LESSON 7.

Welded Connection
7.1 INTRODUCTION
The development of welding technology in 1940s has considerably reduced the riveted joint
applications. Welding is the method of locally melting the metals (sheets or plates –
overlapping or butting) with intensive heating along with a filler metal or without it and
allowing cooling them to form a coherent mass, thus creating a joint. A typical weld showing
various zones of weld is shown in Fig. 7.1. Such joints can be created to make structures,
boilers, pressure vessels, etc. and are more conveniently made in steel. The progress has been
made in welding several types of steels, but large structure size may impede the use of
automatic techniques and heat treatment which becomes necessary in some cases. Welded
ships were made in large size and large number during Second World War and failures of
many of them spurted research efforts to make welding a better technology.

7.2 ADVANTAGES OF WELDED CONNECTIONS

1. The gross sectional area of the welded members is effective since the welding process
does not involve drilling holes.
2. Welded structures are comparatively lighter than corresponding riveted structures.
3. A welded joint has a greater strength sometimes equal to the strength of the parent
metal itself.
4. Repairs and further new connections can be done more easily than in riveting.
5. Welded joints provide rigidity leads to smaller bending moments than corresponding
riveted members.
6. Welded joints are economical to riveted joints due to low maintenance cost.
7. Members of such shapes that afford difficulty for riveting can be more easily welded.
8. A welded structure has a better finish and appearance than the corresponding riveted
structure.
9. Connecting angles, gusset plates, splicing plates can be minimized.
10. Steel bars in reinforced concrete structure may be welded easily so that lapping of
bars may be avoided.
 11. It is possible to weld at any point at any part of a structure, but riveting will always
require enough clearance.
12. The process of welding does not involve great noise compared to the noise produced
in the riveting process.
7.3 DISADVANTAGES OF WELDED CONNECTIONS
1. Welding requires skilled labor and supervision.
2. Testing a welded joint is difficult. An X-ray examination alone can enable us to study
the quality of the connection.
3. Due to uneven heating and cooling, the welded members are likely to get warped at
the welded surface.
4. Internal stresses in the welded zones are likely to be set up.
7.4 TYPES OF WELDED JOINTS
Welds may be classified into two main types namely butt-weld and fillet-weld.
7.4.1. Butt weld
This type of weld is used when the members are in same plane. Butt weld is also termed as
groove weld. The butt weld is used to join structural members carrying direct compression or
tension. It is used to make tee-joint and butt-joint. The following types of butt welds are in
practice. These are named depending upon shape of the grove made for welding.
i. Square butt weld.
A square butt weld is a weld in the preparation of which the fusion faces lie approximately at
right angles to the surfaces of the components to be joined and are substantially parallel to
one another (Fig. 7.2 a & b).

ii.Single V-butt weld

A single V-butt weld is a weld in the preparation of which the edges of both components are
prepared so that in the cross-section, the fusion faces form a V as shown in Fig. 7.3.

iii.Double V-butt weld

A double V-butt weld is a weld in the preparation of which the edges of both components are
double beveled so that in cross-section, the fusion faces form two opposing V’s as shown in
Fig. 7.4.

iv. Single U-butt weld

A single U-butt weld is a weld in the preparation of which the edges of both components are
prepared so that in the cross section, the fusion faces form a U as shown in Fig. 7.5.

v. Double U-butt weld

A double U-butt weld is a weld in the preparation of which the edges of both components are
prepared so that in the cross section, the fusion faces form two opposing U’s as shown in Fig.
7.6.
vi.Single J-butt weld
A single J-butt weld is a weld in the preparation of which the edges of one component are
prepared so that in the cross section, the fusion faces is in the form a J and the fusion face of
the other component is at right angles to the surface of the first component as shown in Fig.
7.7.

vii.Double J-butt weld

A double J-butt weld is a weld in the preparation of which the edges of one component are
prepared so that in the cross section, the fusion faces is in the form of two opposing J’s and
the fusion face of the other component is at right angles to the surface of the first component
as shown in Fig. 7.8.

viii.Single bevel butt weld

A single bevel butt weld is a weld in the preparation of which the edge of one component is
beveled and the fusion face of the other component is at right angles to the surface of the first
component as shown in Fig. 7.9.

ix.Double bevel butt weld

A double bevel butt weld is a weld in the preparation of which the edges of one component
are double beveled and the fusion face of the other component is at right angles to the surface
of the first component as shown in Fig. 7.10.

7.4.2. Specifications of the butt weld

i. Size of butt weld
The size of a butt weld is specified by the effective throat thickness. The effective throat
thickness in case of complete penetration butt weld is taken as the thickness of thinner part
joined. The double V, double U, double J and double bevel butt welds are the examples of
complete penetration butt weld.
The effective throat thickness in case of incomplete penetration butt weld is taken as 7/8 th of
the thickness of the thinner part joined. But for the purpose of stress calculation, a required
effective throat thickness not exceeding 5/8 th of the thickness of thinner part joined should be
used. An incomplete penetration butt weld is also termed as unsealed single butt weld. Single
V, Single U, Single J, Single bevel butt joints are the examples of incomplete penetration butt
weld. In incomplete penetration butt weld, the weld metal is not deposited intentionally
through the full thickness of the joint. The unwelded portion in incomplete penetration butt
weld, welded from both sides shall not be greater than 1/4 th of the thickness of thinner part
joined and should be central in the depth of the weld.
The unsealed butt welds V, U, J and bevel types and incomplete penetration butt welds should
not be used for highly stressed joints and joints subjected to dynamic, repeated or alternating
forces. The shall also not be subjected to a bending moment about the longitudinal axis of the
weld other than that normally resulting from the eccentricity of the weld metal relative to the
parts joined.
ii. Effective length of butt weld
The effective length of butt weld is the length for which the specified size (throat thickness)
of the weld exists.
iii. Effective area of butt weld
The effective area of a butt weld is taken as the product of the effective throat thickness and
the effective length of butt weld.
iv. Reinforcement
The extra metal deposited above the surface of the parent metal as shown in Fig. 7.11 is
called reinforcement. This reinforcement is provided to give sufficient surfaces convexity and
to ensure full effectiveness at the joint. This requires a minimum practical surface convexity
of 1.0 mm. This reinforcement should not exceed 3.0 mm. This is not considered as part of
throat thickness. This reinforcement may also be removed if a flush surface is desired.
When the structural members of unequal thickness are butt welded and difference in
thickness of members exceeds 25 per cent of the thinner part or 3.0 mm in metal arc welding
and 6.0 mm or more in oxy-acetylene welding, the thicker part is beveled so that the slop of
the surface from one part to the other is not steeper than one in five as shown in Fig. 7.12.A.
Where this arrangement is not practicable, the weld metal should be built-up at the junction
with the thicker part to dimension at least 25 per cent greater than that of the thinner part in
metal arc welding as shown in 7.12.B. alternatively, the weld metal should be built-up to the
dimensions of thicker members as shown in 7.12.C. In case of complete penetration butt
weld, generally, deign calculations are not necessary, as these will usually provide the
strength at the joint equal to the strength of the member connected.

7.4.3 Fillet-weld
This type of weld is used when the members to be connected overlap each other. A fillet weld
is a weld of approximately triangular cross section joining two surfaces approximately as
right angles to each other in lap joint or tee joint. A fillet weld is shown in Fig. 7.13.A. When
the cross section of fillet weld is 45˚, isosceles triangle as shown in Fig. 7.13.B.I, it is known
as a standard fillet weld. The standard 45˚ fillet weld is generally used. When the cross
section of the fillet weld is 30˚ and 60˚ triangle as shown in Fig. 7.13.B.II, it is known as a
special fillet weld.
A fillet weld is termed as concave fillet weld or convex fillet weld or mitre fillet weld
depending on the weld face in concave or convex or approximately flat as shown in Fig. 7.14,
respectively. A fillet weld is termed as normal fillet weld or deep penetration fillet weld
depending upon the depth of penetration beyond the root is less than 2.4 mm or more
respectively.

The fillet welds are of three types as shown in Fig. 7.15.

i.Side fillet weld

It is fillet weld stressed in longitudinal shear, i.e., a fillet weld, the axis of which is parallel to
the direction of these applied loads. It is also termed as longitudinal fillet weld.
ii.End fillet weld
It is a fillet weld stressed in transverse shear, i.e., a fillet weld, the axis of which is at right
angles to the direction of the applied load. It is also termed as transverse fillet weld.
iii.Diagonal fillet weld
It is a fillet weld the axis of which is inclined to the direction of the applied load
A fillet weld is placed on the sides or end of the base metal and it is subjected to shear along
with tension or compression and usually bending.
7.4.4 Specification of fillet weld
i. Size of fillet weld
The size of normal fillet weld is specified as minimum leg length of a convex or mitre fillet
weld or 1.414 times the effective throat thickness of a concave fillet weld. The size of deep
penetration fillet weld is specified as minimum leg length plus 2.4 mm. the length of leg is
the distance from the root to the toe of a fillet weld, measured along the fusion face.
The International Standard code has recommended the minimum size of the weld. If the
thickness of thicker part is up to 10 mm, the minimum size of the welding is 3 mm. If the
thickness of thicker part is in between 10 mm to 20 mm, the minimum size of the welding is
5 mm. If the thickness of thicker part is in between 20 mm to 32 mm, the minimum size of
the welding is 6 mm. If the thickness of thicker part is above 32 mm, the minimum size of the
welding is 10 mm. When the minimum size of the fillet weld is greater than the thickness of
the thinner part, the minimum size of the weld should be equal to the thickness of thinner
part. Where the thicker part is more than 50 mm, special precaution like preheating will have
to be taken.
ii. Effective throat thickness
The effective throat thickness of a fillet weld is the perpendicular distance from the root to
the hypotenuse of the largest isosceles right angled triangle that can be inscribed within the
weld cross section. The effective throat thickness of a fillet weld shall not be less than 3 mm
and shall generally not exceed 0.7 times the thickness of thinner part and equal to the
thickness of thinner part under special circumstances.

In general, for the purpose of stress calculation,

Where K is a constant. The value of K for different angles between fusion faces is adopted as
per Table 7.1 as recommended in IS:816-1969
TABLE 7.1. VALUE OF K FOR DIFFERENT ANGLES BETWEEN FUSION FACES

A fillet weld is not used for joining parts, if the angle between fusion faces is greater than
120˚ or less than 60˚.
iii.Effective length
The effective length of the weld is the length of the weld for which the specified size and
throat thickness i.e., correctly proportioned cross section of the weld, exist. It is taken as the
actual length minus twice the size of weld, since the specified size and throat thickness do not
exist at the ends. The effective length of the weld is shown on the drawings. In practice the
actual length of weld is made equal to the effective length shown on the drawing plus twice
the weld size. The effective length of fillet weld should not be less than four times the size of
the weld.
When the ends are returned as shown in Fig. 7.16, then the ends should be carried continuous
around the corners for distance not less than twice the size of weld. This should be applied
particularly to side and top fillet weld in tension.

iv.Effective area
The effective area of a fillet weld is taken as the product of effective length and effective
throat thickness.
7.5 WORKING STRESSES IN WELDS
Working stresses in welds, when welded joints are constructed with mild steel conforming to
IS:226-1962 as parent metal and with electrodes conforming to IS:814-1974 are adopted as
per Table 7.2 are recommended in IS:816-1969.
TABLE 7.2 WORKING STRESSES IN WELDS

The maximum permissible value of stresses of shear and tension are reduced to 80 per cent of
those given in Table 7.2, in case, the welding is done at site. When the effects of wind or
earthquake forces are considered, then, maximum permissible values of stresses are increased
by 25 per cent. It is to note that maximum permissible stresses given in the Table 7.2 are
same as for the parent metal (mild steel IS:226-1962).
7.6 DESIGN OF WELDED JOINTS SUBJECTED TO AXIAL LOAD
The complete penetration butt weld does not require design calculations. In case of
incomplete penetration butt weld, effective throat thickness of the weld is computed and
welding is done up to the required length. In case of fillet weld, size of the weld is fixed
keeping in view the minimum size of the weld as per IS:816-1969 recommends that when
filet weld is applied to the square edge of member, the maximum size of weld should be less
than the edge thickness by at least 1.5 mm as shown in Fig. 7.17. This avoids the washing
down of edges of weld. When fillet weld is applied to the round toe of rolled steel sections,
the maximum size of the weld should not exceed ¾ of the thickness of the section at the toe.
When fillet weld is used for lap joint, then overlap of the members connected as shown in
Fig. 7.17, should not be less than five times thickness of thinner part.

The strength of the fillet weld is determined per mm length for the size of the weld adopted.
The effective length of the weld is then computed for the pull or thrust to be transmitted by
the weld. In case, only side fillet welds are applied, the length of the each weld should not be
less than perpendicular distance between them and spacing between them shall not be more
than 16 times the thinner part.

Example 7.1. Two plates 16 mm thick are joined by i. a double U butt weld, ii. A single U
butt weld. Determine the strength of the welded joint in tension in each case. Effective length
of weld is 150 mm. Allowable stress in butt weld in tension is 142 N/mm2.
Solution
i.In case of double U but weld, complete penetration of weld takes place
Effective throat thickness of weld = 16 mm
Effective length of weld = 150 mm
Strength of single U butt weld = throat thickness x length of weld x permissible shear stress
= (16 x 150 x 142/1000) = 340.8 kN
ii.In case of single U butt weld, incomplete penetration of butt weld takes place
Effective throat thickness = 5/8 x 16 = 10 mm
Effective length of weld = 150 mm

Strength of single U butt weld = (10 x 150 x 142/1000) = 213.0 kN

 Example 7.2. In a truss girder of a bridge, a tie as shown in Fig. 7.18 is connected to the
gusset plate by fillet weld. Determine the strength of the weld. The size of the weld in the
fillet weld is 6 mm.

Solution
Size of weld = 6 mm
Effective throat thickness = 0.7 x 6 = 4.2 mm
Effective length of fillet weld = 200 + 200+ 200 = 600 mm
Strength of fillet weld = (4.2 x 600 x 110/1000) = 277.2 kN
Example 7.3. In Example 7.2, the pull to be transmitted by the tie is 300 kN. Determine the
necessary overlap of the tie.
Solution
Size of weld = 6 mm
Effective throat thickness = 4.2 mm
Pull transmitted by the end fillet weld = (4.2 x 200 x 110/1000) = 92.4 kN
Let l be the necessary overlap required, the pull transmitted by the side fillet is
= (4.2 x 2 x l x 110/1000) =
0.924 l kN
Total pull transmitted = 92.4 + 0.924 l = 300 kN
Therefore, the necessary overlap of the tie l = 224.7 mm.
Example 7.4. The web plate of a built-up welded I-section is 200 mm x 12 mm and the
flange plates are 100 mm x 12 mm. The size of fillet weld is 6 mm. Compute the maximum
shear force that may be allowed at any section, if the average allowable shear in the web is
0.4 fy and maximum allowable shear in the weld is 110 N/mm2.
Solution
Moment of inertia of the built-up section (about xx axis)
Ixx = 1/12[10 x 22.43 – 8.8 x 203] x 104 = 3499.52 x 104 mm4
Intensity of shear stress (at weld section)
Where,

The average shear stress in the web is 0.4 x 250 N/mm2.

Allowable shear force in the web F1=(200 x 12 x 0.4 x 250/1000) = 240 kN.
The design drawing is Fig. 7.19.
Example 7.5. Design a suitable longitudinal fillet weld to connect the plates as shown in Fig.
7.20 and to transmit a pull equal to the full strength of thin plate. Allowable stress in the weld
is 110 N/mm2 and tensile stress in the plate 0.6 fy N/mm2. The plates are 10 mm thick.

Solution
The minimum size of weld required for thickness up to 20 mm is 5 mm. The maximum size
of fillet weld is limited by the thickness of the plate is (10-1.5)=8.5 mm. Provide 6 mm fillet
weld.
Pull transmitted by 1 mm weld = (1 x 0.7 x 6 x 110/1000) = 0.462 kN
Tensile strength of thin plate = (120 x 10 x 0.6 x 250/1000) = 180 kN
Necessary length of the weld = (180 / 0.462) = 389.61 mm
Provide 195 mm longitudinal weld on each side.
Check: Length of the weld 195 mm is greater than perpendicular distance 120 mm
between welds
Example 7.6. Two plates 120 mm x 10 mm are overlapped and connected together by
transverse fillet weld to transmit pull equal to full strength of the plate. Design the suitable
welding. Allowable stress in the weld is 110 N/mm2. Allowable stress in tension in the plate is
0.6 fy N/mm2.
Solution
Minimum size of weld = 5mm
Maximum size of weld = (10-1.5) = 8.5 mm
Total length of two welds = 240 mm
Total load transmitted by 6 mm weld = (240 x 0.7 x 6 x 110/1000) = 110.88 kN
Maximum pull that can be transmitted by the plate = (120 x 10 x 0.6 x 250/1000) =180 kN
To transmit the pull equal to the full strength of plate, provide additional weld by plug
weld. Provide two rectangular plug welds 30 mm x 15 mm as shown in Fig. 7.21 which
satisfies the specification.
Strength of two plug welds = (2 x 30 x 15 x 110/1000) = 99 kN.
Total pull now transmitted = (110.88 + 99) = 209.88 kN > 180 kN. Hence
satisfactory.
Example 7.7. A tie member consists of two MC 225, @ 0.250 kN/m. The channels are
connected to either side of a gusset plate 12 mm thick. Design the welded joint to develop the
full strength of the tie. The overlap limited to 400 mm.
Solution
From ISI Handbook No. 1, for MC 225, @ 0.250 kN/m
Thickness of web = 6.4 mm
Thickness of flange = 12.4 mm
Sectional area = 3301 mm2
Tensile strength of each channel section = (3301 x 0.6 x 250/1000) = 495.15 kN
Provide 4 mm weld
Strength of weld per mm length = (1 x 0.7 x 4 x 110/1000) = 0.308 kN
Total length of fillet weld necessary to connect one channel section = (495.15/0.308)
= 1607.6 mm
The overlap of channe is limited to 400 mm. the width of slot should not be less than 3 times
thickness (3 x 6.4 = 19.2 mm). Provide two slots 20 mm side. The distance between edge of
the slot and edge of channel or between adjacent slots also should not be less than twice the
thickness (2x6.4=12.8 mm). Provide these distances as shown in Fig. 7.22. Let x be the
length of the slot.
The total length of the weld = 800 + 225 + 4x – 2x20 = 1607.6 mm
Therefore, the length of the slot x = 155.65 mm ≈ 160 mm long fillet welding is done as
shown in Fig. 7.22.