• c: Lw= 30in
– Lw/ w = 30 / (1/4) = 120 >100 → β =1.2-0.002(Lw/ w) =0.96 ≤ 1
» Φ Rn β Lw = (5.56)(0.96)(30) =160.1 k

CEE 451 Design of Metal Structures

• Example 2 :
• What is the design strength of the connection shown in figure below, if the plates
consists of A-572 Grade 50 steel (Fu=65 ksi)? E70 electrodes were used, and the
7/16-in fillet welds were made by the SMAW process.

Weld strength
– Lw/ w = 10 / (7/16) = 22.86 <100 → β =1
– ΦRn= 0.75 t Lw (0.6 FEXX )
– ΦRn= 0.75 (0.707x7/16in) (2x10in) (0.6 x70ksi ) = 194.9 k Controls

Check tensile yielding for ¾ x10 PL

– ΦRn= 0.9 Fy Ag
– ΦRn= 0.9 (50ksi)(3/4 in x 10 in)=337.5 K

Check tensile rupture for ¾ x10 PL

– U from table D3.1 page 16.1-28 case 4:
the weld length, l = 10in, is equal to
distance between welds, w → U=0.75
– Ae= U Ag =0.75 (3/4 x10) = 5.625 in2
– ΦRn= 0.75 Fu Ae
– ΦRn= 0.75 (65ksi)(5.625 in2)=274.2 K

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• Example 3 :
• Using 50 ksi steel and E70 electrodes, design SMAW fillet welds to resist a full-
capacity load on the 3/8 x 6-in member shown in figure.
• Tensile yield strength of gross section of 3/8 x 6 bar
– ΦRn= 0.9 Fy Ag
– ΦRn= 0.9 (50ksi)(3/8 in x 6in)= 101.2 K Controls

• Tensile rupture strength of 3/8 x 6 bar

– Assume U =1
– Ae= U Ag =1 (3/8 x6) = 2.25 in2
– ΦRn= 0.75 Fu Ae
– ΦRn= 0.75 (65ksi)(2.25 in2)=109.6 K
• Tensile capacity of bar is controlled by yielding

• Design Weld
– Max weld size = 3/8 – 1/16 = 5/16 in
– Min weld size = 3/16 in (Table J2.4)
– Use 5/16 weld
– ΦRn(of weld per in)=0.75tLw(0.6 FEXX )=0.75(0.707x5/16in) (0.6 x70ksi ) =6.96k/in
– Weld length reqd = 101.2/6.96 = 14.54 in or 7 ½ in each side
– Lw/ w = 7.5 / (5/16) = 24 <100 → β =1
– Use 7 ½ in welds each side ????

Local Shear Fracture of Base Metal

• Design strength of weld, based on local shear fracture of base model:
– ΦRn= 0.75 w Lw (0.6 Fu )
• Design strength of weld, based on fracture through throat of weld:
– ΦRn= 0.75 t Lw (0.6 FEXX )
• For local shear fracture of base metal to control:
– 0.75 w Lw (0.6 Fu ) < 0.75 (0.707w) Lw (0.6 FEXX ) → Fu ≤ 0.707FEXX

– The equation will never be satisfied as long as matching weld metal is used

w
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 Design of Connections For Members With Both
Longitudinal and Transverse Fillet Welds

• AISC section J2.4c (page16.1-117) states the total nominal strength of a

connection with longitudinal and transverse welds is to equal the larger of
the values of two equations:

– Rn= Rnwl+ Rnwt AISC Equation J2-10a

– Rn= 0.85 Rnwl+ 1.5 Rnwt AISC Equation J2-10ab

• Rnwl = total nominal strength of longitudinally loaded fillet welds, Kips

• Rnwt= total nominal strength of transversely loaded fillet welds, Kips
• Both value obtained as before

CEE 451 Design of Metal Structures

• Example 4 :
• Determine the total LRFD design strength of
the 5/16-in E70 fillet welds shown in Figure.

– Effective throat t= (0.707)(5/16 in)= 0.221 in

– Rnwl= Fnw Awe = (t Lw )(0.6 FEXX )
= (0.60x70 ksi)(2x8inx0.221in) = 148.5 k
– Rnwt= Fnw Awe = (t Lw )(0.6 FEXX )
= (0.60x70 ksi)(10inx0.221in) = 92.8 k
– Rn= Rnwl+ Rnwt = 148.5 k + 92.8 k = 241.3 k
– Rn= 0.85 Rnwl+ 1.5 Rnwt = (0.85)(148.5 k) +(1.5)(92.8 k) = 265.4 k controls
– ΦRn= (0.75)(265.4) = 199 k

CEE 451 Design of Metal Structures

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• Example 5 :
• Use Fy=50 ksi and Fu=65 ksi, E70 electrodes, and the SMAW process to design side fillet welds
for the full capacity of the 5x3x1/2-in angle tension member shown. Assume that the WT
member has adequate strength to develop the weld strengths and the thickness of its web is ½
in. Assume that U= 0.87 (Check block shear)
• Tensile yield strength on gross section
– ΦRn= 0.9 Fy Ag
– ΦRn= 0.9 (50ksi)(3.75 in2)= 168.75 K

• Tensile rupture strength of net section

– Ae= U Ag =(0.87) (3.75 in2) = 3.26 in2
– ΦRn= 0.75 Fu Ae
– ΦRn= 0.75 (65ksi)(3.26 in2)=158.9K

• Design Weld
– Max weld size = 1/2 – 1/16 = 7/16 in
– Use 5/16-in weld (largest that can be made in single pass)
– Effective throat t of weld= 0.707(5/16in) = 0.221 in
– Design strength/ in of 5/16-in welds=ΦtLw(0.6FEXX )=0.75(0.221in)(0.6 x70ksi )(1)=6.96k/in
– Weld length reqd = 158.9/6.96 = 22.83 in
– How can we distribute this? What is L1 and L2?

CEE 451 Design of Metal Structures

• If the connection is subjected to repeated varying stresses (such as bridge member) (making
any connection eccentricity undesirable), is essential to place the welds so that their centroid
will coincide with the centroid of the member.
P
– Taking moments about point A:
– (158.9)(1.74)-(5)(P2)=0
– P2=55.3 k
– L2= 55.3 k /6.96 (k/in) =7.95in (say, 8 in)
– L1 = 22.83-7.95=14.88 in (say, 15 in)

– Checking block shearing strength: P2

– Rn= 0.6 Fu Anv + Ubs Fu Ant ≤ 0.6 Fy Agv + Ubs Fu Ant P1

– Rn=(0.6)(65)(15+8)(1/2)+(1)(65)(5x1/2)≤ (0.6)(50)(15+8)(1/2)+(1)(65)(5x1/2)=611k>507.5k
– Rn=507.5 k
– ΦRn=(0.75)(507.5)= 380.6 k> 158.9 k
Ok

CEE 451 Design of Metal Structures

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 Full-Penetration and Partial-Penetration Groove
Welds

• Full-Penetration groove welds:

– When plates with different thickness and strength are joined, the
strength of a full-penetration groove weld is based on the strength of the
thinner and weaker plate

• Partial-Penetration groove welds:

• Find the effective throat of weld based on AISC Table J2.1 (page16.1-109)
• Check weld (Φ=0.8)
• Check base metal (Φ=0.75)

TABLE J2.5 (page 16.1-114)

CEE 451 Design of Metal Structures

• Example 6 :
• A) Determine design strength of a SMAW full-penetration groove weld for the plates shown in
figure. Fy= 50 ksi and E70 electrodes.
o
• B) Repeat above if a partial-joint-penetration groove weld (45 bevel) is used with a depth of ½
in.
• A) Full-penetration
• Tension yielding strength
– ΦRn= 0.9 Fy Ag
– ΦRn= 0.9 (50ksi)(3/4x6)
= 202.5 K CONTROLS
• Tensile rupture strength
– U =1→ Ae= U Ag =1 (3/4x6) = 4.5 in2
– ΦRn= 0.75 Fu Ae → ΦRn= 0.75 (65ksi)(4.5 in2)=219.4 K

• B) Partial-penetration
– Weld values
• Effective throat of weld= ½ - 1/8 =3/8 in as reqd in AISC Table J2.1
• ΦRn=0.8tLw(0.6 FEXX )=(0.8)(3/8inx6in)(0.6x70ksi) =75.6 k
– Base metal values
• ΦRn= 0.75 Fu Ae = 0.75(65ksi)(3/8inx6in)= 109.7 k

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