Académique Documents
Professionnel Documents
Culture Documents
Contents
Section Subject
1 Designing
1.1 Aims
1.2 Course objectives
2 Welded Joint Design
2.1 Welds
2.2 Types of joint
2.3 Fillet welds
2.4 Butt welds
2.5 Dilution
2.6 Welding symbols
2.7 Welding positions
2.8 Weld joint preparations
2.9 Designing welded joints
2.10 Welding standards
2.11 Summary
Revision questions
3 Forces and Strength of Materials
3.1 Forces
3.2 Materials under load
3.3 Stress-strain curves
3.4 Tensile tests
3.5 Hardness tests
3.6 Summary
Revision questions
4 Fatigue
4.1 Characterisation of fatigue loading
4.2 S-N curve
4.3 Fatigue of welded joints
4.4 Residual stress
4.5 Fatigue improvement techniques
4.6 Summary
Revision questions
DAC1-50615
Contents Copyright © TWI Ltd
5 Design of Pressure Equipment
5.1 Types of pressure vessels
5.2 Construction of pressure vessels
5.3 Internal pressure stresses
5.4 Calculation of stresses
5.5 Welding pressure vessels
5.6 Welded attachments
5.7 High and low temperature service
5.8 Standards and specifications
5.9 Summary
Revision questions
6 Stresses in Welds and Types of Forces
6.1 Making things simple
6.2 Different types of stresses in welds
6.3 Butt welds
6.4 Fillet welds
6.5 Different types of forces
6.6 Worked example
6.7 References
6.8 Summary
Revision questions
7 Different Types of Loading
7.1 Static strength
7.2 Effect of temperature on strength
7.3 Stress concentrations
7.4 Modes of failure
7.5 Reading fracture faces
7.6 Summary
Revision questions
8 Design Considerations for Aluminium
8.1 Advantages of aluminium compared to steel
8.2 Welding and joining aluminium
8.3 Disadvantages of aluminium
8.4 Aluminium alloys
8.5 HAZ softening
8.6 References and further reading
8.7 Summary
Revision questions
9 Static Loading
9.1 Structural details
9.2 Strength of beams
9.3 Types of loading
9.4 Node joints
9.5 Designing structures
9.6 Stress reinforced concrete
9.7 Summary
Revision questions
DAC1-50615
Contents Copyright © TWI Ltd
10 Development of Residual Stress and Distortion
10.1 Factors affecting residual stresses and distortion
10.2 Typical material properties
10.3 Characteristics of materials which determine the amount of distortion and
residual stresses (relative values)
10.4 Correcting distortion
10.5 Questions on residual stress and distortion
10.6 Questions on stress-relieving weldments
11 Revision Session
11.1 Multiple choice questions
11.2 Short answer questions
11.3 Long question
DAC1-50615
Contents Copyright © TWI Ltd
Section 1
Designing
1 Designing
An engineering structure is designed and built to withstand loads for a specified
period of time. These loads may arise from a wide range of sources and include
self-weight (such as buildings including the pyramids), external components (eg
cars traversing a bridge), internal pressure (eg pipelines and boilers),
environmental loads (due to wind, waves, ice, snow etc), reaction to an
acceleration (eg rotating components) and many other sources.
Engineering structures are built using materials such as steel, aluminium and
fibre reinforced composites specifically selected to meet the lifetime demands of
the structure. These materials are used to make components which are then
assembled and joined together usually by welding to form the structure itself.
1.1 Aim
The overall aim of the course is to provide guidance on how to design
engineering structures so that they operate safely to satisfy specified
performance targets.
This is the first of these levels and is intended to cover the scope appropriate
for a European Welding Specialist. Two subsequent courses address the scope
of the higher level qualifications.
DAC1-50615
Designing 1-1 Copyright © TWI Ltd
Course Aim
Schedule
Definition Design
Activity:
List four examples of engineering
structures.
1-1
Giza Pyramids (about 4500 years old) Wind Tower
1-2
Boiler Explosion 1850 Sultana, Arkansas, 1865
1-3
Tay Bridge Disaster 1879 Tay Bridge Disaster 1879
1-4
M V Kurdistan 1979 M V Kurdistan Failure Investigation
1-5
Course Objectives Course Objectives
Recognise sources and effects of loads. Recognise the special requirements of pressure
Understand fundamentals of strength of vessels.
materials. Appreciate the principles of designing
Understand principles of weld design. aluminium structures.
Recognise different types of loading.
Understand principles of design for static
loading.
Understand principles of design for fatigue
loading.
1-6
Section 2
Welded Joint Design
2 Welded Joint Design
This course is principally concerned with structures fabricated by welding steel
plates together, examples include bridges, ships, offshore platforms, pressure
vessels and pipelines, although in some cases this may involve welding curved
plates together.
2.1 Welds
A weld is a permanent union between materials caused by the application of
heat, pressure or both and if made between two faces approximately parallel is
known as a butt weld.
A weld made between two faces that are approximately at right angles to each
other is known as a fillet weld.
DAC1-50615
Welded Joint Design 2-1 Copyright © TWI Ltd
For simplicity these diagrams show an arc welding process that deposits filler
weld metal in a single weld pass. Typical features of a butt weld are shown in
Figure 2.3 and those of a fillet weld in Figure 2.4. The weld or weld metal refers
to all the material that has melted and re-solidified. The heat-affected zone
(HAZ) is material that has not melted but whose microstructure has been
changed as a result of the welding. The fusion line is the interface between the
weld metal and the HAZ. The root is the bottom of the weld or narrowest part
and the face is the top or widest part. At the corners of the weld cross section
where the weld metal joins the parent metal are the weld toes. These are at
each corner of both the weld face and weld root in a butt weld but only on the
weld face in a fillet weld.
a
Fusion line Weld metal Weld toe HAZ
Parent
metal
a Butt weld.
b Double-sided butt weld.
DAC1-50615
Welded Joint Design 2-2 Copyright © TWI Ltd
Figure 2.4 Typical features of a fillet weld.
Solid-liquid boundary
Maximum Solid
temperature weld
metal Grain growth
Recrystallised
Partially transformed
Tempered zone
DAC1-50615
Welded Joint Design 2-3 Copyright © TWI Ltd
The distance between weld toes is the weld width. When the distance is
between the toes at the weld cap it is the weld cap width, the distance between
the toes at the root is the weld root width. The height of the additional weld
metal in the weld cap is the excess weld metal which used to be called
reinforcement which wrongly suggests that increasing this dimension will
strengthen the weld. If the excess weld metal is too great it increases the stress
concentration at the weld toe and this extra weld metal is called the excess root
penetration.
Weld width
Excess
weld metal
Excess root
penetration
DAC1-50615
Welded Joint Design 2-4 Copyright © TWI Ltd
Figure 2.8 T joint.
An alternative to a conventional lap joint is to weld the joint using plug or slot
welding, shown in Figure 2.12 showing the typical lap joint can be drastically
altered. The hole for a slot weld should have a width at least three times the
plate thickness and not less than 25mm. In plate less than 10mm thickness, a
hole of equal width to the plate thickness can be welded as a plug weld.
DAC1-50615
Welded Joint Design 2-5 Copyright © TWI Ltd
a b
Figure 2.12:
Corner joints can be fitted and welded in a number of ways. The unwelded
pieces can be assembled either with an open corner or closed together. The
weld can be on the external or internal corner or both in a double-sided weld.
Open Closed
DAC1-50615
Welded Joint Design 2-6 Copyright © TWI Ltd
Throat a
Leg
Leg z
Figure 2.14 Leg length z and throat size a in a fillet weld.
This is only valid for mitre fillet welds having similar leg lengths (Figure 2.15),
so is not valid for concave, convex or asymmetric welds. In concave fillet welds
the throat thickness will be much less than 0.7 times the length. The leg length
of a fillet weld is often approximately equal to the material thickness. The actual
throat size is the width between the fused weld root and the segment linking
the two weld toes, shown as the red line in Figure 2.16. Due to root penetration
the actual throat size of a fillet weld is often larger than its design size but
because of the unpredictability of the root penetration area, the design throat
size must always be taken as the stress parameters in design calculations.
Figure 2.15 Mitre fillet weld. Figure 2.16 Design throat of a fillet weld.
DAC1-50615
Welded Joint Design 2-7 Copyright © TWI Ltd
Actual
throat
Design throat
Design throat
= actual throat
Figure 2.18 Definition of design and actual throat in concave and convex fillet
welds.
The choice between mitre weld, concave and convex fillet weld needs to
account for the weld toe blend. A concave fillet weld gives a smooth blend
profile and a low stress concentration at the fillet weld toe. Convex fillet welds
can have a higher stress concentration at the weld toe. If the fluidity of the
weld pool is not controlled it is possible to obtain an asymmetrical fillet weld
where the weld pool has sagged into the joint preparation and there is also a
risk of undercut on the bottom weld toe (see Figure 2.19). Having a smooth toe
blend is important to give better fatigue performance for fillet welds.
DAC1-50615
Welded Joint Design 2-8 Copyright © TWI Ltd
Figure 2.20 Design throat t1 and the actual throat t2 for butt welds.
The weld toe blend is important for butt welds as well as fillet welds. Most codes
state that weld toes shall blend smoothly, leaving it open to individual
interpretation. The higher the toe blend angle the greater the amount of stress
concentration. The toe blend angle ideally should be between 20-30 degrees
(Figure 2.21).
6mm
3mm
DAC1-50615
Welded Joint Design 2-9 Copyright © TWI Ltd
2.5 Dilution
When filler and parent material do not have the same composition the resulting
composition of the weld depends largely on the weld preparation before
welding. The degree of dilution results from the edge preparation and process
used; the percentage of dilution (D) is particularly important when welding
dissimilar materials and is expressed as the ratio between the weight of parent
material melted and the total weight of fused material (multiplied by 100 to be
expressed as a percentage), as shown:
Low dilutions are obtained with fillet welds and with butt welds with multiple
runs. For a single pass better dilution is obtained with grooved welds, see
Figure 2.22.
Figure 2.22 Effect of weld preparation on dilution and weld metal composition
(for a single pass only).
8-12
DAC1-50615
Welded Joint Design 2-10 Copyright © TWI Ltd
Symbolic representation using weld symbols can specify joining and inspection
information and the UK has traditionally used BS 499 Part 2 which has been
superseded by BS EN 22553. In many welding and fabrication organisations use
old drawings that reference out of date standards such as BS 499 Pt 2. BS EN
22553 is almost identical to the original ISO 2553 standard on which it was
based. In America AWS A2.4 is followed, while symbols for brazing are given in
EN 14324.
Symbolic representation can only be used for common joints and requires
training to understand the symbols. Symbolic representation of a welded joint
contains an arrow line, a reference line and an elementary symbol. The
elementary symbol can be complemented by a supplementary symbol. The
arrow line can be at any angle (except 180 degrees) and can point up or down.
The arrow head must touch the surfaces of the components to be joined and
the location of the weld. Any intended edge preparation or weldment is not
shown as an actual cross-sectional representation but as a line. The arrow also
points to the component to be prepared with single prepared components.
ISO 2553 and AWS A2.4 list all the main elementary symbols, some examples
are shown in Table 2.1. The symbols for arc welding are often shown as cross-
sectional representations of a joint design or completed weld. Simple, single
edge preparations are shown in Figure 2.25.
DAC1-50615
Welded Joint Design 2-11 Copyright © TWI Ltd
Table 2.1 Elementary weld symbols.
DAC1-50615
Welded Joint Design 2-12 Copyright © TWI Ltd
Figure 2.25 Welding symbols for the most common joint types shown on a
reference line.
These simple symbols can be interpreted as either the joint details alone or the
completed weld. For a finished weld it is normal for an appropriate weld shape
to be specified. There are a number of options and methods to specify an
appropriate weld shape or finish. Butt welded configurations would normally be
shown as a convex profile (Figure 2.26 a, d and f) or as a dressed-off weld as
shown in b and c. Fillet weld symbols are always shown as a mitre fillet weld
and a convex or concave profile can be superimposed over the original symbol's
mitre shape.
Key:
a = single V butt weld with convex profile.
b = double V butt weld flushed off both sides on weld
face.
c = single bevel butt weld flushed off both sides on weld
face.
d = double bevel butt convex (as welded).
e = concave fillet weld.
f = double-sided convex fillet weld.
Figure 2.26 Welding symbols showing the weld profile for the most common
joint types.
So the correct size of weld can be applied it is common to find numbers to the
left or right of the symbol. For fillet welds numbers to the left indicate the
design throat thickness, leg length or both (Figure 2.27).
a7 z 10
a7 z 10
Figure 2.27 Throat and leg length dimensions given on the weld symbol for a
fillet weld.
DAC1-50615
Welded Joint Design 2-13 Copyright © TWI Ltd
For butt joints and welds an S with a number to the left of a symbol refers to
the depth of penetration. When there are no specific dimensional requirements
specified for butt welds on a drawing using weld symbols, it would normally be
assumed that the requirement is for a full penetration butt weld. Numbers to
the right of a symbol or symbols relate to the longitudinal dimension of welds,
eg for fillets the number of welds, weld length and weld spacing for non-
continuous welds.
Figure 2.28 Weld symbols showing the weld length dimensions to the right of
the weld joint symbols for an intermittent fillet weld.
DAC1-50615
Welded Joint Design 2-14 Copyright © TWI Ltd
2.7 Welding positions
In weld procedure documents and engineering drawings the type and
orientation of welds are often given a two letter abbreviation which defines
them which can vary depending on the standard the welds are conforming to.
The abbreviations here are consistent with ISO 6947 and are summarised in
Table 2.2.
Flat PA
Horizontal PB
Horizontal vertical PC
DAC1-50615
Welded Joint Design 2-15 Copyright © TWI Ltd
Welding position Figure/symbol Abbreviation
Vertical up,
PG/PF
vertical down
Overhead PE
Horizontal
PD
overhead
DAC1-50615
Welded Joint Design 2-16 Copyright © TWI Ltd
It is normal to use a bevel on the edges of the parent metal to be welded to
allow access to the root for the first welding pass which is filled using fill passes.
Single-sided preparations are normally made on thinner materials or when
access from both sides is restricted. Double-sided preparations are normally
made on thicker materials or when access from both sides is unrestricted.
Edge preparation design includes the bevel angle (or included angle if both
sides are bevelled) and also the square edges root face and root gap. In a joint
where both sides are bevelled the preparation is termed a V or vee preparation
(Figure 2.31). V preparations are usually used for plate of 3-20mm thickness.
An alternative is a U preparation (or J preparation if only one side has the edge
preparation) where the edge is machined into the shape of a U. This is used in
thicker plate, over 20mm thickness, where it uses less filler metal than a V
preparation joint. J or U edge preparations also require a bevel angle and root
face, the gap to be defined, a root radius and land to be specified (Figure 2.32).
Single-sided edge preparations are often used for thinner materials or when
there is no access to the root of the weld (pipelines). If there is access to both
sides of the material then a double-sided edge preparation is used, especially
for thicker materials. Single and double edge preparations are shown in Figure
2.33.
Included angle
Bevel angle
Root face
Gap
Included angle
Root radius
Bevel
angle
Root
face
Gap
Land
Figure 2.32 U bevel.
DAC1-50615
Welded Joint Design 2-17 Copyright © TWI Ltd
Figure 2.33 Range of single and double-sided bevel, V, J and U preparations.
Figure 2.34 Bevel angle to allow electrode manipulation for sidewall fusion.
DAC1-50615
Welded Joint Design 2-18 Copyright © TWI Ltd
The root gap and face are selected to ensure good root fusion (Figure 2.35).
This will depend on the welding process and heat input. If the root gap is too
wide or root face too narrow there is a risk of burn through. If the root gap is
too narrow or root face is too deep there is a risk of lack of root penetration. A
balance must be found and designed for; this difference in weld root size is
shown in Figure 2.36. High heat input processes require a larger root face but
less weld metal which reduces distortions and increases productivity. Typical
values for the root face are 1.5-2.5mm and the root gap 2-4mm.
Figure 2.35 The importance of selecting the correct root face and gap.
a b
Figure 2.36 Root size for welding processes with different heat inputs:
DAC1-50615
Welded Joint Design 2-19 Copyright © TWI Ltd
A b
a Arc.
a b
Backing bar or strip is used to ensure consistent root fusion and avoid burn
through. Permanent backing bar (rather than one removed after welding), gives
a built-in crevice which can make the joints susceptible to corrosion (Figure
2.39). When using backing for aluminium welds any chemical cleaning reagents
must be removed before assembling the joint. A backing bar also gives a lower
fatigue life.
DAC1-50615
Welded Joint Design 2-20 Copyright © TWI Ltd
Separate from the design of the joint and weld access to weld locations and the
order in which welds are made are important. Figure 2.40 shows examples of
the limitations of access in designing welded joints and gives improved designs.
It is important to ensure that it is indeed possible to make welds as required by
the drawing.
Figure 2.40 Examples of improved weld designs where there is limited access.
BS EN ISO 9692: Parts 1-4: ‘Welding and allied processes. Recommendations for
joint preparation’.
2.11 Summary
You should now:
Be able to label the parts of a butt and fillet weld and of a V and U edge
preparations.
Recognise welding symbols and know what they mean.
DAC1-50615
Welded Joint Design 2-21 Copyright © TWI Ltd
Revision questions
1 Draw and label the different features of a butt weld.
2 Draw and label the significant features of a single-sided V preparation butt joint.
3 Sketch the weld that would be fabricated from the weld symbols shown in this design
drawing:
DAC1-50615
Welded Joint Design 2-22 Copyright © TWI Ltd
Outline
Weld features.
Types of welded joints.
Welding symbols.
Weld positions.
Design and Construction Weld bevels.
Welded Joint Design Designing welded joints.
Weld
Toe Face
Permanent union between materials caused by Parent
heat and or pressure (BS499). metal Toe
Weld
HAZ
Root
Weld Features – Butt Weld on Plate Weld Features – Fillet Weld on Plate
Weld
Root HAZ
2-1
Heat Affected Zone (HAZ) Weld Zone Terminology
Excess
Maximum Solid-liquid Boundary weld metal
Solid
temperature weld
metal Grain growth zone
Recrystallised zone
Partially transformed zone
Tempered zone
Unaffected base
material
Excess root
penetration
Weld preparations
Bevels: U, V, J, double V …
T joint
Lap joint
2-2
Lap Joint Corner Joints
t
Open Closed
D
d d If t < 10mm, d = t.
t If t > 10mm, slot technique
should be used, in
t d > 3t
circular holes
but d = minimum 25mm! (d = 3t but minimum
25mm see BS 1011-2).
Throat a
Convex fillet
leg
Concave fillet
2-3
Fillet Weld Geometry Fillet Weld Toe Blend
Actual
throat
Design
throat
Design throat =
actual throat
Leg length = 1.4 x throat size
Does not apply for concave fillets.
t1
2-4
Weld Symbols Constructing Welding Symbols
or
Designation Illustration of joint preparation Symbol Single V butt weld with broad
root face (only in BS EN ISO
Square butt weld standard!)
2-5
Weld Symbols Put it Together
Weld symbol
Fillet weld
Reference line
Identification line
Arrow line
Surfacing (cladding)
Backing run
Other side
Double U Double J
Z10
a7
2-6
Intermittent Fillet Welds Complementary Indications
Number of welds weld length length of gap Weld all round (peripheral weld)
z 10 3 x 25 (50)
50
25
10
Single J Single U
2-7
Double Sided Butt Preparations Joint Preparation Terminology
Double sided preparations are normally made on thicker Included angle Included angle
materials or when access from both sides is unrestricted
Angle of
bevel
Root
radius
Double bevel Double V
Root
radius
Joint Design and Weld Preparation Root Gap and Root Face
2-8
Weld Preparation Weld Preparation
Welding process impacts on weld preparation Welding process impacts on weld preparation
MMA MAG
High heat input process allows a larger root face, less weld metal
required, less distortion higher productivity.
Requires machining slow and Can be flame/plasma cut fast Warning! Backing strips give a built-in crevice
expensive. and cheap. • Susceptible to corrosion.
Tight tolerance easier Large tolerance set-up can be
• Give a lower fatigue life.
set-up. difficult.
2-9
Welding Standards Standards
BS EN ISO 9692: Parts 1-4. Welding and allied BS EN ISO 13920: Welding. General
processes. Recommendations for joint tolerances for welded constructions.
preparation. Dimensions for lengths and angles, shape and
position.
BS EN 14324: Brazing. Guidance on the
application of brazed joints. BS EN 1011-2: Welding. Recommendations for
welding of metallic materials. Arc welding of
ferritic steels.
BS EN ISO 6947: Welds. Working positions.
Definitions of angles of slope and rotation.
BS EN 25817: Arc-welded joints in steel.
Guidance on quality levels for imperfections.
ISO 2553: Welded, brazed and soldered joints
- symbolic representation on drawings.
Copyright © TWI Ltd Copyright © TWI Ltd
2-10
Section 3
A structure is an object or part of an object which has to carry and resist loads
due to the deadweight of the structure itself or an external component. Loads
or forces can arise through the reaction to acceleration or environmental loads
(such as winds or waves). Internal pressure or vacuum imposes loads as do
thermal expansion when a structure is heated and cooled.
Industrial structural elements for carrying loads include cables, bars, beams,
plates, slabs and shells with some of these shown on the bridge structures in
Figure 3.1.
a b c
Figure 3.1 Bridge and crane structures showing cables, bars and beams as
examples of load carrying components.
DAC1-50615
Forces and Strength of Materials 3-1 Copyright © TWI Ltd
Individual load carrying members are joined together to fabricate the entire
structure, such as the complete bridge, crane, offshore structure or building. A
simple arrangement of structural components can form a frame, which is an
assembly of bars arranged to support the loads. These are relatively easy to
design and an example of a truss frame is shown in the bridge verticals in
Figure 3.1a or the crane arm in Figure 3.1c. Joining the components together is
where the importance of welding comes in; although many structures are
riveted or bolted as well as or instead of welded (Figure 3.2).
Rivets
Welding
Bolts
3.1 Forces
A force has a size (magnitude) and a direction. Two or more forces may be
added together to give a single equivalent force, as shown in Figure 3.3.
Instead of simply adding the magnitudes of the forces together, their directions
must be taken into account. The forces are represented as arrows with a length
equal to their magnitude and pointing in the direction of the force. The two (or
more) force arrows are added point to tail and the single equivalent force is the
arrow which points from the origin to the final arrow point. The combination of
five different forces is shown in Figure 3.4.
X
Figure 3.3 Combination of two forces (FX and FY) into a single force, F.
DAC1-50615
Forces and Strength of Materials 3-2 Copyright © TWI Ltd
Y
F1
X
Figure 3.4 Combination of five forces (F1 to F5) into a single force, FR.
Figure 3.5 Resolution of a single force, F, into two forces at right angles (FX
and FY).
DAC1-50615
Forces and Strength of Materials 3-3 Copyright © TWI Ltd
Given that the structure does not move there is no resultant force and all the
loads acting on it must be in equilibrium, ie the sum of all the forces added
together must equal zero. Any applied force is reacted by an internal reaction
force inside the components. This is shown in Figure 3.7 by a free body diagram
of the truss members of a bridge. All the loading on the bridge is carried as
forces inside the truss members. The overall force on the bridge is reacted by
the bearings at either end of the bridge too.
Step 1 - Find out if the frame can be statically calculated. If the design will be
dominated by fatigue then an alternative design approach will be needed.
Step 2 - Find reactive forces in bearings, based on the loads the structure is
designed to carry.
Step 4 - Calculate weld sizes for the connections, based on the forces they are
required to carry (plus a safety factor).
Figure 3.8 The method to determine whether this bridge design is appropriate
and the required welds.
DAC1-50615
Forces and Strength of Materials 3-4 Copyright © TWI Ltd
Load, kN
Extension, mm
Displaceme
Figure 3.10 Load-displacement curves for thick and thin specimens of the same
material.
Stress (Figure 3.11) is defined as load (or force) divided by the cross- sectional
area (CSA). If the force, F, is in newtons (N) and the CSA area in millimetres
squared (mm2), then the tensile stress, given the symbol , is in newtons per
millimetre squared (N/mm2), which is the same as megapascals (MPa).
DAC1-50615
Forces and Strength of Materials 3-5 Copyright © TWI Ltd
The stress equation is often written as:ൌ
Stress can act either as a tensile stress (pulling apart) or a compressive stress
(squashing together) but is calculated the same way for each, ie load over CSA.
Tensile stress is often considered worse because it requires a tensile stress to
propagate a crack.
DAC1-50615
Forces and Strength of Materials 3-6 Copyright © TWI Ltd
A typical stress-strain curve is shown in Figure 3.13, which illustrates the
important characteristics of tensile behaviour.
Elastic
region Plastic region
Ultimate
tensile
strength
Fracture
Stress,
MPa
Yield Yield
strength point
Strain, %
Stress
Young’s modulus E
Strain
Where there is no obvious yield point such as a yield plateau and the stress-
strain curve rises smoothly into the plastic region, it is necessary to define an
arbitrary yield point. In such cases the 0.2% proof strength (Rp0.2) is used as a
design parameter. Rp0.2 describes the stress obtained for an elongation of 0.2%
and is determined by plotting a line parallel to the elastic part of the stress-
strain curve at an offset of 0.2% along the strain axis. Where this line intersects
the stress-strain curve is the 0.2% proof strength (Figure 3.14).
DAC1-50615
Forces and Strength of Materials 3-7 Copyright © TWI Ltd
Figure 3.14 Definition of the 0.2% proof strength for stress-strain curves
without an obvious yield point.
UTS
Necking
point
Strai
The design assumption of load bearing assumes that the CSA remains the same
and this is how the engineering stress-strain curve is produced, as shown in the
stress-strain curves above. Necking of the material reduces the REAL CSA. In
reality stress does not decrease with increasing applied loading but flattens out
around the maximum stress while the CSA decreases. Allowing for this
reduction in CSA gives the real or true stress-strain curve.
After the UTS and necking, fracture occurs at the fracture stress. The strain at
fracture is usually defined as a percentage elongation. In some materials
fracture occurs before the stress-strain curve reaches a maximum and the
ability of a material to deform plastically before fracture is known as ductility.
DAC1-50615
Forces and Strength of Materials 3-8 Copyright © TWI Ltd
High C
steel
Medium C
steel
Pure aluminium
Low C Duralumin
steel
Bronze
As the test progresses and necking and final failure occur, measurements of the
original and final gauge length are taken and of the original and final diameters
at the neck location. The reduction of area and the elongation are reported as
percentages. The yield strength (or 0.2% proof strength) is reported along with
the value of UTS. Often the data points from logging the whole stress-strain
curve are recorded so the curve can be plotted.
DAC1-50615
Forces and Strength of Materials 3-9 Copyright © TWI Ltd
Figure 3.18 Tensile test experimental procedure.
DAC1-50615
Forces and Strength of Materials 3-10 Copyright © TWI Ltd
3.6 Summary
You should now:
Understand how structures carry loads and forces and that reaction forces
are set up to give equilibrium conditions.
Understand how to draw and interpret a stress-strain curve for a given
material.
DAC1-50615
Forces and Strength of Materials 3-11 Copyright © TWI Ltd
Revision questions
1 Describe how to add two forces together.
6 How can you define the yield point where there is no yield plateau?
DAC1-50615
Forces and Strength of Materials 3-12 Copyright © TWI Ltd
Objectives
Welding
Constructed in particular ways – this
course is concerned with welding.
Bolts
3-1
Copyright © TWI Ltd Copyright © TWI Ltd
3-2
Copyright © TWI Ltd Copyright © TWI Ltd
Structures Structures
3-3
Sources of Loading - Eurocodes Examples
Structure Permanent Loads Variable Loads Accidental Loads
Ice/snow
Do vary with time.
Gantry crane Self-weight Payload
Function of the structure or its position……
Wind
Ice/snow
Accidental loads. Ship Self-weight Payload Impact
Low probability events. Wind,Wave
Ice/snow
Pressure Landslip
Cyclic.
fluctuations
Large variation with time.
Boiler/Pressure Internal pressure Vibrations Impact Correspond to variable loads, possible
vessel Start up
contribution from accidental loads.
Shutdown
Impact.
Temperature
change
Short time period, rapidly applied.
Correspond to accidental loads.
Axial loading
Compression. Compression
L
Tension. Tension
3-4
Types of Forces Axial and Bending Loading
Axial loading
Compression. Compression
L
Tension. Tension
P
F
Fy L P
F
Fx x
3-5
Forces Typical Structure
y Fx
Have a size and a Flag pole Axial loading
Fy
direction. F Weight of flagpole.
x
Fx
Axial loading
Sum of all external Compression. Compression
forces is zero.
3-6
Material Response Load Displacement Curve
Load, kN
Answer:
Carry out simple tests to find out.
Extension, mm
Stress definition
Force divided by cross-section area.
Load
Applied
force
F
Stress in the
cross section
area
Displacement
Stress definition F
Force divided by cross-section area.
L L
∆L = Change in Length
L = Original Length
L
F
Strain,
A
L
F = load or axial force (N).
A = cross section area (mm2). Strain is dimensionless
= tensile stress (N/mm2 or MPa). Positive (tensile stress).
1 Pascal (Pa) = 1 N/m2. Negative (compressive stress).
3-7
Tension and Compression Stress-Strain Curve
Tensile stress Compressive stress The tensile stress-strain curve contains typical
features which are specific to each material.
Elastic
Plastic Region
Region
Ultimate
Tensile
Strength
Fracture
Stress,
MPa
Yield Yield Point
Strength
Positive stress Negative stress
Positive strain Negative strain
Strain, %
Young’s modulus:
3-8
Ultimate Tensile Strength (UTS) Fracture
Necking
Fracture
Strain, %
Strain, %
Original yield
Previous history.
3-9
Tensile Test Elastic and Plastic Deformation
Gauge length
Parent
Metal
Parent metal.
Maximum solid solid-liquid Boundary
Tensile specimens.
Temperature weld
grain growth zone
metal
recrystallised zone
Weld metal.
partially transformed zone All weld metal tensile specimens.
tempered zone Sometimes difficult – microstructure not
unaffected base constant.
material
3-10
Hardness Hardness Test: Vickers
d1 d2
d
2
d1 d2
d
2
3-11
Elastic Design Method Factor of Safety
Use design stress which is a fraction of the Ratio of yield stress (or UTS) to design stress
yield strength of the parent material. is known as factor of safety (FoS)
Weld metal overmatches parent metal. Permanent, variable and accidental loads.
Parent strength defines load carrying capacity. Static loading.
Mechanical properties.
High strength low alloy steels. Stress/strain curves.
Weld metal sometimes undermatches parent Material and microstructure dependent.
metal.
Tensile and hardness testing.
Elastic design method.
Welded joints in aluminium.
The static strength may be reduced by the heat
of welding.
3-12
Section 4
Fatigue
4 Fatigue
Fatigue loading is the repeated application of a load and a simplified fatigue
loading cycle is shown in Figure 4.1.
Think of four types of structure that have to withstand fatigue loading and
identify the sources of fatigue loading on them. Which of your structures are of
welded construction? Typical structures that have to withstand fatigue loading
include ships, bridges, offshore platforms and rigs, earth moving and off-
highway vehicles, towers, axles, etc. The sources of fatigue loading include
fluctuating loads from a variety of sources. Acceleration forces in moving
structures, pressure changes, temperature fluctuations, environmental loads
(wind, current, wave, etc), rotation and mechanical vibrations from machinery
or shaft, etc can all cause fatigue.
Fatigue failures have occurred for many years; a train returning to Paris from
Versailles crashed in May 1842 at Meudon after the leading locomotive broke an
axle (Figure 4.2). The carriages behind piled into the wrecked engines and
caught fire, killing at least 55 passengers. The accident was widely reported in
Britain and discussed extensively by engineers, who sought an explanation. An
investigation suggested a crack growth mechanism through repeated stressing,
but this was mainly ignored, so fatigue failures kept occurring on the railways.
It is only since the Second World War that the causes of fatigue failures have
been studied and understood scientifically.
DAC1-50615
Fatigue 4-1 Copyright © TWI Ltd
Figure 4.3 Axle failure from 1843.
DAC1-50615
Fatigue 4-2 Copyright © TWI Ltd
4.1 Characterisation of fatigue loading
The typical characteristics of simple fatigue cyclic loading are shown in Figure
4.5.
Stress
If the minimum stress is zero then the fatigue cycle is known as a pulsating
cycle. If the maximum stress is equal and opposite to the minimum stress then
the fatigue spectrum is known as alternating cycles. If the minimum stress is
half the maximum stress then the cycling is known as half tensile cycles.
a b
DAC1-50615
Fatigue 4-3 Copyright © TWI Ltd
The most important parameters are the stress range Sr (the difference between
the maximum and minimum stress) and the stress cycle, ie the interval
between equivalent points in the stress history. Other fatigue parameters
include the stress ratio R (the minimum stress divided by the maximum stress)
and the stress amplitude which is half the stress range.
Figure 4.7 Graph of stress range against number of cycles to failure - the S-N
curve.
Increasing the stress range or number of cycles increases the fatigue damage
(Figure 4.8).
Figure 4.8 Effect of increasing the stress range or number of cycles on the
fatigue damage.
DAC1-50615
Fatigue 4-4 Copyright © TWI Ltd
It is more common to see S-N curves plotted on a logarithmic scale which
produces a straight line in the high cycle regime at greater than 104 cycles to
failure. Low cycle fatigue occurs at very high stress ranges which result in fewer
than 104 cycles to failure. At sufficiently low stress ranges fatigue cracks may
not propagate at all, the fatigue endurance limit.
Log S
Log N
DAC1-50615
Fatigue 4-5 Copyright © TWI Ltd
Log
DAC1-50615
Fatigue 4-6 Copyright © TWI Ltd
W W
W Toes
Figure 4.13 Stress raisers at weld toes provide easy fatigue crack initiation
sites.
Figure 4.14 High magnification image of a weld toe intrusion, which extends as
far as A, initiating the rest of the fatigue cracking from that location.
The effect of these fatigue initiation sites on the S-N curve is shown in Figure
4.15 which shows fatigue data for one specific steel in three conditions -
unwelded, unwelded but with a stress raiser (a hole) and welded with two
plates attached to the surface. It is clear that the fatigue performance of the
welded material is very much inferior to that of the unwelded material.
DAC1-50615
Fatigue 4-7 Copyright © TWI Ltd
Stress
range,
N/mm2
Cycles
Figure 4.15 Fatigue data for one type of steel in the unwelded, unwelded but
with a stress raiser and welded conditions.
One of the most serious consequences of the fact that the fatigue lives of
welded joints are dominated by crack growth concerns the influence of material
strength. Although the fatigue strength of un-notched material usually increases
with tensile strength, the level of increase decreases if the material contains a
notch until there is no increase at all for welded material. This is because rate of
fatigue crack growth is not dependent on material strength and hence welded
low and high strength materials give the same fatigue life. The benefit of
material strength comes in the crack initiation stage which is effectively absent
in the welded material. Fatigue data from unwelded and welded steels of
different tensile strengths are shown in Figure 4.16.
of 106 cycles, N/mm2
Stress range for life
DAC1-50615
Fatigue 4-8 Copyright © TWI Ltd
A large number of fatigue tests have been carried out on many different joint
geometries, Fatigue tests can be carried out on full scale structures (Figure
4.17a), or on smaller scale specimens. A common specimen is a flat strip with
fillet welded attachments on either side (Figure 4.17b). A series of these
specimens have been tested at a variety of stress ranges and the fatigue lives
plotted on an S-N curve, shown in Figure 4.18. As is often the case with fatigue
data, these results exhibit some scatter and for design purposes, the lower limit
S-N curve is used.
a b
Stress
range
Endurance, cycles
DAC1-50615
Fatigue 4-9 Copyright © TWI Ltd
When the appropriate design curves obtained from fatigue tests on different
geometries are compared, it is clear that fatigue performance is strongly
dependent on joint geometry, Figure 4.19. Fillet welds have a shorter fatigue
life than butt welds under equivalent stress cycles. Welded joints that exhibit
similar fatigue strengths can then be grouped into classes and this approach is
used in fatigue design rules. Welds in the same fatigue class have similar stress
concentration effects. The fatigue joint classifications range from A (plain
material with the best fatigue resistance and longest fatigue life) down the
alphabet as the fatigue resistance decreases to F, F2, G and then W, these
latter few being used only for special types of weld joints.
Stress range, N/mm2
Endurance, cycles
Figure 4.19 Design S-N curves for different joint geometries.
DAC1-50615
Fatigue 4-10 Copyright © TWI Ltd
Residual stress (tensile yield)
Stress
R=0
Stress
Effective stress range
R = -1
Time
0
R = 0 (compression)
Figure 4.20 Effective stress range in the presence of high tensile residual
stresses.
It is the stress range that determines the fatigue strength of an as-welded joint
even if the applied cycle is partly compressive and fatigue cracks can propagate
under these conditions in welded structures, even though compressive cyclic
loading will not propagate fatigue in parent metal.
Figure 4.21 Fatigue improvement technique showing grinding of the weld toes.
4.6 Summary
You should now:
Understand a S-N diagram and describe the influence of notches and weld
defects of fatigue performance.
Recognise which welded joints are most susceptible to fatigue.
Be able to describe modifications for fatigue improvement.
DAC1-50615
Fatigue 4-11 Copyright © TWI Ltd
Revision questions
1 What types of structures and applications are most at risk of fatigue cracking?
2 Sketch an alternating fatigue cycle and label the fatigue parameter on the diagram.
4 What effect does increasing the strength of the steel have on its fatigue
performance?
DAC1-50615
Fatigue 4-12 Copyright © TWI Ltd
Objectives
Variable loads.
Cyclic.
Do vary with time.
Large variation with time.
Function of the structure or its position…… Correspond to variable loads, possible contribution
from accidental loads.
Accidental loads.
Low probability events. Impact.
Earthquake, impact, explosion…… Short time period, rapidly applied.
Correspond to accidental loads.
Time
4-1
Typical Structures
Sources of Fatigue Loading
Subjected to Fatigue
Bridges. Fluctuating loads.
Offshore platforms and rigs. Acceleration forces in moving structures.
Earthmoving/off highway vehicles. Pressure changes.
Ships. Temperature fluctuations.
Towers. Mechanical vibrations: machinery, shafts.
Axles. Environmental loading (wind, currents and
Etc. waves).
Yield stress:
Stress at which permanent deformation starts to
occur.
Stress, MPa
Yield Point
Strain, %
Mean
stress
Minimum Time
stress
4-2
Types of Stress Cycle Types of Stress Cycle
Stress Stress
Smax
Time
Time Smin
Smin= 0 Pulsating cycle Smin= -Smax Alternating cycle
Smin
R
Smax
Stress range:
Maximum
stress
Stress
Cycle Stress
range
Mean
stress
Minimum Time
stress
4-3
S-N Curves (Unwelded Material) S-N Curves (Unwelded Material)
Stress Stress
range, x range, x
Dσ Dσ
x x
Endurance
x x limit
x x
x x
x x
Stress Stress
range, x range, x
Dσ Dσ
x x
x Fatigue x
Strength
x x
at 10
cycles
x x
x x
10 N cycles 10 N cycles
Time
Smin
Smin
Time
Effective stress range = tension portion +
some of compressive portion
4-4
S-N Curve Fatigue - Terminology
Use logarithmic scales for convenience Stress history - variation of stress at a point
with time.
Log ∆S Constant amplitude stress history - a stress
history in which successive stress fluctuations
are equal.
Fatigue life, or endurance - number of stress
cycles sustained before failure.
Low High Fatigue strength - stress range which causes
cycle cycle
failure at a certain specified life.
~105
Log N
With notch
4-5
Stress Concentrations in
Effect of Welding (Schematic)
Welded Joints
Fatigue cracks are most expected in high stress
concentration areas.
Welded material
Log N
Fatigue Cracking in
Influence of Welding
Transverse Butt Welds
Welds introduce stress concentrations from
which fatigue can propagate.
4-6
Fatigue Failure in
Transverse Butt Welds
Made on permanent backing strips Made on permanent backing strips
4-7
Fatigue Failure in Fatigue Cracking From Root of
Friction Welded Joint Fillet Welded Attachment
4-8
Design S-N Curves Design S-N Curves
Determining design curves from experimental data: Determining design curves from experimental data:
Log Log
∆S ∆S Mean line
Log N Log N
Determining design curves from experimental data: Determining design curves from experimental data:
Log Log
∆S Mean line = 50% failure probability ∆S Mean line = 50% failure probability
Log N Log N
4-9
Joint Classes Residual Stresses Due to Welding
Cold Hot Cold
UK, US, European design rules: Welds are Caused by differential
grouped into classes giving similar fatigue Immediately
after welding
thermal
strength (similar stress concentration effect). expansion/contraction of
weld and parent material.
Small differences between codes but principles Cold Cold Cold
After cooling High tensile residual
are the same. if
contraction stresses up to yield
allowed
magnitude are introduced
Class of joint
Cold Cold Cold both along and transverse
After cooling to the weld.
A B C D E F F2 G W with
contraction Has important implications
resisted
for fatigue.
Tension
Residual stress
Expected life increase
Compression
Stress at
weld toe 1
Yield
Strain
Stress at Stress at
weld toe 1 weld toe 1
Yield Yield
Strain Strain
Applied Applied 2
Stress Stress
1 Time 1 Time
4-10
Stresses at the Weld Toe Stresses at the Weld Toe
During a Fatigue Cycle During a Fatigue Cycle
2 2
Stress at Stress at
weld toe 1 weld toe 1
Yield Yield
Strain Strain
Applied 2 Applied 2
Stress Stress
1 Time 1 3 Time
Strain Strain
Applied 2 Applied 2
Stress Stress
1 3 Time 1 3 Time
Strain Strain
Applied 2 Applied
Stress Stress
1 3 Time Time
4-11
Stresses at the Weld Toe Stresses at the Weld Toe
During a Fatigue Cycle During a Fatigue Cycle
Stress at Stress at
weld toe 1 weld toe 1
Yield
Strain Strain
Applied Applied
Stress Stress
1 Time 1 Time
Strain Strain
Applied Applied 2
Stress Stress
1 Time 1 Time
Strain Strain
Applied 2 Applied 2
Stress Stress
1 Time 1 Time
3 3
4-12
Stresses at the Weld Toe Stresses at the Weld Toe
During a Fatigue Cycle During a Fatigue Cycle
2 2
Stress at Stress at
weld toe 1 weld toe 1
3 3
Strain Strain
Applied 2 Applied 2
Stress Stress
1 Time 1 Time
3 3
Stress at Stress at
weld toe weld toe
At the weld toe full stress range
is entirely tensile
Strain Strain
Applied Applied
Stress Stress
Time Time
4-13
Stresses at the Weld Toe Stresses at the Weld Toe
(PWHT Joints) (PWHT Joints)
Stress at Stress at
weld toe Yield weld toe Yield
1
50% yield
Strain Strain
Stress at Stress at
weld toe weld toe 2
Yield Yield
1 1
50% yield 50% yield
Strain Strain
Applied Applied
2
Stress Stress
1 Time 1 Time
Stress at Stress at
weld toe 2 weld toe
Yield Yield
1
50% yield 50% yield
Strain Strain
Applied Applied
2
Stress Stress
1 Time Time
4-14
Stresses at the Weld Toe Stresses at the Weld Toe
(PWHT Joints) (PWHT Joints)
Stress at Stress at
weld toe Yield weld toe Yield
1 1
50% yield 50% yield
Strain Strain
Applied 2
Stress
1 Time
Stress at Stress at
weld toe 2 weld toe 2
Yield Yield
1 1
50% yield 50% yield
3
Strain Strain
Applied 2 Applied 2
Stress Stress
1 Time 1 Time
3 3
Stress at Stress at
weld toe 2 weld toe
Yield Yield
1
50% yield 50% yield
3
Strain Strain
Applied 2 Applied
Stress Stress
1 Time Time
4-15
Stresses at the Weld Toe
Fatigue Design Codes
(PWHT Joints)
Generally allow no improvement in
Stress at
weld toe performance after PWHT.
Yield
At weld toe full stress range is still entirely tensile PWHT may be carried out for other reasons –
Applied it doesn’t degrade fatigue strength.
Stress
Time
4-16
Fatigue Life Improvement Techniques Fatigue Life Improvement Techniques
Reduce stress concentration and eliminate Reduce stress concentration and eliminate
sharp discontinuities at weld toe: sharp discontinuities at weld toe:
Weld toe grinding. Weld toe grinding.
TIG or plasma re-melting. TIG or plasma re-melting.
Summary
4-17
Section 5
Shell
Main body of the vessel, most often cylindrical but some are conical or spherical
shells.
Head
At each end to complete the basic shape and produce a closed container, are
most often dished but can be flat.
DAC1-50615
Design of Pressure Vessels 5-1 Copyright © TWI Ltd
Nozzles
A number of openings for filling, inspection or drainage.
Saddle supports
Hold the pressure vessel in place.
Nameplate
Indicates the main working parameters of the pressure vessel including work
pressure and temperature. Details may include the manufacturer, year of
manufacture, the code to which the pressure vessel has been designed and
manufactured and the inspection body stamp.
Offset
The shell of a pressure vessel can range in thickness from a few millimetres for
a BBQ propane gas bottle to several hundred millimetres for industrial pressure
vessels. The minimum design thickness is dependent on the shape and
diameter of the vessel, internal pressure and material strength. A spherical
shell requires a much thinner wall thickness than a cylindrical shell for the same
diameter, internal pressure and construction material.
DAC1-50615
Design of Pressure Vessels 5-2 Copyright © TWI Ltd
5.2.2 Dished heads
Dished heads are produced from a blank (usually circular) by pressing or
forming it in a die using a former. Sometimes the blank is small enough to be
cut from a single plate but often the blank is so large that it cannot be obtained
from a single plate and must be fabricated by welding together a central round
piece called the crown with a number of petals as shown in Figure 5.3.
Knuckl
Petal
Crown
a b c
DAC1-50615
Design of Pressure Vessels 5-3 Copyright © TWI Ltd
Ellipsoidal dished head the longitudinal section of this type of dished head (ie
a section along its longitudinal axis) is half an ellipse. Since the stress
developed in the dished head in this case is equal to the hoop stress, the
required thickness for an ellipsoidal dished head is equal to that of the
cylindrical shell. Advantages are that there is no need to supply different plate
thickness to manufacture a pressure vessel with ellipsoidal dished heads nor for
a transition between two different thicknesses, making manufacture easier.
Knuckle
radius, r
Crown
radius, R
The junction of the torus with a cylinder gives rise to bending stresses as the
greater the deviation from a sphere, the higher these stresses would be.
Torispherical dished heads are often preferred to ellipsoidal since the depth of
drawing is less so they are cheaper to manufacture. The small axial dimension
is an advantage when the longitudinal size of the pressure vessel is a critical
factor but their higher stress concentration and lower allowable pressure for a
given material size may outweigh this as a result, the thickness required for a
torispherical dished head is larger than for a cylindrical shell.
DAC1-50615
Design of Pressure Vessels 5-4 Copyright © TWI Ltd
5.3 Internal pressure stresses
5.3.1 Internal pressure
Consider a cylindrical closed end pressure vessel, with radius r and thickness t
subjected to internal pressure p as shown in Figure 5.5.
The force which acts on each closed end of the cylinder due to the internal
pressure is dependent on the CSA on which this pressure is acting. Cylinders
with larger ends but the same internal pressure have a smaller force pushing
against them.
X
DAC1-50615
Design of Pressure Vessels 5-5 Copyright © TWI Ltd
L
y
y
Figure 5.7 Hoop stress in the shell due to internal pressure.
pr
x
2t
The hoop stress y is twice the axial stress and is calculated by:
pr
y
t
Since the hoop stress is twice that of the axial stress, failure of a cylindrical
pressure vessel will preferentially occur along the longitudinal welds, also true
for other similar pressure components such as pipelines. Consequently
longitudinal welds are subjected to more stringent acceptance standards than
the circular girth welds (welds around the circumference of the vessel or pipe).
For a spherical pressure vessel the stress in the vessel wall is symmetric about
all planes so only one membrane stress is calculated:
pr
2t
DAC1-50615
Design of Pressure Vessels 5-6 Copyright © TWI Ltd
5.5 Welding pressure vessels
5.5.1 Longitudinal welds
Since the hoop stress is twice the axial stress, problems are more likely to occur
along the longitudinal welds which experience the hoop stress. To avoid the
propagation of such a defect from one course to the next, it is common to offset
longitudinal welds as shown in Figure 5.8.
Offset
In the ASME Boiler and Vessel Code, Section VIII, Division 1, vessels made of
two or more courses shall have the centres of the welded longitudinal joints of
adjacent courses staggered or separated by a distance of at least five times the
thickness of the thicker plate.
Minimum 1:4
DAC1-50615
Design of Pressure Vessels 5-7 Copyright © TWI Ltd
Various weld joint designs exist to join the heads to the shell and the choice of
joint will depend on the welding process to be used, access conditions and the
material to be welded. Some examples are shown below.
a b
c d
The weld preparations shown in Figures 5.10a and b are the simplest joint
designs and assume that access for welding can be made from the inside of the
vessel so would not be used for small pressure vessels. Figure 5.10c shows a
self-jigging joint design with an integrated backing strip which can be welded
entirely from the outside, appropriate for thick section material whereas Figure
5.10d shows a self-jigging joint that could be formed in thinner material.
DAC1-50615
Design of Pressure Vessels 5-8 Copyright © TWI Ltd
5.6 Welded attachments
5.6.1 Nozzles
Nozzles connect the pressure vessel to other components such as pipework.
Depending on the vessel and application a vessel can have a large number of
nozzles of varying size and design. The type of nozzle used can depend on:
Diameter/thickness ratio of the shell.
Diameter/thickness ratio of the nozzle.
Access (one or both sides).
Type of joint required (partial/full penetration).
Groove preparation methods available.
a b
Figure 5.12:
a) Set-on nozzle.
b) Set-through nozzle.
Gasket
Bolt
Flanges are available in designs to suit every application. As with the nozzle to
shell weld, the flange to nozzle weld has various different profiles to suit the
type of flange and pipe used.
DAC1-50615
Design of Pressure Vessels 5-9 Copyright © TWI Ltd
5.6.3 Reinforcement
A hole or opening in the shell of a pressure vessel for nozzles can have a
detrimental effect on the structural integrity of the shell. The hole can act like a
local stress concentration. The shell thickness is a function of the operating
stresses within the shell, if the shell experiences greater stress in a region due
to stress concentration the shell thickness needs to be greater in this region to
withstand the stresses. Welded plates of additional thickness around openings
in the pressure vessel are called reinforcement or compensation plates.
Reinforcement can be used on the shell, nozzle or both. Figure 5.14 shows two
types of reinforcement. Holes are made in the compensating plates to allow the
weld to be tested.
Reinforcing ring/
compensating plate Long neck
nozzle
Autoclaves
Sterilise medical equipment by heating to a high temperature inside a
sealed container. An autoclave is a pressurised device designed to heat
aqueous solutions above their boiling point without evaporation. Heating is
by feeding hot steam into the outer envelope. During sterilisation, medical
equipment must be protected from contamination by being in a hermetic
container, ie the inner container.
Dewar vessels
For storing low temperature fluids like liquefied gases. To avoid heat
transfer from the outside to the contents in the inner vessel, the jacket
space between the two walls is evacuated.
DAC1-50615
Design of Pressure Vessels 5-10 Copyright © TWI Ltd
5.8 Standards and specifications
1 ASME 2007: ‘Boiler and Pressure Vessel Code’, Section VIII.
5.9 Summary
You should now:
Understand the weld design details for pressure vessel construction of the
vessel shell, head and attachments.
Be able to outline how to calculate hoop and axial stress in a pressure
vessel shell.
DAC1-50615
Design of Pressure Vessels 5-11 Copyright © TWI Ltd
Revision questions
1 Sketch a pressure vessel and label the shell, head and a nozzle connection. Show the
weld joints on your sketch.
2 When welding a thicker plate dished head onto a thinner plate shell wall, what
gradient of taper should be used?
DAC1-50615
Design of Pressure Vessels 5-12 Copyright © TWI Ltd
Pressure Vessel
Examples Shapes
5-1
Design Aspects Design Aspects
Failures Failures
Shell.
Main body, usually cylindrical.
Head.
Used to close the cylindrical shell, usually dished.
Nozzle.
Opening for filling, drainage or inspection.
Saddle supports.
Used to hold vessel in place.
Nameplate.
Contains important information about the vessel.
5-2
Pressure Vessel Shells
Disadvantages
• Difficult to manufacture.
Crown
Always an odd number of petals
Advantages Advantages
Thickness equal to that of the shell. Smallest axial dimension.
Easy to generate.
Disadvantages Disadvantages
• Ellipse difficult to generate. • Thickness greater than that of the shell.
• Big axial dimension.
5-3
Pressurisation Welding Pressure Vessels
Nozzles Nozzles
5-4
Nozzles Flange Joints
Set-on Set-through
• A hole in the shell weakens the vessel. Vessels often insulated or double walled.
• To compensate for loss in strength, add
reinforcement to the shell or nozzle. Autoclave.
High temperature internal chamber.
Reinforcing ring/ Used to sterilise medical apparatus.
Long neck
Compensating plate nozzle
Dewar vessel.
Low temperature storage.
Gap between internal and external chamber is
evacuated.
5-5
Section 6
Stresses in Welds
6 Stresses in Welds
6.1 Making things simple
In most situations it is very difficult, if not impossible to consider all the factors
that might influence the load carrying capacity of a welded joint. This is why
designers use assumptions to simplify the approach and reach a practical result
without over-complicated calculations.
a b
DAC1-50615
Stresses in Welds 6-1 Copyright © TWI Ltd
a b
DAC1-50615
Stresses in Welds 6-2 Copyright © TWI Ltd
6.2 Different types of stresses in welds
6.2.1 Stress units
Welded structures are designed to carry loads so the welds contribute to the
support of these loads and materials supporting a load will be subject to stress.
Common units of stress measurement are Pascals, Pa, or Newtons per metre
squared, N/m2. The Pascal is a very small unit so MegaPascals (MPa) or
Newtons per millimetre squared (N/mm2) are normally used.
1MPa = 1N/mm2
Stress MPa or N/mm2
Cross-section area
Load Load
Joint factors are sometimes used to reduce this initial design stress to reflect a
reduced level of NDT and the risk of weld flaws being present, eg if only 10% of
welds will be inspected, the value of 2/3 yield strength is multiplied by a joint
factor of 0.8 thus reducing the value of the design stress.
Traditionally design calculations and experimental test data are generated using
the nominal stress approach. Alternative design methods estimate the strength
of connections using structural stresses which are a summation of the
membrane and bending stresses that occur across welds, based on a linear
stress distribution and ignore local non-linear stress profiles.
DAC1-50615
Stresses in Welds 6-3 Copyright © TWI Ltd
The concept of hot spot stress was developed in the 1970s for determining the
strength of tubular joints in offshore platforms. The approach is now used to
assess the resistance of fillet welds and its concept extrapolates the structural
stress profile measured close to the weld toe. The hot spot stress can be
experimentally determined using strain gauges positioned at very specific
locations or using finite element calculations.
A particular advantage of using the hot spot stress approach is that it is far
easier to extract the hot spot stresses from finite element analysis (FEA)
instead of trying to determine the equivalent nominal stress. When much of the
current design of welded joints is done using finite element modelling, this
makes it easier to extract the stresses to compare with the design stress limit.
Stress
Notch stress
Structural stress
Nominal stress
Figure 6.4 Stress terminology close to the weld toe of a fillet weld.
The notch stress design approach uses the peak stress by capturing the
increase in stress intensity due to the presence of the weld and takes into
account the radius of the weld toe and geometry of the joint. This calculation
requires more parameters than the hot spot stress approach so is more
complex.
DAC1-50615
Stresses in Welds 6-4 Copyright © TWI Ltd
T
Figure 6.5 Full penetration butt weld under uniaxial tension load.
Using the simplifying assumptions from Section 6.1 the design throat would be
equal to the thickness of the parent plate t. Because the load P is acting
perpendicularly to the weld, the joint is subjected to tension. The stressed area
of the weld CSA is directly calculated by:
The CSA is in millimetre squared (mm2) if the thickness and length are both
expressed in millimetres (mm).
For a flat plate in uniaxial tension with a butt weld (Figure 6.5), the stress is
calculated in the same way as in a flat plate under uniaxial tension with no weld
(Figure 6.3). In a full penetration butt weld the stress is given by the following
equation:
Load, P Load, P
Stress, = =
Cross-section area (CSA) Length, L x thickness, t
For the stress to be calculated in MPa (equivalent to N/mm2), the load must be
converted into Newtons (N) and the length and thickness of the weld are both
in millimetres. Often loads are given in kiloNewtons and will need to be
multiplied by 1000 to get the equivalent number of Newtons.
DAC1-50615
Stresses in Welds 6-5 Copyright © TWI Ltd
The tensile stress which occurs in the weld is therefore calculated by:
Load, P Load, P
Stress, = =
CSA Length, L x total thickness, t1 + t2
If the stress is to be in MPa, the load must be converted into Newtons (N) and
the length and thicknesses of the welds are all in millimetres.
Figure 6.6 Partial penetration, double sided butt weld under uniaxial load.
Another feature to consider in this type of weld is the crack-like gap left
between the two welds. Since defects are more likely close to the weld root,
adding a sharp corner in this area is not good practice. Therefore, it is strongly
advised to avoid partial penetration butt welds and to opt for fully penetrated
butt welds with a prepared edge to obtain a reliable joint.
Outer diameter
(OD)
Average diameter
DAC1-50615
Stresses in Welds 6-6 Copyright © TWI Ltd
The CSA of the weld under loading (ie the shaded area) is therefore equal to:
CSA = length, L x thickness, t = x ½ (ID+OD) x t.
To get the most accurate calculation use the mean diameter (½ (OD + ID))
instead of the ID.
The second method to determine the CSA of a pipe is to imagine a larger and
smaller circle and take the area of the small circle away from that of the large
one. The formula for the area of a circle is CSA = r2, where r is the radius of
the circle. The radius of the larger circle is OD/2 and the radius of the smaller
circle is ID/2.
Shear force, P
Simplest design: One piece is stood against the other and the welding
electrode/gun is run where the parent metals touch.
Can be made with any number of passes: The welder can either
increase productivity and reduce distortion by reducing the number of
passes or avoid a wide HAZ in a sensitive material (eg fine grained
structural steel) by reducing the heat input and increasing the number of
passes.
DAC1-50615
Stresses in Welds 6-7 Copyright © TWI Ltd
6.4.2 Disadvantages
If not performed correctly lack of penetration can occur so even if the leg
size is achieved, the weld throat which carries the load is reduced. This
defect can only be revealed by macro examination but since this is a
destructive test it cannot be applied to a welded assembly.
The volume or weight of weld metal is proportional to the square of the leg
length. Once you calculate the required throat/leg size, stick to it. Over-
welding fillet welds is easy but costly in terms of consumables used and can
lead to heavy distortion and lamellar tearing.
a b c
DAC1-50615
Stresses in Welds 6-8 Copyright © TWI Ltd
Actual
throat
Design throat
Design throat =
actual throat
Figure 6.11 Design versus actual throat thickness for fillet welds.
The convex fillet is generally undesirable for two main reasons. The junction of
the weld metal with the parent metal at the weld toe can form a significant
stress raiser and will adversely affect both fatigue life and brittle fracture
resistance. Excess weld metal in the cap costs time and money to deposit
without contributing to joint strength.
The concave fillet weld can be beneficial with respect to fatigue strength but the
minimum specified throat thickness MUST be achieved.
Deep penetration fillet welding can give a stronger joint but it is not possible to
allow for this during design as the actual penetration depth cannot be verified
by inspection techniques during production.
DAC1-50615
Stresses in Welds 6-9 Copyright © TWI Ltd
In a simplified way, the stress in the weld throat can be calculated by the
following equation:
Load, P
Stress =
Length, L x throat, a
This equation also holds for fillet welds under shear such as in Figure 6.13.
Often when fillet weld sizes are calculated they are mainly subjected to shear.
The allowable or design shear stresses on the weld throat area are applied.
Some codes specify these values depending on the welding electrode but in the
absence of such information ½ yield stress of the parent material is assumed as
the design shear stress (compared with ⅔ yield for the design axial tensile
stress). This value of design shear stress takes into consideration the higher
sensitivity towards cold cracking shown by fillet welds due to the increased
combined thickness (see MAB module) as well as the effect of the natural lack
of penetration present at the root of the joint.
Figure 6.12 Weld throat and leg length in a mitre fillet weld.
DAC1-50615
Stresses in Welds 6-10 Copyright © TWI Ltd
For a fillet weld with equal leg lengths, the cross section triangle is a right-angle
triangle with angles of 45 degrees in each corner. The relationship between
weld throat, a and leg length z is given by:
Tension and compression act perpendicular to the CSA and give rise to direct
axial stress as discussed in Section 3.3. When the load is applied parallel but
offset to the CSA a shear stress results.
a b
Figure 6.14
a) Axial stress.
b) Shear stress.
Shear stresses are particularly significant for calculating stresses in fillet and lap
welds, is represented by the Greek symbol tau, and is calculated as the shear
force, Q, over the CSA but it is the force that acts parallel to the CSA, A.
DAC1-50615
Stresses in Welds 6-11 Copyright © TWI Ltd
Shear strain, , is also the change in dimensions from the original but it is the
shear strain, , (acting parallel to the applied, Q) over the offset between the
two opposite shear forces, h, shown in Figure 3.22.
Figure 6.15 Dimensions for the definition of shear stress and strain.
Bending a beam, such as shown in Figure 3.23, imposes tension (tensile stress)
in the outer surface and compression (compressive stress) on the inner surface.
There is a line at which there is no net stress called the neutral axis, shown as a
dashed line.
DAC1-50615
Stresses in Welds 6-12 Copyright © TWI Ltd
The amount of axial stress in the beam caused by the applied moment depends
on how stiff the design of the beam is, characterised by the beam’s second
moment of area (moment of inertia) and given the symbol, I. A stiff beam with
a large second moment of area tends to be tall and thin, with most of the
beam’s mass at a vertical distance from the neutral axis (such as a tube section
or an I-beam). Beams with low stiffness (low second moment of area) are wide
flat beams. Bend a ruler while it’s flat then turn it on its edge and trying to bend
it that way - it’s much harder! A range of beam cross-sections are shown in
Figure 3.25 in order of stiffness for the same CSA.
= My / I
This means that for the same applied bending moment (ie the same length of
cantilever beam with the same load on the end); a beam with a larger second
moment of area will result in a much lower maximum stress at the tension
surface. This is why structures are designed with square or round hollow section
beams and I-beams, because they allow greater loads to be carried without
redundant extra weight being required.
Answer: 64MPa
DAC1-50615
Stresses in Welds 6-13 Copyright © TWI Ltd
What size fillet weld is needed in this joint? Steel has a yield strength of
350MPa.
8mm
Answer: 5.8mm
Let’s use the example of the cantilever beam to calculate the bending stress as
a result of an applied load on the free end of the beam. No calculations of this
kind will be on the specialist exam but by using an example with actual
numbers it can help to show what the effect of the bending moment and second
moment of area mean for a beam under load.
Start by assuming the beam is square section (10 x 10mm) and then we’ll
calculate the bending stress if we use a rectangular section beam of the same
CSA, but 5 x 20mm.
Assume the beam is 300mm long with a load of 200N on its free end. First,
calculate the bending moment, M.
Let’s calculate the second moment of area of the beam. For square and
rectangular beams the formula for a beam with a breadth, b and depth, d is
I = bd3/12.
DAC1-50615
Stresses in Welds 6-14 Copyright © TWI Ltd
This means that the second moment of area for the square section beam is
833mm4, whereas the rectangular beam has a second moment of area of
3333mm4.
The rectangular beam is four times stiffer than the square beam. The distance
from the neutral axis, y, is basically half the depth of each beam, ie 5mm for
the square beam and 10mm for the rectangular beam.
The engineer’s bending formula, = MY/I can now be used to work out the
bending stress in each beam. The square section beam has a stress equal to
60,000 x 5/833 which equals 360MPa.
The rectangular section beam has stress equal to 60,000 x 10/3333 which
equals 180MPa. Therefore by changing the square section beam to a
rectangular beam the stress in the beam is halved!
6.7 References
IIW Guidelines; Niemi E, Fricke W and Maddox S J: ‘Fatigue analysis of welded
components’. Designer's guide to the structural hot-spot stress approach’.
Woodhead Publishing, 2009.
6.8 Summary
You should now:
Understand the CSAs of different welds and how forces act on them.
Know the difference between design nominal, hot spot and notch stresses.
Know how to calculate a bending moment and to recognise the engineer’s
bending formula.
DAC1-50615
Stresses in Welds 6-15 Copyright © TWI Ltd
Revision questions
1 What is the cross sectional area that carries the load in a full penetration butt weld in
a 4m wide plate of 12mm thick steel?
2 A plate has a yield strength of 320MPa. What will you assume the design strength is?
3 Therefore, what is the maximum load that this weld can carry?
4 A single fillet weld attaches a plate of length 200mm onto a base plate. The single
fillet weld has a throat thickness of 6mm. If the designer wishes to change the design
to have two fillet welds, one on either side of the attachment plate, what size leg
length will they specify?
5 A 50kN load is carried by a 300mm long fillet weld in shear. If the steel has a yield
strength of 240MPa, what size does the fillet weld need to be?
Maths answers:
1: 48000mm2. 2: 213MPa. 3: 10,240KN. 4: 4.5mm. 5: 1.4mm
throat.
DAC1-50615
Stresses in Welds 6-16 Copyright © TWI Ltd
Making Things Simpler
Load Load
Design stress for a structure is often ⅔ yield Stress distribution over the cross-section is
stress. not always uniformly distributed.
Ensure that the stress in the weld does not Near geometric features and stress
exceed the maximum allowable design stress. concentrators distribution increase the
maximum stress.
Joint factors are often used to reflect the level
of NDT and risk that flaws could be present. For fillet welds, use hot spot stress.
6-1
Hot Spot Stress Notch Stress
Originally developed for tubular joints in Approach uses peak stress by looking at stress
offshore platforms intensity due to presence of weld.
Stress
Determined by: Takes into account the radius of the weld toe
Notch stress
Strain gauges. and joint geometry.
Finite element analysis. Hot spot stress
Structural stress
Complex approach since requires knowledge of
Nominal stress microstructural parameters.
Weld metal overmatches parent metal. Partial penetration, double sided butt weld
Butt welds can usually be neglected.
Full penetration butt weld under uniaxial tension.
P Load, P
Load, P σ t2 t1
Load, P
Lt
Thickness, t Load, P Length , L
Crack-like unfused land
Length, L
Thickness Outer
Method 1: Unroll the
(t) diameter tube into a flat plate: Shear force, P
(OD) Shear force, P
Length is the average
circumference.
t
Circumference is p x ID.
Average Multiply this by the wall
diamete thickness. Length, L
r
Inner
diameter Method 2: Subtract area
(ID)
of large circle from small
one:
Area of circle = pr2. Shear force, P
Shear stress, t =
Large radius, r1 is OD/2. Length, L x thickness, t
Small radius, r2 is ID/2.
6-2
Fillet Welds Fillet Welds
Advantages: Terms.
Cheap. Toe.
Root.
Simple.
Leg length.
Can be made flat (PA) or horizontal (PB).
Weld throat.
Can be made with any number of passes.
Cheap weld design.
Disadvantages: Easy to weld.
Lack of penetration may occur which cannot All positions and
be revealed by NDT. multi-passes.
Volume and weight of weld increases with the Lack of penetration risk.
square of the leg length.
Easy to overweld.
Copyright © TWI Ltd Copyright © TWI Ltd
weld toe.
Excess weld metal.
Design throat
Concave
Smoother transition at the
weld toe.
Ensure weld throat is big
enough.
Design throat =
actual throat
Stresses supported by weld throat In fillet welds the stress is supported by the
throat.
P
Mitre fillet is assumed.
Load, P
Stress =
Length, L x throat, a 1
L √2
a a ≈ 0.7z
z ≈ 1.4a
z √2
a
6-3
Types of Forces Types of Stress
σ Q τ
Compression
τ Q
Q
Tension Shear Stress, τ
A
Shear F
F
Bending
Direct stress, σ
A
M M
h
Q Compression (-)
After bending
A
Neutral axis - longitudinal stresses are zero
A cantilever beam:
Force, F
Fy
M
Fx
Reaction forces: Fx Fy M
6-4
Bending Stress Worked Example
M=Fxd
= 200 x 300 = 60,000Nmm.
10mm 20mm
Depth, d 10mm 20mm s=My/l
y
Simplifying assumptions.
800kN
Design stresses and nominal stresses:
Butt welds.
Fillet welds.
CSAs of welds. Thickness = 800kN
Stress calculations. 25mm
Length =
500mm
6-5
Revision Question 1 - Solution Revision Question 2
Thickness = 800kN
25mm 200mm
Length =
500mm
What size fillet weld is needed in this joint? What size fillet weld is needed in this joint?
Steel with a yield strength of 350MPa Steel with a yield strength of 350MPa
Load
200kN 200kN Length x throat =
Design stress is ⅔ of 350 Stress
= 233MPa
200mm 200mm Throat
Throat =
= 200,000
load
200,000
Load 200 xx stress
233
Stress = length
200
CSA
6-6
Section 7
Specimen 1
Specimen 2
The load-extension curves from the two specimens are shown in Figure 7.2 and
it can be seen that specimen 2 can withstand the greater load. Tensile strength
is a material specific property and these specimens are of the same material so
should have the same strength regardless of size so the size of the specimen is
taken into account, when determining the stress (as opposed to the load) and
the units of stress are N/mm2.
DAC1-50615
Different Types of Loading 7-1 Copyright © TWI Ltd
Stress takes into account the CSA of a specimen so is the true indicator of
strength not the maximum load applied. The CSA of the specimen in Figure 7.3
is the area being tested perpendicular to the tensile direction of loading and is
often a circle in a round tensile specimen but square or rectangular section
specimens are also possible. The tensile specimen is thicker at the ends where
it is gripped but the material being tested is in the central parallel section,
called the gauge of the specimen. It is the CSA within the gauge length that is
used to calculate stress.
Strain,
Figure 7.4 Different sized specimens of the same material give the same stress-
strain curve.
DAC1-50615
Different Types of Loading 7-2 Copyright © TWI Ltd
The stress–strain curves for different materials can be used to help design
structures. To ensure there is no plastic deformation in structures, engineers
usually design each structural member to operate at a static stress equivalent
to two thirds of the yield stress, leaving a third as a safety factor so the
structure can tolerate further loading without plastic deformation. Some design
codes limit the applied stress to half yield strength. Other loads that can act on
the structure are mostly due to adverse weather conditions such as added
weight due to snow fall or additional forces due to high winds. Figure 7.5 shows
this safety margin between the design stress, σdesign and yield stress, σy.
desig
Stress,
Strain,
Figure 7.5 Indicated design stress at two thirds yield stress.
DAC1-50615
Different Types of Loading 7-3 Copyright © TWI Ltd
Bronze
Copper
Strength, % of ultimate strength
Structural steel
Steel castings
Cast iron
Wrought iron
Temperature, °F
Test
DAC1-50615
Different Types of Loading 7-4 Copyright © TWI Ltd
Choosing materials which best suit certain applications and the method to
assess a material’s suitability are termed material selection. An example
where this has been optimised to the maximum is the turbine engine, shown in
Figure 7.8.
Ni-superalloy
Colour coding shows what sort of material is used at different locations within
the engine. At the back, where combustion takes place, the temperature is very
high and normal materials would not be able to withstand the heat generated
and would lose their integrity. Ni-superalloys have been engineered by
materials scientists to perform the duties required of turbine blades without
degrading.
As with all aerospace components, weight saving is a big issue. The fan blades
at the front need to be light but strong and resistant to creep so selecting the
correct material is challenging. A titanium alloy is used due to its excellent
mechanical properties and most of all its strength to weight ratio.
The engine’s driveshaft running through the centre of the engine is made of
steel which is three times heavier than titanium. There is no real replacement
for this component due to the intense levels of torque that it must tolerate.
Titanium is as strong as steel but cannot withstand twisting forces to the same
extent.
DAC1-50615
Different Types of Loading 7-5 Copyright © TWI Ltd
7.3 Stress concentrations
Sudden changes in geometry in a material section (such as holes, notches,
grooves, corners, fillet welds or defects) can act as stress raisers which
concentrate the stress so that the local stress increases. The lines of
transmission of the stress are similar to flow lines if fluid were to enter the
material from one end to the other as in Figure 7.9. Densely packed flow lines
represent the concentration of stress at those points.
Figure 7.10 shows the stress concentration effect of a circular hole in a large
flat plate under tension. Even this simple detail increases the stress at the edge
of the hole by a factor of 3 so close to the edges of holes (such as bolt holes),
the maximum stress in the plate is about three times the nominal applied
stress. Sharper notches concentrate the stress by much more and very sharp
notches such as cracks have a very high concentration of stress at their tips.
Maximu
m
DAC1-50615
Different Types of Loading 7-6 Copyright © TWI Ltd
7.4.1 Ductile failure
Ductile failure or plastic collapse occurs when yielding and deformation precede
failure and is the result of overloading. Purely ductile failures are rare since
most structures are designed well within their load bearing capacity but can
occur when the strength has been degraded, for example in high temperatures
during a fire. Ductile failures are most likely to occur in service as a secondary
failure mode after the section thickness has been reduced due to fatigue crack
growth, corrosion or erosion.
When examining the fracture surface, a ductile failure shows evidence of gross
yielding or plastic deformation, the fracture surface is rough and torn and may
be highly fibrous as a result of deformation. The failure surface may show 45
degree shear lips or have surfaces inclined at 45 degrees to the load direction.
Two ductile failures are shown in Figures 7.11 and 7.12.
DAC1-50615
Different Types of Loading 7-7 Copyright © TWI Ltd
7.4.2 Fatigue failure
Fatigue is discussed in detail in Section 4 of this course. The failure surface
from a fatigue failure is smooth, flat and bounded by a curve (Figure 7.13).
There are sometimes bands, known as beachmarks on the fracture surface
which show the progress of the crack front. The beachmarks can help identify
the point of origin at the middle of the beachmark curves. A fatigue failure
surface is always at 90 degrees to the load, but final fracture will usually take
the form of gross yielding, or sometimes will result in a brittle fracture.
DAC1-50615
Different Types of Loading 7-8 Copyright © TWI Ltd
The likelihood of brittle fracture is caused by three main factors: Sufficiently low
toughness; the presence of a flaw; and the application of a stress. These can be
remembered visually using a triangle.
Low toughness
Bang
Brittle fracture is more likely in the presence of high residual stresses or if the
structure is highly loaded, particularly under high strain rate (impact loading).
Stress-concentrations (from weld toes, change of section, notches) and weld
defects (such as cracks or lack-of-fusion) can have a major effect on the
likelihood of brittle fracture.
DAC1-50615
Different Types of Loading 7-9 Copyright © TWI Ltd
7.5 Reading fracture faces
It is rare that a fracture surface will exhibit just one kind of failure mode so
when reading a fracture face it is important to look for clues to all the modes
which might play a part in the overall failure. In particular, beachmarks will be
characteristic of fatigue failure and river lines will indicate that brittle fracture
has occurred. Failure planes at 45o to the main loading is evidence of ductile
failure but the absence of any of these clues does not mean that those failure
modes could not have occurred.
In Figure 7.16 the smooth flat region with beachmarks identifies that fatigue
has occurred. The final fracture is rough and torn and is at 45 degrees to the
fatigue crack, pointing to ductile overload as the final failure.
7.6 Summary
You should now:
DAC1-50615
Different Types of Loading 7-10 Copyright © TWI Ltd
Revision questions
1 What effect does high temperature have on strength?
3 What are the three main factors for brittle fracture to occur?
DAC1-50615
Different Types of Loading 7-11 Copyright © TWI Ltd
Static Strength
Load, N
Specimen 2
Stress is the load divided by the CSA. Stress-strain curve normalises different
In a tensile specimen, use the gauge CSA. specimen sizes
Gauge length
CSA
Specimens 1 and 2
Stress, σ
Width/diameter
Strain, ε
Design components to operate at stresses less Metals (including steel) lose tensile strength at
than material yield strength. higher temperature
Limit static stress to ⅔ of yield.
Factor of safety.
σy
σdesign
Stress, σ
σdesign = ⅔σy
Strain, ε
7-1
Materials Selection: Select the Most
Effect of Temperature on Toughness
Suitable Material for a Given Application
Sudden changes in geometry cause localised The stress concentration at the edge of a hole is 3.
areas of high stress. The maximum stress is three times the applied
stress.
Imagine flow lines which get close together at
Sharper notches concentrate the stress much more.
stress concentrations.
Maximum
stress
Applied
stress
7-2
Ductile Fracture Fatigue Failure
Ductile fracture or plastic collapse occurs when Fatigue failure surface is smooth, flat and bounded by a
yielding and deformation precedes failure. curve.
Bands or beachmarks may sometimes be seen showing
Fracture surface appears torn and fibrous. the progress of the crack front from the point of origin.
The surface is 90 degrees to the load.
Final fracture usually takes the form of gross yielding.
Low toughness
Bang
Stress Flaw
7-3
Brittle Fracture – Low Toughness Brittle Fracture – Stress and Flaws
7-4
Section 8
a b
DAC1-50615
Design Consideration for Aluminium 8-1 Copyright © TWI Ltd
Corrosion resistance
Aluminium alloys have excellent corrosion resistant properties due to a thin
self-healing oxide layer and can normally be used unpainted. It’s corrosion
resistance makes it widely used for food packaging such as aluminium foil, drink
and food cans. Other uses include gas cylinders, ladders and ski poles. Higher
strength alloys will corrode in some hostile environments and may need
protection.
Magnetic properties
Aluminium is non-magnetic so can be used where no electromagnetic
interference is allowed such as avionics devices. This means that magnetic
particle examination cannot be used as an NDT method to detect surface/near
surface defects in an aluminium weld.
Figure 8.2 Extruded complex aluminium sections frictions stir welded together.
Machinability
Milling can be an economic fabrication technique for aluminium because of the
high metal removal rates possible so U or J weld preparations are easier to
produce. These machined preparations can lead to better joint fit-up, reducing
the amount of weld metal required to fill the preparation and avoiding possible
weld defects caused by mismatch.
DAC1-50615
Design Consideration for Aluminium 8-2 Copyright © TWI Ltd
Figure 8.3 Storage spheres for holding cryogenic liquids.
Electrical conductivity
Aluminium possesses a high coefficient of electrical conductivity which
combined with a lower price per kg compared with copper make it the standard
material for overhead transmission lines (with a central steel strand to carry the
weight of the cable). Aluminium alloys have an electrical conductivity
approximately 65% that of copper but because of their density can carry more
than twice the electricity as an equivalent weight of copper.
Thermal conductivity
Aluminium has a high coefficient of thermal conductivity (237W/m°C - about
four times greater than steel) so pure aluminium can be used in heat
exchangers as an alternative to copper tubes. For welding high thermal
conductivity is a disadvantage since the heat tends to dissipate quickly from the
heated point.
Molten aluminium has high fluidity (compared with molten steel) so the weld
pool can spill out or run ahead of the joint preparation, leading to possible
fusion or burn-through problems. To avoid this, a smaller (or no) root gap is
used.
Electron beam and laser welding is now used extensively for joining aluminium
components with the advantages of high processing speeds, ease of automation
and low heat input (low distortion). Friction welding processes (such as friction
stir welding) avoid the disadvantages of fusion welds and can produce
extremely strong defect-free welds in aluminium alloys.
DAC1-50615
Design Consideration for Aluminium 8-3 Copyright © TWI Ltd
Adhesive bonds
Adhesive bonding is well established for making structural joints in aluminium
and does not produce residual stresses or other defects which can occur during
welding (hot cracking, porosity, etc). Unfortunately adhesive bonded joints have
limited life as most adhesive systems degrade rapidly when the joint is both
highly stressed and exposed to a hot, humid environment.
Thermal expansion
Aluminium expands and contracts with temperature approximately twice as
much as steel – its coefficient of thermal expansion being 24×10-6 ºC-1
compared with only 11×10-6 ºC-1 for steel. Greater thermal expansion leads to
greater distortion; expect twice as much distortion in an aluminium structure
compared with steel. Because of the lower Young’s modulus, thermal stresses in
a restrained member are only two-thirds those in steel.
Thermal conductivity
Having a high coefficient of thermal conductivity, aluminium is capable of
cooling the weld pool much faster than steel. Since heat is dissipated much
more quickly, a larger included angle is required to prevent lack of sidewall
fusion. If the included angle for a V preparation in structural steel weldment is
approximately 60 degrees, this value may need to be increased to 90 degrees
for aluminium. High thermal conductivity means that a larger area will be
heated up by welding, thus increasing distortions and giving a wide HAZ.
DAC1-50615
Design Consideration for Aluminium 8-4 Copyright © TWI Ltd
Young’s modulus
Aluminium exhibits a low Young’s modulus value, 0.7×105N/mm2 a third that of
steel so aluminium beams are more prone to buckling than equivalent steel
ones and have lower stiffness and rigidity. Elastic deflection is a key factor to
consider when designing aluminium structures, which may not be a concern
when using steel.
Fatigue resistance
Aluminium alloys are more prone to fatigue than steel because of their lower
Young’s modulus. When designing steel structures potential fatigue sites should
be identified. The number of fatigue cycles to failure for a given stress range is
normally obtained from an endurance curve, according to the weld geometry.
For a mass-produced component the fatigue life can be found by testing.
Fatigue is covered in more detail in Section 4.
Tensile strength
Pure aluminium has modest UTS (70-150N/mm2 depending on delivery
condition, annealed or cold worked). For use in structural applications it is
alloyed with different elements to increase its tensile strength up to 650N/mm2.
This compares with standard grades of steel which have yield strengths of 150-
450MPa and tensile strengths of 300-650MPa. Aluminium does not present a
clear yield point so to define a useable limit for the stress, proof stress is used
(ie the stress at which the material undergoes a certain permanent strain,
commonly 0.2%). It should be noted that when designing steel structures, the
limit state is usually the rigidity of the structure rather than its strength.
Corrosion
Serious electrolytic corrosion of aluminium may occur at joints with other
metals unless correct precautions are taken. This can apply even when using
alloys that are otherwise highly durable. Aluminium is also susceptible to stress
corrosion cracking (SCC) which can occur in aqueous chloride solutions and
tropical marine conditions.
Affinity to oxygen
Aluminium forms a tenacious oxide film with a melting point more than three
times that of aluminium. Failure to remove this oxide both before and during
welding results in entrapment of oxides and/or incomplete fusion giving a joint
with impaired mechanical properties. To produce a sound weld the oxide layer
needs to be removed by mechanical or chemical methods. Chemical cleaning
must be considered from the design stages as since the reagents used are
highly corrosive, permanent backing strips and lap joints should be assembled
after chemical cleaning due to possible entrapment. Due to its high affinity to
oxygen, aluminium is mainly welded using gas-shielded arc welding processes
and since the shielding gas column can be affected by draughts, on-site welding
of aluminium is difficult unless special measures are used to protect the weld
area. This high affinity to oxygen requires larger diameter gas nozzles for TIG
and MIG welding which leads to an increase in included angle and/or an
increase of land in U preparations.
DAC1-50615
Design Consideration for Aluminium 8-5 Copyright © TWI Ltd
8.4 Aluminium alloys
Alloy series Main alloying element Heat treatable?
1XXX None (pure Al) No
2XXX Copper Yes
3XXX Manganese No
4XXX Silicon No
5XXX Magnesium No
6XXX Magnesium and silicon Yes
7XXX Zinc and magnesium Yes
Non-heat treatable alloys gain strength from cold working. Heat treatable alloys
gain strength from both work and precipitation hardening.
The lower strength of the HAZ must be considered in the design by allowing for
the amount of softening (loss of strength) when calculating the load carrying
capacity of a weld. This may be done by locally thickening the material in the
region of the weld or by designing the locations of the welds away from the
most highly stressed regions (ie on neutral axes).
Wel
Figure 8.5 The loss of strength (and hardness) in the HAZ of welds in
aluminium.
DAC1-50615
Design Consideration for Aluminium 8-6 Copyright © TWI Ltd
8.6 References and further reading
AWS D1.2: ‘Structural Welding Code – Aluminium’. American Welding Society.
8.7 Summary
You should now:
Be able to name typical applications of aluminium alloys and the advantages
of aluminium over steel.
Recognise common aluminium imperfections and how to avoid them.
Recognise typical weld preparations for aluminium alloys.
DAC1-50615
Design Consideration for Aluminium 8-7 Copyright © TWI Ltd
Revision questions
1 What is the density of aluminium compared with steel?
4 What effect does the difference in Young’s modulus have on the fatigue resistance of
aluminium welds?
DAC1-50615
Design Consideration for Aluminium 8-8 Copyright © TWI Ltd
Use of Aluminium Alloys
Lightweight.
High strength-to-weight ratio.
Good corrosion resistance ideal for food and Generally good weldability but
drink industry - foil, packaging, drinks cans. Fusion welds can suffer porosity, lack of
High electrical conductivity - transmission fusion, solidification cracking.
lines, welding cables. Loss of strength in HAZ region.
Building industry - roofing, windows, doors, Very fluid weld pool.
cladding, fittings. Consider laser welding or FSW.
Wide range of other uses - ski poles, ladders, Adhesive bonding is widely used has no
gas cylinders. residual stress so is not for hot/humid
environments.
8-1
Disadvantages of Aluminium Other Properties of Aluminium
8-2
Objective
Stress, MPa
Tension. Tension
Yield Point
Strain, %
9-1
Elastic Design Method Elastic Design Method
Parent
Metal
High strength low alloy steels.
Weld metal sometimes undermatches parent
metal.
L x y
R P
P
For equilibrium: Rx = Py
9-2
Bending Moment Bending Stresses
Before bending
M
Tension (+)
P M M
After bending
At fixed end, bending moment M: M = PL Compression (-)
Tension (+) M M
M M
y
Neutral
Compression (-) axis
Stress
M M M M
y y
Neutral Neutral
axis axis
Stress stress
Stress at point y:
My
σ=
I
I is moment of inertia
Depends only on beam geometry
9-3
Yield and Proof Strength Bending Loading
Yield stress:
Stress at which permanent deformation starts to
occur. L
Stress, MPa
Yield Point P
Strain, %
Space Frames
Space frames
or
Designing to avoid bending
Use of Triangles
Very rigid.
Loads transmitted along lengths.
9-4
Copyright © TWI Ltd Copyright © TWI Ltd
Frames/Trusses
9-5
Structural Details Fixed Offshore Platform
Saddle point
Chord
Heel Toe
Side
= local dihedral angle (usually 30-150°) T-K nodal joint T-Y nodal joint Cross nodal joint
9-6
Types of Nodal Joints K Nodal Joints
Greater
than 10°
Max.10°
Gap
Max.10°
Offset
e=0 e>0
Eccentricity
Through
Overlap member
e<0
Chord
= local dihedral angle (usually 30-150°)
Toe Toe
9-7
Hot Spot Stress
Nominal stress
9-8
Principle Rebar
Rebar Joints
The term reinforcing-steel is used to describe Reinforcing bar is available in sizes ranging
the use of steel to reinforce materials, most from 6mm up to 50mm diameter.
often concrete.
A whole assembly of reinforcing bars will
Concrete is a brittle material which is strong in usually be used.
compression but weak in tension.
To join bars together there are several
This limits the use of concrete in construction methods:
and makes it unsuitable for use in many Welded joint (for weldable compositions).
structural members. Wire joint - wire wrapped around bars and
tightened.
Rebar coupler – mechanical fixing.
9-9
Types of Joint Types of Joint
Summary
Nodal joints.
Joint designs and differences to nozzles.
9-10
Section 9
Static Loading
9 Static Loading
For some structures the main loading does not change over time, it is
essentially static. A typical example is a building based on a steel frame where
the frame supports the weight of the building (and the frame itself) and the
weight of the contents. The majority of new buildings are based on steel frames
because this is also a fast and efficient construction method. Figure 9.1 is a
classic image of construction workers on a 1920s skyscraper in New York, which
shows the steel frame skeleton of the structure.
Figure 9.1 Construction workers take a break on a New York skyscraper in the
1920s.
DAC1-50615
Static Loading 9-1 Copyright © TWI Ltd
Figure 9.2 Pylon truss joints.
a b c d
DAC1-50615
Static Loading 9-2 Copyright © TWI Ltd
9.2 Strength of beams
For a structure under stable conditions, ie static, all the forces on the structure
must balance in equilibrium. An example is a truss bridge where the forces in all
the members are shown in a free-body diagram in Figure 9.5.
Figure 9.5 Free body diagram of a truss bridge (not every force is shown here).
The stress, , that each force, F, imposes is calculated by dividing the force by
the CSA, A, of the member. The units of force or load is Newtons, N, the units
of area is mm2 and the units of tensile stress is N/mm2 or megapascals, MPa.
The elastic design method bases the design stresses on the elastic limit of the
structure but ensures that the stresses in the structure do not exceed the yield
stress (ie elastic deformation is designed for, but no plastic deformation
occurs). It is not normally possible to design up to the yield stress safely due to
the presence of material defects, joint/weld mismatch, unforeseen loads such
as wind or snow and degradation over time.
For static design, the allowable stress is limited to a proportion of the specified
minimum yield strength of the material. Relevant design codes provide
guidance on what proportion this should be but it is quite common to use an
allowable design stress that is 2/3 of the material yield strength, although
historically for safety critical structures such as pressure vessels the stress was
limited to a quarter of the UTS. Generally the welding consumable is chosen
such that the weld metal strength is greater than the parent material. In these
cases the parent material strength defines the load bearing capacity of the
structure but when defining the throat dimension of load carrying welds it is the
weld metal strength that is used.
DAC1-50615
Static Loading 9-3 Copyright © TWI Ltd
Necking occurs
at this point
The ratio of the yield stress (or UTS) to the design stress is known as the factor
of safety (FoS) which depends on the material and utilisation of the structural
member.
Yield stress
FoS = ≥1
Design stress
A material’s load capacity depends on design method, whether it’s based on the
minimum yield strength or the UTS. A welded joint is very complex since it is
heterogeneous; it has parent, HAZ and weld metal microstructures, each with
different individual strengths. To simplify the approach to calculating the load
capacity of welded joints, it is assumed that the weld metal overmatches parent
metal and therefore that the parent strength defines load carrying capacity but
there are significant exceptions to this rule HSLA steels sometimes have weld
metal that undermatches the very high strength parent metal. Welded joints in
aluminium very often have strength undermatching in the weld metal and HAZ,
as the static strength can be reduced by the heat of welding.
DAC1-50615
Static Loading 9-4 Copyright © TWI Ltd
Figure 9.8 Different kinds of static loading.
DAC1-50615
Static Loading 9-5 Copyright © TWI Ltd
In these joints it is usually fatigue considerations that limit the design, the
materials and joint design have to satisfy static design criteria. The parts of a
simple node joint are shown in Figure 9.11. Figures 9.12-9.14 illustrate typical
node joint geometries. T nodal joints have the brace attached at roughly right
angles to the chord. Where the offset from perpendicular is greater than 10
degrees then the joint becomes a Y nodal joint. Two such braces positioned in
opposite directions is called a K nodal joint and adding a perpendicular brace to
two angled braces forms a T-K nodal joint.
degrees)
DAC1-50615
Static Loading 9-6 Copyright © TWI Ltd
Figure 9.12 X joint. Figure 9.13 K joint. Figure 9.14 T-K joint.
Greater than 10
Maximum 10
Maximum 10
When designing a nodal joint consideration must be given to the gap between
the various braces so that there is sufficient access for welding all round both
seams. If the braces need to be close then a seam weld which incorporates the
welding of both can be designed by allowing the two to overlap, resulting in a
complex weld seam and challenges for welding and inspection access.
Sometimes a brace may be offset from the centre of the chord although this will
impose additional bending on the joint.
Usually in a K joint the two braces are angled so that their axes meet at the
middle of the chord diameter to give the joint its strength. It is also possible to
angle the braces more sharply or shallowly and the difference is known as the
eccentricity of the joint.
DAC1-50615
Static Loading 9-7 Copyright © TWI Ltd
Ga
The stresses in nodal joints must take into account the stress concentration that
occurs at the intersection of the chord and brace. The hot spot stress approach
was developed to account for the stress concentration at nodal joints in offshore
platforms (Figure 9.19) and has been readily adopted since it is easy to extract
from a numerical model of a joint and can be measured from strain gauges at
the toes of the node joint welds.
DAC1-50615
Static Loading 9-8 Copyright © TWI Ltd
Figure 9.19 Hot spot stress definition.
a b
DAC1-50615
Static Loading 9-9 Copyright © TWI Ltd
The various ways that a beam can be carried by a crane illustrate the different
types of loading that can be imposed. Carried vertically it imposes only tensile
stress, but carrying it horizontally from a single point hook will impose bending
as well. If the horizontal beam is carried using a chain attached to each end
then compression as well as bending occurs. If the beam is carried from a chain
attached at a single point in the middle, the loading becomes mainly bending, a
rather unstable way to carry a long beam.
a b c
DAC1-50615
Static Loading 9-10 Copyright © TWI Ltd
Correct design Poor design Improved design
Concrete has good strength properties in compression but very low strength in
tension which limits its use in construction and makes it unsuitable for use in
many structural members when used on its own. By introducing a high initial
compressive stress such that the concrete still experiences compression
stresses when loaded in tension, concrete can be used in tension members and
these loaded in bending. Compression is introduced by pre-stressing steel
reinforcing bars in tension then pouring the concrete around them which shrinks
when it sets and grips the steel bar. The pre-stressing in the steel bar is then
released and the contraction of the steel bar introduces compressive stresses in
the concrete. One common application is in the tension flange of concrete
members loaded in bending, Figure 9.23. The term reinforcing-steel describes
the use of steel to reinforce any materials but is most often used in concrete.
Figure 9.23 Reinforcing steel bars (rebars) in the tension flange of a concrete
beam loaded in bending.
DAC1-50615
Static Loading 9-11 Copyright © TWI Ltd
A range of materials is used for the rebars and different welding techniques are
used to join them. The rebars have a textured profile (Figure 9.24) so they key
into the concrete and provide the pre-stressing and come in 6-50mm diameter.
A whole assembly of rebars will usually be used and the frame fabricated before
the concrete is poured into a surrounding mould. The bars are joined using one
of several methods: welded, joined using a wire joint where wire is wrapped
around bars and tightened, or using a rebar coupler which is a mechanical
fixing. Rebars are available for a wide range of chemical compositions and
mechanical properties. Not all rebars are weldable with weldability determined
by the carbon equivalent value and the limitations on the content of certain
elements.
Rebars are usually welded using MMA or MAG welding processes. Welding
rebars using butt joints (Figure 9.25) is usually used for load bearing joints only
because they need joint preparation and possibly backing strip may be used as
well. Lap welds (Figure 9.26) are used for non-load and load bearing joints and
it is possible to weld double sided lap joints. The requirement is for a minimum
throat thickness, a, greater than 30% of the rebar diameter, ie a ≥ 0.3d.
a b
DAC1-50615
Static Loading 9-12 Copyright © TWI Ltd
Figure 9.26 Lap welding steel rebars.
9.7 Summary
Finally, you should be able to describe welded joints for joining steel
reinforcement bars for concrete structures.
DAC1-50615
Static Loading 9-13 Copyright © TWI Ltd
Revision questions
1 Sketch a structure which incorporates a truss frame. How is the load transmitted?
4 Sketch a Y nodal joint and label the brace, chord, heel and toe of the structure.
Why are steel reinforcement bars used in structures? List three ways to join them.
DAC1-50615
Static Loading 9-14 Copyright © TWI Ltd
Objective
Stress, MPa
Tension. Tension
Yield Point
Strain, %
9-1
Elastic Design Method Elastic Design Method
Parent
Metal
High strength low alloy steels.
Weld metal sometimes undermatches parent
metal.
L x y
R P
P
For equilibrium: Rx = Py
9-2
Bending Moment Bending Stresses
Before bending
M
Tension (+)
P M M
After bending
At fixed end, bending moment M: M = PL Compression (-)
Tension (+) M M
M M
y
Neutral
Compression (-) axis
Stress
M M M M
y y
Neutral Neutral
axis axis
Stress stress
Stress at point y:
My
σ=
I
I is moment of inertia
Depends only on beam geometry
9-3
Yield and Proof Strength Bending Loading
Yield stress:
Stress at which permanent deformation starts to
occur. L
Stress, MPa
Yield Point P
Strain, %
Space Frames
Space frames
or
Designing to avoid bending
Use of Triangles
Very rigid.
Loads transmitted along lengths.
9-4
Copyright © TWI Ltd Copyright © TWI Ltd
Frames/Trusses
9-5
Structural Details Fixed Offshore Platform
Saddle point
Chord
Heel Toe
Side
= local dihedral angle (usually 30-150°) T-K nodal joint T-Y nodal joint Cross nodal joint
9-6
Types of Nodal Joints K Nodal Joints
Greater
than 10°
Max.10°
Gap
Max.10°
Offset
e=0 e>0
Eccentricity
Through
Overlap member
e<0
Chord
= local dihedral angle (usually 30-150°)
Toe Toe
9-7
Hot Spot Stress
Nominal stress
9-8
Principle Rebar
Rebar Joints
The term reinforcing-steel is used to describe Reinforcing bar is available in sizes ranging
the use of steel to reinforce materials, most from 6mm up to 50mm diameter.
often concrete.
A whole assembly of reinforcing bars will
Concrete is a brittle material which is strong in usually be used.
compression but weak in tension.
To join bars together there are several
This limits the use of concrete in construction methods:
and makes it unsuitable for use in many Welded joint (for weldable compositions).
structural members. Wire joint - wire wrapped around bars and
tightened.
Rebar coupler – mechanical fixing.
9-9
Types of Joint Types of Joint
Summary
Nodal joints.
Joint designs and differences to nozzles.
9-10
Section 10
If we consider a simple butt weld, the molten metal is deposited in the joint and
the plate edges on either side of the joint are heated to high temperature.
Further away from the joint the plate remains cool. The result is that the heated
zone tries to expand along the joint but is restrained by the remainder of the
plate.
Therefore, the area around the joint expands but also plastically deforms due to
its reduced yield strength at higher temperature. The expansion tends to bend
the plate during welding. On cooling the area that has plastically deformed
would contract to a reduced length if it was unrestrained; however, this cannot
happen as the welded zone remains in tension and pulls on the surrounding
material, causing high residual stresses or, if the welded component is not
sufficiently stiff, pulling it out of shape or distorting it.
The distributions of the residual stresses are illustrated on the next page. Note
that the longitudinal tensile stress extends beyond the weld and HAZ into the
parent plate. The higher the heat input, the wider the tensile zone. The longer
the weld, the higher the tensile stress required to reach the yield stress.
It should be noted that these residual stresses are situated around the weld,
but additional stresses due to general shrinkage and restraint will be present in
many structures. The magnitude of this additional stress may be controlled by
attention to the method of jigging, tacking and welding sequence, etc.
DAC1-50615
Development of Residual Stress and Distortion 10-1 Copyright © TWI Ltd
DAC1-50615
Development of Residual Stress and Distortion 10-2 Copyright © TWI Ltd
10.1 Factors affecting residual stresses and distortion
10.1.1 Material properties
Coefficient of expansion
The greater the value, the greater the local expansion due to welding and the
resultant residual stress.
Yield strength
Where yielding has occurred, the residual stresses are determined by the yield
stress of the material.
Modulus of elasticity
The greater the value of E, the higher the level of stresses; but also, as the
stiffness increases the tendency to buckle is reduced.
Transformation temperature
If the material undergoes phase changes, internal expansion and contraction of
the material structures takes place. The lower the transformation temperature,
the lower the residual stresses.
Thermal conductivity
The higher the thermal conductivity, the more heat is conducted away from the
weld zone and the lower the residual stresses.
10.1.2 Design
These factors are covered in the Design and Construction module(s).
10.1.3 Procedural
Thickness
As restraint usually increases with thickness, so do the stresses.
Number of passes
Every weld pass adds to the total contraction. However, as each additional pass
partially stress-relieves the previous passes, the effect is not entirely
cumulative.
Preheat
Whilst this may be necessary to combat H2 cracking, in many cases it may also
increase the level of stresses.
Misalignment
Misalignment may reduce the stresses in some cases.
Root gap
An increase in root gap increases shrinkage.
Heat input
The higher the total heat input the greater the shrinkage.
DAC1-50615
Development of Residual Stress and Distortion 10-3 Copyright © TWI Ltd
Balance weld
About neutral axis of weld.
Weld sequence
On seam.
Stitch welding
On structure.
Peening
Stress relief
10.1.4 Mechanical
Assembly method
Tack welding, strongbacks, jigging.
Pre-setting
Components set out of line to compensate for movement resulting from
welding.
Back-to-back assembly
DAC1-50615
Development of Residual Stress and Distortion 10-4 Copyright © TWI Ltd
DAC1-50615
Development of Residual Stress and Distortion 10-5 Copyright © TWI Ltd
10.3 Characteristics of materials which determine the amount of distortion
and residual stresses (relative values)
Carbon steel - 1
Stainless steel - 1.4
Aluminium - 1.7
Thermal conductivity
Low value – higher heat retained in welded zone – higher level of stress on
cooling.
Carbon steel - 1
Stainless steel - 0.3
Aluminium - 4.2
Yield strength
Higher yield - higher residual stress.
Carbon steel - 1
Stainless steel - 1.2
Aluminium - 0.5
Modes of elasticity
Measure of stiffness; greater stiffness - greater distortion resistance.
Carbon steel - 1
Stainless steel - 0.95
Aluminium - 0.3
Effect of preheat
Preheating is advantageous against hydrogen cracking, but can cause problems.
Consider the case of a butt weld under high restraint. Preheat closes the gap,
so the weld deposited is smaller in volume. On cooling, both plates shrink and
the normal weld transverse shrinkage stresses.
DAC1-50615
Development of Residual Stress and Distortion 10-6 Copyright © TWI Ltd
10.4 Correcting distortion
Flame straightening
Any heating and cooling of metals in a restrained environment imposes some
residual stress and subsequent distortion. This effect can be used to modify the
shape of a component by localised heating and subsequent cooling.
Typical examples of flame straightening are:
Heating must be done quickly using a localised intense heat source. Oxy-
acetylene torches are therefore recommended, but not cutting torches. The
temperature rise needs to be sufficient to produce plastic deformation in the
material, but too high a temperature may be detrimental to the material
properties as well as having little extra effect on the amount of deformation
obtained. For C and C-Mn steels that have developed higher strengths through
a quenching and tempering or controlled rolling production technique,
temperatures should not exceed approximately 650°C. Steels that are supplied
in the normalised condition are not likely to be damaged by higher
temperatures, but without specialist knowledge it is probably safest to avoid
higher heating temperatures.
Heating to full or only part thickness has a significant effect on the type of
distortion achieved. Full thickness heating procedures promote longitudinal
distortion, whilst part thickness heating will produce more angular movement.
For removing bulges in thinner plate, the expansion which occurs on heating
must be removed by hammering, as upsetting of the material must occur.
The effect of the operation cannot be fully assessed until the component has
cooled completely. Care must also be taken to ensure cold air is not flowing
across the component, as differential cooling will take place which will cause
distortion.
Stress-relieving weldments
Stress-relieving operations are carried out on welded components for many
reasons: to reduce the level of residual stress and the risk of brittle fracture, to
aid machining stability, etc.
DAC1-50615
Development of Residual Stress and Distortion 10-7 Copyright © TWI Ltd
The most common method of stress relief is a thermal treatment which involves
the heating and cooling of the component in a controlled manner. This heats
the material to a temperature where the yield strength reduces and high
residual stresses cause plastic deformation to relieve these stresses. On
cooling, the residual stresses in the weldment are significantly reduced.
Mechanical peening
Mechanical deformation of individual runs by mechanical methods. This can be
as crude as hammer peening and may be effective but difficult to control.
These methods vary in their effectiveness and not all are covered by
international codes or practices.
Thermal stress relief may be carried out in a furnace where the whole
component will be stress relieved. This is the usual situation for pressure
vessels and boilers, etc, but local stress relief may also be considered, eg on
pipework, wherein usually only the joints are stress relieved. This is carried out
using local heating bands.
A written procedure should be in place and rigorously worked to, to ensure the
operation is performed correctly. Such a procedure should include:
DAC1-50615
Development of Residual Stress and Distortion 10-8 Copyright © TWI Ltd
For local stress relief the following must also be considered:
DAC1-50615
Development of Residual Stress and Distortion 10-9 Copyright © TWI Ltd
10.5 Questions on residual stress and distortion
DAC1-50615
Development of Residual Stress and Distortion 10-10 Copyright © TWI Ltd
10.6 Questions on stress-relieving weldments
2 Produce a checklist of the controls required to ensure that the stress relief conforms
to a specification.
4 Name the different information sources where guidance on stress relief can be found.
5 Which factors require consideration in relation to the use of furnaces or local stress
relief?
DAC1-50615
Development of Residual Stress and Distortion 10-11 Copyright © TWI Ltd
Residual Stress
Hot weld
Tension YS at room
temperature
Compression
The higher the heat input the wider the tensile zone!
The longer the weld, the higher the tensile stress!
10-1
Types of Residual Stress Residual Stress
Welding sequence:
Number of passes - every pass adds to the total
Ɛ [%]
Rm
contraction.
Heat input - the higher the heat input, the greater Ɛ
E [kN/mm2]
σ [N/mm2]
the shrinkage.
Re
Travel speed - the faster the welding speed, the
less the stress.
Build-up sequence. E
Molecular Steel
Temperature ºC
10-2
Section 11
Revision Session
11 Revision Session
11.1 Multiple choice questions
1 Charpy tests are carried out on steels to:
3 Strain is:
a Bolted joints.
b Magnetic fields.
c Weld distortions.
d Vibration.
5 By how much does a carbon manganese steel beam deflect compared with
an aluminium alloy beam of the same size under the same load?
a One third.
b Four times.
c The same.
d Twice.
a IIW formula.
b S-N curve.
c Schaeffler diagram.
d A flow chart.
a Prevent vibration.
b Stop corrosion.
c Reduce stress concentrations at openings.
d Balance the weight.
DAC1-50615
Revision Session 11-1 Copyright © TWI Ltd
8 Fatigue cracks in otherwise sound butt welds transverse to the stress start
at:
a The root.
b The toe.
c Inter-run ripples.
d Chipping hammer marks.
a Smooth.
b Jagged.
c Torn.
d With a chevron pattern.
DAC1-50615
Revision Session 11-2 Copyright © TWI Ltd
16 The static strength used for designing a building frame is based on the:
a Percentage elongation.
b Hardness.
c Ultimate tensile strength.
d Yield strength.
a Heat input.
b Stress concentration effect.
c Thickness.
d Current.
18 A mitre fillet weld with two equal leg lengths of 12mm has a throat
thickness of:
a 0.8mm.
b 17mm.
c 9.5mm.
d 8.5mm.
DAC1-50615
Revision Session 11-3 Copyright © TWI Ltd
24 Welds often reach which level of residual stress?
a 50% yield.
b 80% yield.
c Yield stress.
d Twice the yield stress.
DAC1-50615
Revision Session 11-4 Copyright © TWI Ltd
11.2 Short answer questions
1 Which law describes the elastic area on a stress-strain graph?
2 How does the Young’s modulus for aluminium alloys compare with that for
steel? Give the value of Young’s modulus in steel.
4 What is stress?
6 What is the typical level of residual stress in a welded joint before and after
PWHT?
DAC1-50615
Revision Session 11-5 Copyright © TWI Ltd
7 Will a different grade of steel have a different fatigue life?
DAC1-50615
Revision Session 11-6 Copyright © TWI Ltd
11.3 Long question
A lifting lug attached by fillet welds requires a design review. Comment on 50
items which would be assessed during such a review.
DAC1-50615
Revision Session 11-7 Copyright © TWI Ltd