Weld design integrity Approach: 1.

Firstly, a suitable joint preparation will be selected from BS EN ISO 9692 1, based on material thickness and recommended welding process (MMA, TIG or MIG). 2. Area of this edge will then be calculated and the load (F1) acting on this joint as a result of the operating pressure will be computed as well. 3. Finally, based on the design strength determined from the working temperature, the allowable load (F2) will be computed, and F1 & F2 will be compared. Designer must then ensure that F1 < F2. 4. Properties of the welding consumable will be taken into consideration, before a suitable type is selected. Common weld types: Fillet weld Butt weld Single V-butt preparation Square preparation

Area calculation: 1. Fillet weld:

a Throat thickness s Leg length l Weld length

Method 1: Minimum area for fillet weld, is measured by multiplying throat thickness a, by the length of the weld. To measure throat thickness, an assumption is made that the weld is symmetrical, thus an angle of 450 on each side. Therefore, a Area = sin 450 x s = 0.7071 x s x l

Method 2: In reality, chances are that the weld will not be symmetrical. Hence the weld area will be computed from: Area = (s1 x s2)/2

2. Butt welds: Square edge:

Area = a x t or t x l Where: t Plate thickness a Root gap l Weld length or plate length

V- Edge preparation: Area for a V-edge, is calculated by splitting the shape into individual sections, the area of each section is found and then summed up. An example is detailed below; Example: Design conditions: Operating pressure: 1.5bar 0.15N/mm2 Welding consumable type: BHLER FOX EV 50, tensile strength @ room temperature 560 MPa. Edge preparation details: Thickness, t Root gap, b Root face, c Weld cap height, h Included angle, Bevelled angle Edge area: = 8mm = 3mm = 4mm = 2mm = 600 = 300

Area 1: Root gap x material thickness = (3 x 8) mm2 = 24mm2 Area 2: Base of triangle = (Tan 300 x 4) mm = 2.31mm Area of one triangle = x 2.31 x 4 = 4.62 mm2 Total area of the two triangles = (2 x 4.62) mm2 = 9.24 mm2

Area 3: Width of weld cap, w = 2 (tan 300 x 8) + 3 = 12.24mm Area of weld cap = (12.24 x 2)/2 = 12.24 mm2 Total area: Area 1 + Area 2 + Area 3 = 24 + 9.24 + 12.24 = 45.48 mm2 Result analysis: a. Load on joint (F), as a result of operating pressure: = 0.15 x 45.48 = 6.822 N b. Assume a design strength of 112.4 N/mm2 at an elevated temperature, the allowable load on joint will be: = 112.4 x 45.48 = 5112 N