GOVERNMENT POLYTECHNIC, NANDED

MICRO PROJECT

Academic Year : 2024-2025

TITLE OF THE PROJECT

Prepare a report &Model of

Fillet weld

Program: Civil Engineering Program code:CE5I(A)

Course : Design of steel and RCC structure
Course Code :22502

Name of Guide: Dr. S. M. Dumne

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 MAHARASHTRA STATE
BOARD OF TECHNICAL EDUCATION

Certificate
This is to certify that Mr. Ruturaj Chavan, Manthan More, Nagesh Potjale, Roll No. 1327 ,

1334 , 1337 of 5th Semester of Diploma in Civil Engineering of Institute, GOVERNMENT

POLYTECHNIC, NANDED (0020) has completed the Micro Project satisfactorily in Subject-

Design of steel & RCC Structure (22502) for the academic year 2024-25 as prescribed in the

curriculum.

Place : Nanded

Date : 25/11/2024
Exam Seat No. 367245, 367252 , 367257

Subject Teacher Head of the Department Principal

Dr. S. M. Dumne L. T. Jadhav Dr.N.L.Janrao

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 ANEEXURE l
Evaluation Sheet for the Micro Project

Academic Year : 2024-25. Name of the Faculty: Dr.S.M.Dumne

Course: DSR Course Code: 22502 Semester: V

Title of the Project: - Prepare a report & model on Fillet weld.

Cos address by Micro Project:
A: Formulate grammatically correct sentences.
B: Give presentation by using audio visual aids.
C: communication skillfully.
D: write reports using correct guidelines.

Major learning outcomes achieved by the students by doing the project.

(A) Practical outcome:

1) Deliver presentation (seminar) effective.
(B) Unit outcomes in Cognitive domain.
1) Prepare the points for computer presentation.

2) Make seminar presentation.

Outcomes in affective domain:
(C)
1) Function as team member.
2) Follow Ethics.
3) Make proper use of computer and Internet.
Comment /suggestions about team work/leadership/inter-personal communication (if any)
……………………………………………………………………………………………………
Roll No. Student Name Marks out of 6 for Marks out of 4 for Total out
performance in group performance in of 10
activity oral/presentation
(D5 Col.8) (D5 Col.9)
1327 Ruturaj Chavan
1334 Manthan More
1337 Nagesh Potjale

(Signature of Faculty)
…………………

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 WEEKLY PROGRESS REPORT
TITLE OF THE MICRO PROJECT:-

“Prepare a report & model of Fillet

weld”
WEEK ACTIVITY PERFORMED SIGN OF DATE
GUIDE
1st Discussion and finalization of Topic 14/08/2024
2ND Discussion and finalization of Topic 28/08/2024
3RD Preparation and submission of Abstract 09/09/2024
4TH Literature Review 16/09/2024
5TH Collection of Data 20/09/2024
6TH Collection of Data 27/09/2024
7TH Collection of Data 06/10/2024
8TH Collection of Data 12/10/2024
9TH Discussion and Outline of Content 20/10/2024
10TH Formulation of Content 26/10/2024
11TH Editing and 1st proof Reading of Content 30/10/2024
12TH Editing and 2nd Reading of Content 04/11/2024
13TH Compilation of Report and Presentation 11/11/2024
14TH Seminar 18/11/2024
15TH Viva-voce 24/11/2024
16TH Final submission of Micro project 25/11/2024

Sign of the Students Sign of the Faculty

Roll Sign

no.

1327

1334

1337

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 INDEX

Sr. Chapter/Title Page

No. No.
01. Introduction 07.
02. Applications of Fillet welds 08.
03. Advantages 09.
04. Disadvantages 10.
05. Types of fillet welds 11.
06. Welding procedure 12.
07. Factors affecting Fillet weld 13.
Quality
08. Types of fillet weld failure 14.
09. Uses of fillet weld 15.
10. Sample Calculation of Fillet weld 16.
Model
11. Conclusion 18.
12. Reference 18.

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 Acknowledgment

I would like to express my special thanks of gratitude to my teacher Dr. G.D.

Awachat sir who gave me the golden opportunity to do this wonderful project on
the topic, Fillet weld. which also helped me in doinga lot of Research and i came to
know about so many new things I am really thankful to them. Secondly I would
also like to thank my friends who helped me a lot in finalizing this project within
the limited time frame.

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Introduction

A fillet weld is a triangular-shaped weld joint commonly used to join

two metal surfaces at a right angle. This welding technique is widely
used in the fabrication of structural steel, piping systems, and other
metal structures. This micro project focuses on understanding the basics
of fillet welds, the types, applications, and how quality control is
performed.

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Applications of Fillet Welds
1. Structural Steel Fabrication:
o Used in the construction of buildings, bridges, and towers.

o Fillet welds are ideal for joining beams, columns, and braces.

2. Piping Systems:
o Commonly used in plumbing, oil and gas pipelines, and

HVAC systems.
o Fillet welds provide quick and secure joints for cylindrical

sections.
3. Automotive Industry:
o Used in the manufacture of frames, bodies, and exhaust

systems.

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ADVANTAGES
1. Simplicity of Setup and Application
o Fillet welds do not require beveling or extensive edge

preparation, which reduces setup time and costs.

2. Versatile in Joint Types and Positions
o Fillet welds can join various joint types, such as T-joints, lap

joints, and corner joints, making them suitable for diverse

applications in structural and fabrication work.
3. No Special Tools Required
o Basic welding tools are typically sufficient for performing

fillet welds, making it accessible for general welding tasks.

4. Strength and Durability
o When executed correctly, fillet welds provide strong and

durable joints that can support significant loads.

5. Cost-Effective
o Fillet welds are generally more cost-effective than full

penetration welds, as they require less filler material and time

to complete.

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DISADVANTAGES
1. Lower Strength than Full Penetration Welds
o Fillet welds may not provide the same level of strength as full

penetration welds, which may be a limitation in critical load-

bearing structures.
2. Limited Penetration
o The depth of penetration in fillet welds is limited, which may

result in weaker joints, especially under dynamic loads or

impact forces.
3. Higher Risk of Weld Defects
o Common defects, such as lack of fusion, undercutting, or

porosity, can occur more frequently in fillet welds due to the

joint configuration and welding position.
4. Stress Concentration
o Fillet welds can create stress concentration points, especially

if not executed properly, leading to potential failure points

under cyclic or impact loading.
5. Difficulties in Inspection
o Visual inspection of fillet welds can be challenging due to the

joint’s geometry, and non-destructive testing (NDT) may be

required for quality assurance, increasing inspection time and
cost.

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Types of Fillet Welds
1. Concave Fillet Weld:
o The weld bead is slightly curved inward.

o Advantages: Provides better stress distribution.

o Disadvantages: Potential for incomplete fusion.

2. Convex Fillet Weld:

o The weld bead is slightly bulged outward.

o Advantages: Stronger appearance.

o Disadvantages: More prone to stress concentration.

3. Miter Fillet Weld:

o The weld face forms a straight line between the two

workpieces.
o Advantages: Good appearance and easy to produce.

o Disadvantages: Less penetration compared to other types.

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Welding Procedure
The steps involved in making a fillet weld are as follows:
1. Preparation of Metal Surfaces:
o Clean the metal surfaces to remove any contaminants like rust,

grease, or paint.
o Align the workpieces to maintain a proper right-angle joint.

2. Welding Process:
o Use appropriate welding techniques like Shielded Metal Arc

Welding (SMAW), Gas Metal Arc Welding (GMAW), or

Flux-Cored Arc Welding (FCAW).
o Select the correct electrode or filler material depending on the

base metal.
3. Weld Execution:
o The weld should start from one end of the joint and proceed

steadily with controlled heat input to avoid defects like

undercutting or excessive distortion.
4. Inspection and Quality Control:
o Visual inspection to check for uniformity and defects.

o Non-destructive testing (NDT) methods like ultrasonic testing

(UT) or magnetic particle inspection (MPI) can be used to

ensure weld quality.

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Factors Affecting Fillet Weld Quality
1. Welding Parameters:
o Current, voltage, and travel speed directly impact the quality

of the weld.
o Higher currents may result in deeper penetration, but

excessive heat can lead to warping.

2. Material Properties:
o The base material's thickness, composition, and thermal

properties influence how the weld forms.

3. Weld Position:
o The orientation of the joint (flat, horizontal, vertical, or

overhead) affects weld quality. Vertical and overhead

positions are more difficult to weld.
4. Weld Size:
o The correct weld size is essential for the strength and

durability of the joint. Undersized welds may fail under load,

while oversized welds waste material and time

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Types of Fillet Weld Failures
1. Shear Failure
o Description: Shear failure occurs when the weld cannot

withstand the shearing forces acting parallel to the weld axis.

o Causes: Often due to undersized welds, poor welding

technique, or inadequate weld throat thickness.

o Result: Weld separation, which may lead to structural

instability, particularly in load-bearing joints.

2. Tensile or Pull Failure
o Description: The weld joint fails when subjected to forces

pulling perpendicular to the weld.

o Causes: Inadequate weld size, poor filler material selection,

or excessive tension forces.

o Result: Fracture of the weld metal or base material, leading to

joint failure.
3. Fatigue Failure
o Description: Occurs over time under repeated cyclic loading,

especially at stress concentration points.

o Causes: Fillet welds create stress concentrations at the weld

toe, which can lead to crack initiation and propagation.

o Result: Progressive cracking and eventual weld failure,

common in structures exposed to cyclic loads, such as bridges

and machinery.

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Uses of fillet weld
Fillet welds are widely used in construction, fabrication, and repair due
to their versatility and ease of application. Here are some common uses:
1. Joining Metal Parts at Right Angles: Fillet welds are ideal for
connecting two pieces at a 90-degree angle, such as in T-joints, lap
joints, and corner joints, making them useful in structural
applications, frames, and support structures.
2. Strengthening Connections: These welds add strength to joints
without requiring precision cuts, as they fill in gaps between metal
pieces. This feature is essential in load-bearing structures,
especially in building frames and heavy equipment.
3. Sealing Joints: Fillet welds are often used to seal joints and
prevent leakage. This application is common in tanks, pressure
vessels, and piping systems where airtight and watertight seals are
critical.
4. Reinforcing Weak Points: By applying fillet welds to stress
points, such as the base of a welded connection, engineers can
reinforce areas that may experience high tension or stress, reducing
the risk of material fatigue.
5. Joining Dissimilar Metals: Fillet welds can join metals of varying
thicknesses and types, providing a flexible solution when working
with different materials, such as in automotive and shipbuilding
industries.

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Sample Calculation of Fillet weld Model

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Model Image

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 ❖ Conclusion

Fillet welds are an essential and versatile type of weld used in various
industries. The quality of a fillet weld depends on proper technique,
material preparation, and careful execution. Ensuring the correct weld
size, controlling welding parameters, and conducting thorough
inspections are crucial for producing a reliable and durable weld. This
micro project helped understand the practical aspects of fillet welds and
how their quality is maintained through industry standards and
procedures.

❖ Referances :-
➢ Books:-
i. Design of Steel & RCC Structure (22502)
➢ Websites: -
i. www.google.com
ii. www.chatgpt.com

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