Factors in Weld Design

I Strength (static and/or fatigue)

I Material and the effects of heating
I Cost
I Distortion
I Residual Stresses
I Easy to Weld

Static Strength

I Stress - strain diagram

F

Stress (σ)
L
F yield ultimate
= (tensile)
A

F
∆L
Strain (ε) = L

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 Shear Strength

I In general, material fails in shear due to

distortion (at a molecular level)
I Criteria for failure:
• Ductile: Shear Strength ~ 0.5 Tensile Strength
• Brittle: Shear Strength ~ 0.75 Tensile Strength
I Weld strength analysis is generally based on
Shear Strength

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 Static Strength of Welds

Butt
F
F F Normal = w*h
F
1/8
Shear = w*h
3/8
75o
Fillet
1/4
F
F Max Normal = 0.618w * h
2F
F F
Max Shear =
0.707w * h
h = throat size!

Weld Size vs. Throat Size

Butt

h = plate thickness = weld size

1/8
3/8
75o
Fillet
1/4

h = 0.707 * plate thickness

0.707 * weld size

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 Fatigue Strength
Static Tensile Strength

Fatigue Endurance
Strength Limit

Low High
Cycle Cycle Infinite
Life

1 1000 1,000,000
Cycles of Loading

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 Endurance Limit

I For Steel:
• Endurance Limit = 0.5 * Tensile Strength
or 100 kpsi, which ever is lower.

I For Aluminum:
• No endurance limit (cannot have an infinite
life)

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Factors for Fatigue Stress Analysis

Type of Weld Stress Increase

Butt Weld 1.2
Transverse Fillet 1.5
Parallel Fillet 2.7
T-butt with corners 2.0

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 Strength Considerations

I Try to minimize the stresses in welds; make

the parent materials carry highest stresses.
I Butt welds are the most efficient
I Avoid stress concentrations
I Intermittent weld length should be at least 4
times the fillet size
I Minimize weld size to reduce potential for
fatigue failure

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Effects of Welding on Metallurgy

I Depends on the alloy and welding process

I In general, cracking is promoted by:
• stress concentrations
• brittle parent material after welding (low
carbon steels)
• hydrogen in the weld metal
• impurities in the weld metal

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 Reducing Distortion

I Prevent overwelding
I Intermittent welding
I Minimize number of passes
I Place welds near the neutral axis of the part
I Balance welds around the neutral axis
I Anticipate shrinkage forces
I Residual stress relief

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 Neutral Axis

I The line (plane) where bending stresses are

zero.

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