Y

U IT 7 WELDED CONNECTIONS AND

DETAILING
St
4a ture
7.1 Introduction
Objectives
1 7.2 Historical Development of Welding
7.2.1 Forge Welding
7.2.2 Electnc Arc Welding
7.3 Important Methods of Welding
73.1 Welding with Pressure
7.3.2 .Welding without Pressure

I 7.4
7.3.3 Automatic Welding
WeldingEquipment
7.4.1 Source of Electric~Power
7.4.2 Transmission of Current
7.4.3 Electrode Holder
7.4.4 Other Accessories
7.4.5 Weld C;auges
1 7.5 Electrodes
7.5.1 Bare Wire Electrodes
7.5.2 Covered Electrodes

7.6 Types of Welded Joints and Symbols

7.6.1 Butt Weld
7.6.2 Fillet Weld
7.6.3 Allowable Stresses in Weld
1 7.7 Inspection, Testing and Safety
7.7.1 inspection
7.7.2 Tasting of Weld
7.7.3 Safety in Welding
1 7.8 Summary
1 7.9 Keywords
1 7.10 Answers to SAQs

7.4 INTRODUCTION 1
I

I
of the art of welding involv d heating the two ends of the steel members till they
and then hammering them ntil their ends become homogeneous one, and this
ocess is known as forge (blaciksmith) welding which is almost 3000 years old.
om this simple and crude Fethod, welding techniques have changed dramatically
'

g now is carried out with elktrical power and with'or without pressure. Welding
vely a new technology, more efficient and less cumbersome than rivetting, is
fast and hence very popular now.

unit will help you to understand the importance of the latest and fast developing
of welding.
~ f t lstudying
r this unit. you should he able to

I know important types of weld.

I decide the welding equipment and electrodes.

I select and design types of welded joint, and

I *
e inspect and test welds.
Detailing of Steel Construction
7.2 HISTORICAL DEVELOPMENT OF WELDING
Wclding may be defined as a localized colisolidatioli of metals by meals of heat. It consists of
joining two pieces of metal by establishi~igbetween them a metallurgical bond.

7.2.1 Forge Welding

The forge (blacksmith) welding was the only method to join metal pieces for centuries and
ordinary fire was used as the principal source of heat energy for the purpose. The skill,
experierice and the strength of the blacksmith is more important in making the forge welded
joint. The heating of the pieces, the use of flux for dissolving the iron oxide on the surface of
the joint and application of strong hammer-blows rapidly helps to make a good joint. Even
though Humphrey Davy discovered that an arc could be created between two termi~ialsof an
electric circuit in 1801, this principle was used in making the carbon-arc street lamp very
much later in 1881. In 1885, a Russian scientist named Bernardos .used carbon- arc as a
source of heat and he invented the Electric Arc Welding process. 'Oxygen-Acetylene' welding
process developed in Fraice (1901-03) by Fouche and Picard by far has been found to be the
most popular as it develops a higher temperature (over 3400°C) and combustion products are
harmless. At sucli a high temperature, the solid metal part end gets collverted illto inolte~i
"puddle" without application of any pressure, and to compensate reduction Dithickness, a
tiller rod of same composition has to be added to the puddle. Refer Figure 7.1 for sche~i~atic
details.

7.2.2 Electric Arc Welding

The priliciple that intense and concentrated heat is produced when electricity passes through
an air gap from one conductor to the another is used in electric arc welding. Thus, rnetal work-
pieces are connected to negative pole and carbon electrode is connected to the positive pole of
a direct current circuit. An electric arc is formed (Figure 7.2) between end of the carbon
electrode and two pieces of metal, generating temperature of about 3600 'C: and melting tlie
faces of work pieces as well as the filler rod.

Gas t o v A

F~llcrrod
FLIIII~~
&la

-
Figure 7.1 :Oxy Acetylene Welding Figure 7.2 : Electric - Arc Welding
In lilst 5 0 to 60 years, electric arc welding has become so popular that it has become
synonymous with structural welding. I11 1890, Slavianoff replaced the carbon electrode with a
metallic electrode functioning as a filler rod as well. This is "Metal" - Arc welding. The arc
often caused overheating and burning of the weld metal, producing weld of brittle quality due
to reaction with gases in the atmosphere. In 1907, Kjellerg of Sweden removed this deficiency
by a chemical coating or fluxing the electrode which produced a stablc arc and also protected
the molten joint by shielding. This method of welding is referred to as Shielded - Arc
Welding.

7.3 IMPORTANT METHODS OF WELDING

Refer Chart 1 for summary of various welding methods.
Chart 1 :Welding Methods
i) Welding with pressure ii) Welding without Rrazing
pressure
a) Forge welding a) (;as welding a) Electric brazing
b) Pressure b) Thermit welding b) Furllace brazing
Themi t welding
c) Electrical Resistance C) Arc welding c) (;as brazillg
welding
d) Pressure welding d ) Dip brazing
 1
7. 1 Welding with Pressure
a ) Forge Welding
Welded Connection nnd
Detailing

1
Ge erally know11 as blacksmith welding, forge welding consists of heating the parts to be,
unt they become plastic. Sand or suitable tlux is then spread on the surfaces to be welded to
dis Ive iron-oxide. The parts are then superimposed and joined hy rapid hammer blows. This
pro ess, however, is not practised these days in stnlctural fabrication work.
b) ressure Thermit Welding
process, the parts to be joined are brought into contact and preheated. Then, by means
finely divided aluminium and iron oxide), a weld is
(3000' C) and produces pure iron and aluminium
ty of the joint and an excellent weld is formed.

ric Resistance Welding

between the abutting surfaces and the welding heat is produced by
and adjacent to these surfaces during the passage of current. No
fusion takes place after the current is discontinued. Various types of

1 v) Projection, and

t1
vi) Percussion.
The methods have a wide use in manufacturing processes such as automobile, furniture, etc.
The ower supply can be either AC or DC.
d) tressure Welding

1
This s also known as cold-pressure welding and is useful in the case of ductile metals such as
alu nium and copper. The connection is achieved through sustained pressure without heat or
filler metal.

7.3. Welding without Pressure (Fusion)

a) Welding
etween the metals is obtained by using a gas torch as a source of heat. A filler rod
not be used. The gases used are acetylene (oxy-acetylene welding), hydrogen
en welding), propane (oxy-propane welding). Gas welding may be used for
ts rind fittings requiring small welds.

(Fusion) Welding
is used in preference to thermit (pressure) welding. It is partly a casting process.
running the liquid thermit in and around the joint enveloped by a sand-lined
iquid thermit hses with the preheated parent metal. This process is used for
I I large
~ castings, fractured shafts and for replacing fish-plates in the permanent way

ss. The bond between the metals to be joined is produced by reducing the
iquid state, and then allowing the liquid to solidify. When the liquid
1 of the two pieces is completed. The heat required for welding is obtained
. A tiller rod may or may not he used. The arc-welding has seven

i) Metal-arc welding,
1 ii) Submerged-arc welding,
iii) Inert-gas welding,
iv) Carbon-arc welding,
 V) Shielded arc welding,
vi) Firecracker welding, and
vii) Atomic hydrogeii welding.
i) Metal-arc Welding
Figure 7.3 shows the details of the process. The intense heat required to convert the metal to a '
liquid-state is produced by an electric arc. The temperature at the tip of the electrode is around
3600' C and both; the tip of the electrode and a small portion of the parent-metal gets melted in
a common pool in a crater. The molten metal gets agitated by the action of the arc which
causes the metal to get thoroughly mixed with the filler metal. As this mixture gets cooled, it
solidifies. By moving the electrode along the joint. the two pieces get joined.

Figure 7.3 :Non-shielded Welding

The weld metal in its molten state combines with oxygen and nitrogen of the atmosphere.
When the molten weld solidifies rapidly, these gases get trapped as bubbles, before they cat1
escape. Sulphur dioxide formed from sulphur contents in steel and oxygen from the air also
form bubbles. Such gas entrapment weakens and embrittles the weld. The gas absorption by
weld deposits can be minimized or prevented by shrouding the area with an inert gas or by
using flux coated electrodes, known as "shielded" or "coated" electrodes which yield sound,
tougher and ductile metal joint and stable arc. The welding process requires colltinuous and
controlled AC or DC supply of adequate amperage.
ii) Submerged Arc Welding
The melting action takes place entirely under the flux and there is no evidence of elther an arc
or a welding flame and hence is also known as hidden arc process. Refer Figure 7.4. Since the
process uses heavy currents, heat development is intense and penetration is very rapid,
therefore a nominal 'V' preparation is adequate. First, a special flux pulverised to uniform size
(two volumes of parent metal to one volume of filler metal) is poured through the feed tube on
the joint. A bare wire is used for the welding electrode. The arc is established by illserting a i
piece of steel-wool between the rod and the work-piece.

Figure 7.4 :Submerged Arc-Welding

The electrode follows the feed tube. As it advances it is also simultaneously fed down. A -
 tage of flux is ;~ctuallyfused. The Welded Connection and
ue of submerged arc-welding, it is Detailiug
good strength, ductility,
rocess call. be manual.
e and magnitude of work.

t
lii) I ert (;as Welding
oncc~nsumahletungsten electrode and the workpiece. helium
metal) is used to protect the arc from effects of oxygeil or
ller metal is added separately. The tungsten electrode does
This process is mainly used for welding of aluminium,
ium and stainless steels. With consumable electrode adopted with inert-gas welding,
trode is used which acts as a filler and to develop the arc.
eavy sections of aluminium, stainless steels, copper etc.
1v) ~(birhonArc Welding
head mounted.on a trolley to travel on rail or the welding
on and the job is moved underneath, with the
cally to maintain a correct arc length and flux or filler metal
c or semi-automatic process is very economical in the shops

V)
I.
Sh lded Arc Welding

i
In this echnique. a bare wire electrode is used in place of a coated one and the arc is shielded
by car on dioxide. Good speed, penetration and shape welds are possible with this process.
Refer igure 7.5 for details. This technique is normally used for automatic or semi-automatic
weldin of li~ildsteeland low carbon steels.

Molten b o d (HI A~G&MM

weld

Figure 7.5 :Shielded -Arc Welding

Welding
similar to shielded - arc welding ill which an electrode is
arted between one end of the electrode and the job and

R
Arc we1 ing in wh~cllhydrogen passes through an arc between two tungsten electrodes, and
atomise then recoinhiiles whereby immense amount of heat is supplied for welding.

utomatic Welding

, the advance of the welding as well as the feed of the filler metal are automatic.
Welding
, only the feed of the tiller metal is automatic, the other operations are manual.
Arc Automatic or Semi-automatic Welding Process

I
Thi is cli~ssitiedinto two types; namely visible arc process and submerged arc process.
Detailing of Steel Construction a) I11 the visible arc process, the electrode feed (either bare wire or coaled) and the
control of the arc length are accomplished by meails of a specially desigiied
automatic welding head. The operator call handle the switches, control the amperagc
and arc voltage. The welding head feeds the electrode into the arc at a ullifornl rate
and maintains a constant arc wattage. In one method the work piece remains
stationary while the welding head travels on a track parallel to the welds.
b) The automatic submerged arc process is identical to the one executed except
manually that the control of the arc and flux feed is automatic.

7.4 WELDING EQUIPMENT

Since most of the normal structural welding process is by electric-arc method, let us proceed
to know about welding equipment for the same.
The equipment may be divided broadly under following heads:
i) Source of electric power,
ii) Transmission of current from the source to work- piece,
iii) Electrode holder, and
iv) Other accessories.

7.4.1 Source of Electric Power

The process of electric arc welding consists of traiismittlng electrical energy from the source to
the workpiece and converting the same into heat for melting the ends of the metal for fusioii.
This process requires a continuous supply of electric current of adequate amperage and voltage
to maintain the arc. The equipment to supply the current is of two categories, i.e. one that
which supplies alternating current (AC) and other direct current (DC). Both the types may be
stationary or mobile and may bc connected to more than one job.
a) Alternating Current Equipment
A transformer is used to obtain "Alternating current" for welding. The primary side of the
transformer is connected to the supply mains and the secondary side connected to the
electrode and workpiece. Usuplly, the welding transformers are designed to have an open
circuit voltage between 45 and 100 volts, 100 volts being used for special applications.
Multiple operator sets usually have am open circuit voltage of
90 volts. In the transformers, the welding current may he controlled by any one of the
following methods:
i) Moving core method,
ii) Moving coil method,
iii) Tapped choke method, and
iv) Amplifier method.
b) Direct Current Equipment
DC welding equipment is of two types : in one type the current is supplied by a generator
(Figure 7.6) which is driven either by a motor or an engine, in the second type, an AC
transformer is used and the output is rectified by metal plate rectifiers in the circuit. It is
known as a transformer rectifier set. In this first type a generator is con~iectedto AC or
DC motmwhich draws its power from the supply mains. When electric power is not
available, the generator may be connected to a petrol or diesel engine. Since the DC
welding equipment can be driven by several types of power sources, this welding set can
be independent of electric power.
AdvantagdDisadvantages of DC Equipment
a) Advantages
i) Suitable for arc-welding of all metals.
ii) Very satisfacturpwhere more stable arc and smooth uni-directional metal transfer is
needed such as in sheet metal welding.
iii) Very satisfactory for stainless steel, hard surfacing and non-ferrous metals.
 Welded Connection and
~etahin~
i) Main disadvantage is its high initial cost as well as higher maintenance and
operation cost.
ii) Polarity becomes importmt with DC when it is realised that approximately 70% of
the heat of the arc is produced in the positive pole.

Figure 7.6 :Mobile Arc Welding Generator Set for DC Arc Welding

AC Equipment
a) Advantages
i) Low initial cost, the machine being a simple transformer.
ii) Low mainte~lallcecost, as it has no moving parts. No-load losses are very small.
iii) Low operating cost.
iv) No magnetic arc blow.
v) . Very suitable for electrodes with iron coating and requiring heavy
. currents.
vi) No change of polarity when working with various types of electrodes.
b) Disadvantages
i) Confined mostly to ferrous metal arc welding.
ii) Not suitable for weldin* thin-gauge metal sheets.
7.4.2 Transmission of Current
An insulated copper or aluminium cable connecting a welding set to the electrode holder, is
called a welding cable, and that connecting the welding set to the workpiece, is called an
"earthing cable", as shown in Figure 7.7. As voltage is higher on the power side of the
machine, welding cables are thus required to be adequately insulated with tough
abrasion-resisting insulation so that it will stand up rough usage, these cables are also flexible
ellough so that they do not interfere with the working. The earthing cables are multi-strand
cables with a rubber cover and having adequate flexibility.The two cables can be connected by
xdevice called "cable-connector" as sllown in (Figure 7.7).
Detailing r ~ Steel
f Construction

Figure 7.7 (a) :Cable (Earthing) Figure 7.7 (b) : Cahle Coo~rectur

7.4.3 Ejectrode Holder

.This is a device used for holding the electrode mechanically. It has an insulated handle for the
operator's hand and the electric current is conveyed through it to the electrode. The jaws of the
holder is of such a design that they can firmly grip the electrode at any desired angle. The laws
of the holder are of hard copper alloys having good electrical conductiv~ty.The holder 1s tully
Insulated and is usually attached to the welding cable by means of solderless connectloll whlch
ensures good contact to prevent overheating.

Figure 7.8 :Fully Insulatdd Electrode Holder

7.4.4 Other Accessories

The accessories the welder uses are as follows :
i) During welding : earth-clamp, hand-screen (shield) or head-screen or
head-screen (helmet), apron, gloves.
ii) After welding : chipping hammer for removing the slag and wire brush for
cleaning.
Earthclamp
Earth clamps shown in Figure 7.9 are used for fixing the earthing cable to Ule workplece o r to
the welder's bench. They have a good grip to ellsure proper electrical contact.

Figure 7.9 :Earth Cla~np

Hand Screen and Helmet

These are the appliances intended for the protection of the operator's eyes and face. A hand
screen is held 111 the hand, whereas a headscreen is worn on the head and kept in position
usually by a band passing round the back of the head. They are fitted with specially deslgned
dark glasses through which the operator is able to look at the arc without darnaging his eyes.
 Welded Connection and

An apron is intended for the protection of the operators clothes from the sparks and the heat of
the arc. It is usually made of heat resistant chrome leather and is tied round the waist and neck.
overhead welding, a legging and a skull cap of chrome leather are also used.

ey are usually made of chrome leather.

hipping Hammer
chipping hammer is used for removing the slag from the weld.

ire brush is used for cleaning the weld.

efer Figure 7.10 (a) to (0for various applications of same typical weld gauge. Weld gauge is

at a joint M, weld of leg-size (L) = LM is provided the gauge will read (L) when its
t position is touching the weld point N, lowest thus the distance (MN) is the size of its

TO CHECK T H E MAXIMUM
PERM IS5IBLE CONVEXITY.

Figure 7.10 :Typical Weld Gauges

 CHECKING BUTT W E W FW TO DETERMINE THE SIZE OF A
MAXIMUM AND MINIMUM CONVEXITY. CONCAVE FILLET

Figure 7.10 :Typical Weld Gauges

N.B :T h ~ convexity
s is given by [ d - b cos 45'1. As shown in Figure 7.10 (a), the different scalzs for various
measurements are marked by the side of the movable plate (MP).

The gauge shown in Figure 7.10 (d) has its guiding plates making an angle of 90'. These
faces of the guiding plates are placed along a fillet-weld of 90°. The movable plate (MP) is
then moved down to touch the convex surface of the weld. This scale is adjusted to read the
distance (d ) whereby actual convexity or concavity (Figure 7.10 (e)) of the weld can be
determined.

SAQ 1
i) Indicate the various methods of welding giving two techniques in each.
ii) Draw a neat sketch of electric-arc-welding.
iii) Explain the advantages of using "Flux Coated Electrode" in metal-arc: welding.
iv) Explain the use of Electrode-Holder.
(N.B.: Answers for the above queshons are ~ncludedin the text given In Sedons 7.2 to 7.4).

7.5 ELECTRODES
An electrode consists of a metallic wire called core wire which is coated uniformly with tlux.
The core wire received from rolling mills in large coils is cleai~edand straightened. There are
two methods of application of coat. In the first method, the straightened wire is cut idto
standard lengths and then dipped into a container carrying the flux paste. In this process,
uniformity of flux coating cannot be assured and production speed is also low. In the second
method, the straightened wire or cut lengths are fed into an extrusion press where the coatlng is
applied under pressure (hence this method is termed as extrusion process), and'then cut into
smaller pieces when wire is fed. Electrodes are thoroughly dried or baked after production
because moisture causes an unstable arc, heavy spatter and porosity in the weld metal.
Two kinds of welding electrodes are used:
a) Bare wire electrodes.
b) Covered electrodes.
7.5.1 Bare Wire Electrodes
The bare electrodes oxidise readily and suffer high losses of elements such as carbon,
manganese and silicon. The formation of compounds with oxygen and nitrogen of the air make
bare electrodes undesirable. Moreover they are suitable only with D C They produce brittle
welds with little resistance to impact. Bare wire electrodes when used in automatic welding
should be protected from the atmosphere by either powdered flux or inert gas.
7.5.2 C o v e i d Electrodes I

The defects in bare wire electrodes are remedied by covering the wires with chemicals or
fluxes. The coating contains, cellulose like starch, wood-flour and carbonate type materials. It
decomposes in the arc and produces a gas shield of COz, CO, or H around the weld and
protects the molten metal of the weld from the bad effects of exposure to air. Coating
containing arc-stabilisers like titanium dioxide, calcium carbonate and potassiunl compounds'
 . --

ntaining arc-stabilisers like titanium dioxide, cdciuni carbonate and potassium compounds Welded C:onnection imd
Detailing
Ips better ionisation in the arc and makes it more stable. The coating often colltaills
ag-for~ningingredients, deoxidising elements, in addition to arc stabilizers and gas shielding
aterials referred above. The slag producing elements are iron-oxide, miulganese dioxide,
ina-clay, mica illid other silicates. The.deoxydising elements are ferrosilicon, ferro-titanium,
erro-manganese and ferro molybdenum. Alloying elements are also added to the coating to
roduce alloy steel weld metal, the electrode wire being of mild steel. The coated electrodes
roduce denser, stmnger, tougher and inore ductile welds.

The ratio of coating thickness to diameter of the core wire is called as the coating factor of the
electrodes and three types of coatillg factors are in use:
a) Heavily-coated electrodes with coating factor between 1.6 to 2.2,
b) Medium-coated electrodes have a coating factor of 1.4 to 1.5, and
c) Lightly-coated ones have a coating factor of 1.25 to 1.3.
Heavily-coated electrodes have a tendency to form a sleeve or a cup at the end of the arc
because the core wire is burning ahead of the coating. This sleeve helps to direct and
concentrate the heat of the arc, giving greater depth of fusion at the joint. It also increases the
temperature of the electrode tip. The slag from heavy coated electrodes is very thick and it is
usually self-detaching. Heavily-coated electrodes are however difficult tuuse in vertical and
overhead positions; for these locations the other two types of coated electrodes are best suited.
Lightly coated electrodes giving a heavily shielded arc are very popular for vertical and
overhead welding as there is less slag to be controlled.
Function of the Flux Coating Covering
i) It helps to strike and maintain the arc with incorporation of arc stabilisers.
ii) It helps to produce a gaseous shield around the cut by including the gas shielding

iii) It helps to produce a slag which protects the metal from attack by oxygen and
nitrogen from air, by incorporating slag producers.
iv) It helps to deoxidise and retine the weld metal by incorporation of deoxidizers.
v) It helps to modify and control the strength of the weld metal by including
alloying compounds.
vi) It helps to form a sleeve at the burning end of the electrode md to conceiltrate
the heat.
vii) It helps to make vertical and overhead welding easy for the welder.
viii) It helps to insulate the electrode so that it may be used at a higher current level
compared to bare wire.
nded appearance to the

Types of Flux Covering

The covering contains high cellulose and titanium. It is used in all positions. By using
heavy current, it can be used for deep penetration in the downward position. It is suitable
for all types of M.S. welding aid is of particular value for applications involvillg changes
in position of welding, for example in pipe welding, storage tanks, etc. The burn-off rate is
high and spatter loss is somewhat high with coarser weld finish.

The covering contains a high proportion of titanium. It is used for butt and fillet welds in
all positions especially for fillet welds in horizontallvertical positions. It produces little
spatter and good finished-weld.

The covering coiltains an appreciable amount of titanium but the addition of basic
m3terials yields a much more fluid slag than produced by electrodes of type 2. It is used in
Detailing of Steel Construction iv) Type 4
This has a thick coating and is used for welding in the flat position only. Ttie weld finish is
smooth, ripples being less pronounced than on deposits produced by the other types of
electrodes. The principal application is for deep groove welding in thick plates where
radiographic tests are must.
v) Type 5
The covering consists principally of iron oxides with or without oxides of rn'anganese. It is
chiefly used for single run fillet welds where appearance is of primary importance. The
degree of penetration is low.
vi) Type 6
Electrodes of this type are known as low hydrogen electrodes. The weld metal has a high
resistailce to hot and cold cracking and is less sensitive to variation in plate yuality than
that of other electrode types. These are particularly suitable for welding high tensile M.S
.
where best physical properties are required. They can be used for steels having higher
carbon and sulphur and for steels of unknown composition.
vii) Type 7
Electrodes with hydrogen-controlled coveril~gare used in all cases where medium and low
aljoy steels or heavy sections are to be welded.
viii) Type 8
Metal powder (iron) is added commonly to flux and coverings of type 7,4,6, iu sufficient
quantities to give metal recovery more than 1 10%.These electrodes give.performance
characteristics very similar to those of respective types hut have high deposition rates and
higher metal recovery and can be used for flat position and horizontal/vertical tlat weldiiig
only.

7.6 TYPES OF WELDED JOINTS AND SYMBOLS

There are five hasic types of welded joints: butt, lap, tee, edge and corner as shown in Figure
7.1 1 (a) and some of the basic types of welds: groove, fillet, plug and slot as shown in Figure
7.1 1 (b).

TEE CORNER.

(a) Basic Types of Welded Joints

FILlLP UNFILLED

FI LLET
(b) Basic Types of Welds
Figurc 7.11 a
 .-
Weldrcl Corirwction and
7.6.1 Butt Weld l)ris~iling
A butt weld is ~rscdin connecting two members to develop full capacity of the smaller of the
two menlhcrs (i.e. the n1t:mber wllh smaller thickness). Table 7.1 shciws various types of
welded ioinls. their applicabilily and the relevant symbols. The throat thickness in a butt joint
\hould he eclt~allo tl~icknessof smaller plate (refer Figure 7.12).

{a) I'latrs of Equd Thickness (b) Plates of Unequal Thickness

Figure 7.12 :Types of Jvit~ts

a ) The effective throat thickness 111 a butt joint shoilld be equal to the thickqess of the
slnallest plate of an incomplete penetration hutt-weld is to be taken as shown ill

EFFECTIVE TWOAT

2.4 MM MINIMUM ROOT PENETRATION.

h) Unsealed single butt weld of V,U.J and bevel types and incomplete penetration hult welds.
welded fro111one sidc only, should have a minimum throat thickless of718th thickness of
lhinner plale ns shown 111 Figure 7.14 as per I.S. 816 Clause 6.1.4.2 and i'or stress
calcnlations. the throat thickness is to be considerecl as 518th of the thinner plate.
- -

TI-
- SIZE WEU
_L_

Figure 7.11

c) For unwelded portion in incomplete penetratlou butt welds, wclded from both sides. tliroat
thickness shall not he greater than 1/4 th the thickness of thinner plate and should b e in
central portion of the depth as shown in Fipnre 7.15

Figure 7.15
Detailing of Steel Construction

TABLE7.1
TYPES OFJOINT5,APPLfCABLE TPE OF WEDS AND SYMBOLS
I I

SINGLE -V

7
is INGLE BEVEL [f
-
1I

Lx
DOUBLE BEVEL

is. INGLE-J

k. UBLE-J
1-
TYPE OF JOINT TYPE OF WELD APPLICABLE. SYMBOL
7

SINGLE FILLET
I 1 n

DOUBLE FILLET.
'Yh -
9 % >
p
SLOT

LA? JOINT

I YA 1
I
x,x, [PLUG]

CORNE'R. .
JOINT.
SINGLE FILLET

L7 h_.

DOUBLE FILLET. B
 Sealing Run : For a cornplete penetration, the weld must have a sealing run of weld Welded Connection and
dl
Detailing
metal on the back of joint (Figure 7.12) after cutting the first run of previously deposited
weld metal to a depth of 5 mm.The groove should then he filled in and sealed by welding.
Without back gauging, penetration is considered as incomplete. The back gauging should
be deep enough to expose sound weld metal. Refer clause 6.12 of I.S. 81611969 which
indicates the weaknesses of the unsealed joints.
e) Backing Strip : It is a piece of metal placed at a root and penetrated by the weld metal. It
may remain as a part of the j o i ~ or
~ tcan be removed by machining or other means. When it
is not possible to weld frorn the other side also and when full plate thickness weld is
required, this strip is mandatory. In case of V,U,J or bevelled butt welds, welded from one
side only, the parts should be bevelled to an edge with a gap 3 to
5 mm to ensure proper fusion.
A butt weld joint nornially acts in direct tension or compression.

7.6.2 Fillet Weld

Any fusion weld approximately triangular in cross-section (but not a butt weld) is known as a
fillet weld. Thc fillet weld may bc convex, flat or concave. Refer Figure 7.16 (a),(b) (c).

EFFECTIVE

<EFFEcmvE LED LT.'

a) Convex Fillet b) Flat Fillet c) Concave Fillet
Figure 736 :Fillet Welds

X-X

ELEVATION

EfFCcIive WLM Len&

L = weld sire .
Le= L-21.

I PLAN-VIEW.
Figure 7.17
CoustructiOn a) Stretigtli of normal structural fillet weld (between 60" and 90") is equal to fillet
size x 0.7 x allowable shear stress.
b) A fillet weld is normally subjected to shear and sometimes tension, compression and
flexure as well.
C) The side or end fillet welds should be returned around the corner for a distance of at least
twice the leg size (Refer Figure 7.17).

7.6.3 Allowable Stresses in Weld

Full penetration butt weld has the same strength at joint as that of the tliiniler plate. For
penetration not less than 718th of thi~inerplate thickness, the throat thickness assumed tor
calculation shall not exceed 518th of the thinner plate thickness (Refer I.S. 816-C1 6.1.4.2).
For fillet welds the permissible shear stress base0 on throat thickness IS 110 ~/nun'$o.~llso
weld [IS : 8 16-C1 7.11 and ol,,.or o,,,
is 165 ~ l r n m ~ .
Permissible shear and tensile stress on fillet welds done at site ]lot to exceed 80% of
11 0 ~ 1 n i r n ~ .
Permissible increase in stress whcn effects of earthquake or wind are considered is 25%:
Example 7.1
Design the splice of a truss tie in fillet weld to carry 200 kN, the section being
L 2 angles (65 X 65 X 6) as shown in Figure 7.18
Solution
Capacity of 5mm size, site fillet weld
Weld length required = 200,000/308 = 649 mm
Capacity of weld = 0.7 x 0.8 x 5 x 110
= 308 Nlmm
Capacity in tension of L 2 angles 65 x 65 x 6 = 2 x 744 x 150 N = 223 kN
Hence, provide a weld length for 223 kN = 649 x 2231200 = 724 mm.
Effective weld length = (199 - 5) x 4 = 776 mm > 724 mm.
Use 4.5 mm (i.e. 6 X 314) fillet weld instead of 5 mm as per I.S. 816 - C1. 6.2.5.2. Refer
Figure 7.18 for detailing of welded joint.

Figure 7.18
Xxample 7.2
Design connection of ISMB 250 carrying 150 kN at a clear distance of 200 lilm from
column IS MB 200 using 10 mm fillet weld at site as shown in Figure 7.19.
1 q50 kN

(Q) ELEV-N Figure 7.1'1 (b) SIDE VIEW

 Welded Connection and
Solution Detailing
Assume all rouild weld
Total weld length (L) = 2[(100 - 20) + (100 - 20 - 6.9) + (250 - 2 x 12.5 - 20)]
:. L = 716 mm

b = 5.79 x lo6 mm4/mmthick

Y z,, = Direct shear stress along vertical direction

I o, = Bending stress along horizontal direclion

\ 7, =
= a:,= 681 Nlmm = Resulta~~tstress at point (A)
I Cnpacity of 10 inm fillet weld = 0.7 x 0.8 x 10 x 1 10
< 681 N/mm :.
I :.
= 6 16 N/mm

Instead of 10 mm fillet weld use 12 mm weld.

Inadequate

Ex;tmple 73
Design connectioris of ISMB 250 carrying 150 kN load as shown in FIpure 7.20.

-
PLAN.

Figure 7.20
Detailing of Steel Construction ~,,l~ti~,,
This structure is like the previous one as in the earlier example except that thc fillet
weld joint is not only in direct shear (t,) but torsion (7,) as well.
Connection is done through en.d channels (E.C. - 2 Nos.)
Weld lengths = 680 mm

I, = I,, + I,, = 6.55 x 106 mm4/mm

At point (B), the radial distance = T,

.
r, = 445' + 1 2 5 ~ )= 133 ; 0 = 70.2' , cose = 0.34

Since the load of 150 kN is shared equally by each end-channel.

Maximum stress at conier (B) = 2, = J(+, + 'c$ + 2 ,T . t,cOS 0)

Capacity of 6 mm site fillet weid = 0.7 x 0.8 x 6 x 110

= 370 N/mm > 358 N/mm
To compare total weld material in Examples 7.2 and 7.3 :
Considering area of cross-section of weld to be triangular.
We get for Example 7.2

Volume = 780 x 12 12 = 5.6 x 1 0 4 mm3

2
For Example 7.3

Volume = 62 = 2.45 x 10' rnm3

2
Example 7.4
Design the above connection by considering only the flange welds.
Solution

r = 133 mm. cos0 = 0.34

 Welded Connection and
Detailing

6, = 4(7:+,oi, + 2 .,7 oh. cos 8)

I = $(417'+ 6812+ 2 x 4 1 7 ~ 6 8 1x0.14) = 911 Nlmm

Use 16 mm fillet weld with capacity 986 Nlmm > 91 1 Nlmm

xample 7.5
A secondary hearn ISMB 300 transmits 100 kN load on the main beam ISMB 500
(Figure 7.2 1). Design the connections.

la) ELEVATION. '

SIDE VIEW
(=I

Figure 7.21

D.esign of weld 011 ISMB 300 by means of cleat angles

~2x75x75x8nlrn
-
R x = C.G. of weld from vertical leg (B) of weld
Detailing of Steel Construction

r. = d(48.7' + 100') = 111.2 mm , 0 = tan

-1
-
100 - 64"
48.7
-

Design M = 100 ( 75 - 11.3) = 6.37 x 10' N mm (Total)

Capacity of 4 mm fillet weld = 0.7 x 4 x 110 = 308 Nlmm

b) Design of weld on ISMB : 500

The load is transferred to tlle web of girder through two lines of field welds @)
75 rnm from ISMB 300, which resists a moment of$x 75.

The resisting couple excites hearing pressure between the angles ant1 the weh of
beam on upper part and between field weld and the outstanding legs of tlie angle
over the remaining length. Maximum betiding stress is qh .

5 mm fillet weld on site has capacity = 0.7 x 0.8 x 5 X 110 = 308 Nlmm
. 5 rnm fillet weld is O.K.

---
75000 - 417 Nlmm
- 180

= d ( 4 1 7 ~+ 6812 -t 2 x 417 x 681 X 0.34)

= 911 N/mm
Use fillet weld 16 mm size 3 986 Nlmm z Y 11 Nlmm.
 Welded Con~lectior~
a ~ d
Detailing
Design weld lengths for members (A) and (B) meeting at joint (J)
Meinber A(2L90x90x6) B 2 L 75 x 7 5 x 6
Load in (kN) 150 (compression) 210 (tension)

Figure 7.22

SAQ 3
A bean ISMB 450 on 5 m span carries total load of 3x1 kN and is supported by
ullstiffe~ledflange cleat of an ISHB 200 column. Design the connection (shop fillet
weld). Design also the splice if maximum available length of beam is 4m.

SAQ 1 ,

colu11111ISHB 300 carries direct load of 1000 kN and has to be spliced by providing
ates 011 the flanges as well as both sides of the web. Design the joint to carry 500 kN
rough each llange plate and each web plate of the splice.

t
To obta' I a dependable joint, it is necessary to inspect and exercise adequate colltrol
a) befor . b) during ald c) after welding.
n before welding consists in ascertaining whether
proper facilities exist for storing of electrodes,
the operators are familiar with the types of work, the electrode, the machine etc.
and their work has been tested as per the requirements given in IS.823 and 822,
proper types of equipment, electrode, machine are chosen,
the materials to he welded are of weldable quality,
1 Detailng of Steel Conrtnction
e) the edges are prepared, are accessible and free from surface defects,
I
f) polarity of the electrode is correct in the case of DC welding current, and

I g) all required jigs, gauges etc. are available.

I Irispection during welding consists of

studying the sequence of weld deposits to minimize distortioiis and get
a)
uniformity, and
b) removal of slag before the next run of welding. It is possible to judge whether
the amperage, speed of travel, arc length and manipulation of the electrodes are
properly set from
i) the shape of the' deposit electrode, and
ii) under or overl-lusting of the metal dming welding,
Inspection after welding consists in visual inspection of the welds after their execution. A good
weld will show an evenness of ripples or waves and well formed beads with good fusion along
the edges of the welds. Surface defects in and around the welds, such as alr bubble holes,
longitudinal and transverse cracks (Figure 7.23(a)) undercuts (Figure 7.23(b)) and the overlaps
(Figure 7.23(c)) excessive convexity formation of small craters and gauge marks may be
detected by visual inspections or by magnifying glasses. Refer Figure 7.23(d) for acceptable
welds, as also the defective weld.

Figure 7.2Xa) :Weld Defect5

PI LLET BUT$
Figure 7.23(b) :Schematic Diagrmn of Undercut (U) in Rllet nnd Butt Welds

Figure 7.2.3(c) :Schematic Diagram of overlap in Fillet and Butt Weld.;

EXCESSIVE CONVEXITY UNDERCUT OV ERLA'l?

I 'DEFECTIVE WELD PROFILES.

ACCEPT'ABLE BUTT WELD PROFILE.

I:igurr 7.2&d) :Acccptablc &DcSeclive Bull luld I;illel W'clcl I'rufilcs
 I
--

Welded (

T (Y

1t 4 DESIRED FILLET W -E D PROFILE.

-- k-slz*\
G
'f

INSUFFICIENT THROAT EXCESSIVE CONVEXITY. \ UNDESCUT

I I W ER LAP INSUFFICIENT LEG.

Figure 7,23(e) :.Defective Fillet Weld Profiles
Figure 7.23 :Acceptable and Defective Welds

Minute surface cracks may also be detected with the help of the ordinary paraffin and chalk
method, or magnetic crack detector or by fluorescent flow detection method.

I If the metal has a rusty or dull red colour or appears crystallized, it is an indication that the
head has been too great and the metal has been burnt.
Due to the very nature of the welding operation, defects which are confined to the interior of
the welds could also occur. They are porosity, blowholes, slag-inclusions, under bead cracks,
root defects, incomplete penetration and internal cracks. These defects could be detected by
nondestru$tive testing (by portable or laboratory equipment like i) ultrasonic testing machine,
ii) x-ray machine, iii) gamma ray testing) or by destructive tests on port of cut welds by deep
etching and inspecting (by using hydrochloric and nitric acid or using ammonium-persulphate
or iodine and potassium iodide).
7.2.2 Testing of Welds
The testing of welds mechanically on test samples gives the idea
i) whether the quality of the electrodes is acceptable,
ii) whether the ability of the welder is upto the mark,
C

I iii)
iv)
whether the material is weldable, and finally
whether the welded joint is suong and acceptable.
The samples of welded joints are usually tested for tensile test, bend test and impact test. It is
proposed to summarize some of the tests and their general purpose.
a) For groove welds
i) Reduced-section-Tension-test for tensile strength and for procedure
qualification.
ii) Free-bend test for ductility and for procedure qualification.
iii) Root-bend test for soundness, used extensively for operator's qualification skill
and ability.
I I iv) Face-bend-test for soundness, used extensively for operators skill and ability.
Detailing of Steel Constraction b) For fillet welds
i) Longitudinal or transverse shear test for shear strength and procedure -
qualification (Ref. Figure 7.24 (a)).
ii) Free-bend-test for ductility and procedure qualification.
iii) Fillet weld soundness test for soundness, used extensively for operator
qualification.
iv) Fillet weld break test for soundness, used extensively for operator
qualification.
Refer Figure 7.24 (b) wherein the method of fillet weld shear test sample for transverse load as
well as longitudinal 1oads.i~indicated.

FFlClENT W

QTLST -WENS.

0s-

(;,) Methnd of IBrepdnl:Tnnsverse Elllet Weld Shenri~tgTest Spvcitltol

(b) Method of Preparing Longitudinal Wlet Weld Shearing Test Sample

Figure 7.24

7.7.3 Safety in Welding

Generally high temperature and high currents are used in welding against which safety has to
be ensured.
Dangers Associated with G s Welding and Cutting
In these processes combustible gas like acetylene is used available commercially in cylinders.
The gas is compressed and dissolved in "acetone". Acetone may be generated on the spot by
reaction of water on calcium carbide. Combustible gas cylinder valve outlets are screwed left
handed and others right handed.
When using Oxygen and Dissolved Acetone
* Cylinders or fittings shall not be tampered.
* No attempt shall he made to mix gases in cylinder.
* The cylinders shall not be used for any purpose other than for welding or cutting.
* Acetylene cylinders be stacked on their sides and upright.
* Cylinders shall not be exposed to heat.
* No oil or grease be used near oxygen.
 * Use correct apparatus such as regulator, hose torch etc. Welded Connection and
Detailing
* No naked flame shall be used to test leakage.
* Store the cylinders properly, empty ones and full ones being kept clear of each
other.
* The cylinder valves shall be kept shut when work has been stopped or cylinder is
exhausted.
* The blowpipe to be lighted by sparklighter after setting regulator to correct
pressure.
L Dangers Asscriated with Hechic Welding
The welding equipment like welding generators, transformers, cables, electrode-holders, hand
screen or shields, electrodes etc. shall conform to relevant Indian Standards and welders shall
I
be instructed in the use of above as per the manuals. Normally the low voltages used may not
cause problem of shock but under certain conditions, these voltages may be fatal, i.e. when
welder's clothing has become damp due to perspiration. When not in use, the electrode should
be removed from the holder and welding machine switched off. The current cables should be
often checked for any damage as they are normally roughly used and also carry higher
voltages.

SUMMARY
I 1 In this unit you have been given a brief idea on historical development of welding, important
types of welding and welded joints ,welding equipment and electrodes. You ive also be
given an idea on inspection, testing:and safety aspects of welding which are important
desigining the joints. The examples given would help you to solve all the ba! problems
may face at sites. Weld gauges can be manufactured individually also.
Refer the following references to understand
a) Quality of raw materials,
b) Equipment for welding, and
c) Design of Butt weld and Fillet weld.

KEY WORDS
Forge Welding
Electric Arc Welding
Welding with Pressure
Welding without Pressure :
Carbon Arc-welding
Shielded Arc Welding
Direct Current Equipment :
Earth Clamp
Apron & Gloves
Bare Wire Electrode
Butt welded Joint (stronger :
than parent metal)
Direct Shdar Stress (&)
: Blacksmith's Welding.
: Heat generated by electric arc is made use of in causing
fusion of surfaces to be welded.
: Pressure Thermit welding.
Arc welding.
: AutomaticISemi-automatic in the shops.
: Alternating current equipment using a transformer.
Using a rectifier.
: Hand-screen.
: Weldgauges.
: Covered electrodes with flux (coating) covering.
Fillet welded joint.
: Shear stress due to torsion ('rT).

I I
a Exwsive Convexity1
undercut/Overlap
1-ciet k g
:

:
Insufficient Throat.

Physical test of weld in tensionlshearlbend Ultrasonic

*,."*:." -.."LA-,.lv -..-......,.,.:-,. -6..
Detailing Steel Construction
7.10 ANSWERS TO SAQs
The answers for the solution of the above referred examples are provided in Figure 7 25, 7.26.
7.27

7.25
Fi~ure
7
COLUMN 1 3 6 200

PLATE 52Ox2Or140

I
BEAM ISMBlcSO

Figure 7.26

/
/
/'
/'
/

f z0)-SECTION A-A
L

Figure 7.27