Module: Steel Structure (H23 S07)

Connection Design - Weld

-Types of weld process
-Types of weld defects
-Types of weld inspections
-Types of weld connections
-Weld design
-Work examples

Module: Steel Structure (H23 S07)

Types of Weld Processes

-Manual metal arc (MMA) welding
-Gas shielded welding
-Submerge arc welding
-Electro-slag welding

Module: Steel Structure (H23 S07)

Manual metal arc (MMA) welding

Electrode is hand held and manually
feed into the weld pool.
Electrode is flux (as fuel) coated to
electrodes.

Advantages:
Flexible reach all weld positions.
Commonly used Not rear.
Minimum setup duration.

Disadvantages:
Quality of welding closely depends on welders skills.
High pay required for good welders, hence, expensive process.

Module: Steel Structure (H23 S07)

Gas Shield Welding

Also, known as Metal Active Gas (MAG),
CO2 or Metal Inverted Gas (MIG).
Electrode (no flux coated), weld arc, and
weld pool are protected by gas shield.
Electrode from drum, shielding gas
(CO2), electric current, are all
automatically control-led.
Advantages:
Can be fully or semi automated.
High deposition rates - economical.
With stable current pulsed current, weld quality comparable with MMA.
Disadvantages:
Reliance on current stability pulsed current.

Module: Steel Structure (H23 S07)

Submerged Arc Welding

Entire arc is submerged within the
granular flux, high current can be used
without danger of air entrainment.
Generally fully automatic.
Advantages:
- Depositions rate are considerably higher
than MMA or Gas shield method. Can be
further increased by the use of more than
one electrode wire for the same weld pool.
- No reliance of manipulative skills, hence,
high weld quality can be achieved. High
current ensure for greater penetrations
and consistencies.
Disadvantages:
- Granular flux limiting the weld application to flat surfaces.
- At very high deposition rates, weld metal with low toughness may be produced
due to low cooling rates lead to large-grain micro-structure.

Module: Steel Structure (H23 S07)

Electro-slag Welding
Automatic process for butt
weld of thick plates in vertical
or nearly position. The flux is
conduct in molten state.

Advantages:
-No preparations are required on
plates.
-Plates can be cut square.
-Plates can be positioned
vertically and with gap of 30mm.
Disadvantages:
- With high heat input and large weld volume, therefore cooling rates are low,
thus coarse grain micro-structure with poor fracture toughness are produced.
Required post weld heat treatment to rectify.

Module: Steel Structure (H23 S07)

Types of Weld Defects

-Under cuts
-Slag inclusion
-Incomplete penetration
-Lack of fusion
-Heat affected zone or cold cracking
-Weld metal solidification or hot cracking
-Lamellar tear

Module: Steel Structure (H23 S07)

Under cuts
Too much parent metal wash into the weld pool, or some
disturbance of the pool preventing deposition at that point.
Disturbance might due too high a current, producing
turbulence in the weld pool. Also, with large single run of
weld metal would creating a large weld pool, where metal
tends to sway away from the vertical plate.

Slag inclusions
Non metallic particles derived from the flux trapped
by the weld pool. If their cross section & length is
large, they would influence the strength of the weld.
They can arise in multi-passes weld and in
conjunction with inadequate cleaning between
passes. Alternatively, they can occur in the weld
root as a result of too narrow a root gap.

Module: Steel Structure (H23 S07)

Incomplete penetration
This can occur either at root or, more rarely,
between passes of welds. It can be cause by too low
a current or to inclined an electrode angle, giving
insufficient concentration of energy into the weld
pool. For these reason it is more common with
manual welding, and less of problem with
submerged arc welding due to higher currents.

Lack of fusion
This defect is less extreme form of lack of
penetration. There are no voids left in the weld
metal but the individual runs have not entirely
fused. This can be caused by milder forms of the
same shortcomings that lead to lack of penetration,
and may also be result of contamination by rust or
mill scale of the joint surface.

Module: Steel Structure (H23 S07)

Heat affected zone (HAZ) or cold cracking

Present of hydrogen in the weld arc, at high
temperatures, both the weld metal & HAZ dissolve
significant amount of hydrogen that is available. As
temperature drops, the solubility of the hydrogen
diminishes and concentrations of gas build up in
microscopic voids with very high pressure. The weld
metal can accommodates this with its ductility and
toughness, but HAZ has became too brittle hence
cracks will develop.

Weld metal solidification or hot cracking

This defect usually forms a longitudinal crack
down the centre of the weld, and formed shortly
after the metal solidified. Usually caused by
impurities in weld pool. Since most impurities have
lower melting points than steel, and due to central
portion is the last to solidify, they can be collected
in this region and form semi-continuous films of
segregations along the grain boundaries. These
segregations become wider as temperature drops
causing weld metal to contract further.

Module: Steel Structure (H23 S07)

Lamellar tearing
This defect derives from the presence of impurities
during rolling process of the parent steel. These
impurities were elongated into disc-shape elements
forming layers of segregations which may reduce the
strength in the lateral directions. With significant
strains inducing from weld shrinkage, lamellar
tearing be resulted.

Module: Steel Structure (H23 S07)

Types of Weld Inspections

-Magnetic particle inspection (MPI)
-X-ray and gamma ray radiography
-Ultrasonic inspection

Module: Steel Structure (H23 S07)

Magnetic Particle Inspection (MPI)

Monitor the leakage in magnetic flux that occurs
in presence of any surface or near surface
defects when parent metal is magnetized.
Magnetized powder or ink will be drawn to any
leakage of magnetic flux , thus highlighting the
defects. A range of flux directions should be
used to because cracks will only show up if they
cut across the flux lines.

X-ray and gamma x-ray radiography

Electromagnetic radiation pass more readily
through substances of lower those of higher
density. Thus there will be a higher emission in
regions of defects. These variations can be
recorded by means of photographic film.

Module: Steel Structure (H23 S07)

Ultrasonic Inspection
Base on the reflectivity of ultrasonic waves. Measures the time taken of
returning pulse echo by receiver. Shorter returning will be noted in the
presence of defects. This method allow for search of internal defects in wide
variety of joints, thus can detect most of the common defects found in welding.
But rely on skill and integrity of the operator, as no permanent records.

Module: Steel Structure (H23 S07)

Welding Symbols

Module: Steel Structure (H23 S07)

Welding Symbols

Module: Steel Structure (H23 S07)

Welding Symbols

Module: Steel Structure (H23 S07)

Welding Symbols

Module: Steel Structure (H23 S07)

Design Basis

Module: Steel Structure (H23 S07)

Design Basis

Module: Steel Structure (H23 S07)

Design Basis

Module: Steel Structure (H23 S07)

Example 1
Consider an outstand plate welded to a base plate that is subjected to a horizontal
force, FEd. If the welding is fillet weld having throat size, a5, on both sides of the
outstand, determine what is the maximum allowable, FEd.
a5
a5

75
S2

FEd
S35
5

0
30

mm

Module: Steel Structure (H23 S07)

Example 1
75
S2

Design Shear Strength of Fillet Weld;

Eqn (4.4 ) f vw,d =

fu

w m2

a5
a5

=
FEd

Design Shear Resistance of Fillet Weld per unit length;

Eqn (4.3 ) Fw,Rd = f vw,d a =

S35
5

0
30

mm

Effective weld length;

Cl. 4.5.1 L w,eff =
Ultimate Allowable Shear Resistance ;
Fult, w, Rd =

Module: Steel Structure (H23 S07)

Example 2
Consider an outstand plate welded to a base plate that is subjected to a horizontal
force, FEd. If the welding is fillet weld having throat size, a5, looped both sides of
the outstand, determine what is the maximum allowable, FEd.
a5
a5

55
S3

FEd
0
30

S35
5

mm

Module: Steel Structure (H23 S07)

a5

Example 2
Eqn (4.4 ) f vw,d =

fu

w m2

FEd

S35
5

Design Shear Resistance of Fillet Weld per unit length;

Eqn (4.3 ) Fw,Rd = f vw,d a =

a5

55
S3

Design Shear Strength of Fillet Weld;

0
30

mm

261.732 N mm 2 5 mm = 1308.66 N mm

Effective weld length;

Cl. 4.5.1 L w,eff =
Ultimate Allowable Shear Resistance;
Fult, w, Rd = 2 Fw,Rd L w,eff
= 2 1308.66 N mm 300 mm
= 785.196 kN.

Module: Steel Structure (H23 S07)

Example 3
Consider an outstand Ibeam welded to an end plate and is subjected to a
moment, MEd = 30 kNm. If the welding is fillet weld having throat size, a3, looped
around the Ibeam, check the suitability of the welds.
a3
55
S3

S355

MEd
100
10
100

Module: Steel Structure (H23 S07)

100

Example 3

10

Moment of Inertia, Ibeam & I weld ;

bd 3
Ibeam =
12

bd 3
-
12

100 100 3
=

12
j

bd 3
=
12

bd 3
-
12

Ibeam =

I weld

90 80 3
-
12

= 4.493 10 6 mm 4

I Beam

Moment induce normal stress in weld, ;

Design resistance of fillet weld;

Eqn (4.1) 2 + 3 2 + II 2

106

16

M
= Ed y =
I weld

100

10

fu

+ 3 2 + II 2

( w m2 ) =

or

0.9 fu

510

m2

)]

0 .5

16

)]

0.5

fu

( w m 2 ) or

(0.9 1.25) = 453 N/mm

= 0.9 510

1.25

(OK)

= 367.2 N/mm 2 (OK)

0.9 f u

m2

106

Welds around I beam