Designing Weldments

Ramesh Singh, MS, IEng, MWeldI, is registered as an Incorporated Engineer with the British Engineering Council UK and a Member of The Welding Institute, UK. He worked as an engineer for various operating and EPC organizations in the Middle East, Canada, and the US. Most recently, he worked for 10 years with Gulf Interstate Engineering, Houston, TX. He is now consulting in the field of welding, corrosion engineering, pipeline integrity, and related materials and corrosion topics. Ramesh is a graduate of the Indian Air Force Technical Academy, with diplomas in Structural Fabrication Engineering and Welding Technology. He has been a member and officer of the Canadian Standard Association and NACE and serves on several technical committees. He has worked in industries spanning aeronautical, alloy steel castings, fabrication, machining, welding engineering, petrochemical, and oil and gas. He has written several technical papers and published articles in leading industry magazines, addressing the practical aspects of welding, construction, and corrosion issues relating to structures, equipment, and pipelines. He recently authored Welding Processes Handbook (Wiley-Scrivener, 2021).

• List of Figures xiList of Tables xvForeword xviiPreface xix1 Properties and Strength of Material 11.1 Introduction 12 Properties of Metals 32.1 Material Properties 32.1.1 Structure Insensitive Properties 42.1.2 Structure Sensitive Properties 42.1.3 Mechanical Properties 52.1.3.1 Modulus of Elasticity 52.1.3.2 Tensile Strength 62.1.3.3 Yield Strength 72.1.3.4 Fatigue Strength 72.1.3.5 Ductility 82.1.3.6 Elastic Limit 92.1.3.7 Impact Strength 102.1.3.8 Energy Absorption in Impact Testing 102.1.3.9 Transition Temperature for Energy Absorption 112.1.3.10 Transition Temperature for Lateral Expansion 112.1.3.11 Drop-Weight Tear Test (DWTT) 112.1.3.12 Fracture Toughness 112.1.4 Low Temperature Properties 142.1.4.1 Metal Strength at Low Temperature 162.1.5 Elevated Temperature Properties 162.1.6 Physical Properties 172.1.6.1 Thermal Conductivity 172.1.6.2 Coefficient of Thermal Expansion 172.1.6.3 Melting Point 172.1.7 Electrical Conductivity 182.1.8 Corrosion Properties 183 Design: Load Conditions 193.1 Design of Welds 193.2 Design by Calculations 203.2.1 Different Types of Loading 213.2.2 Tension 233.2.3 Compression 243.2.4 Bending 253.2.5 Shear 283.2.6 Torsion 293.2.7 Flat Sections 313.2.8 Round Cross Sectionals 323.2.9 Transfer of Forces 334 Design of Welds and Weldments 354.1 Introduction 354.1.1 Structural Types that Affect Weld Design 384.2 Full Penetration Welds 384.3 Partial Penetration Welds 394.4 Groove Welds 394.4.1 Definitions of Terms Applicable to Groove Welds 394.4.1.1 Effective Length 404.4.1.2 Effective Size of CJP Groove Welds 404.4.1.3 Effective Weld Size (Flare Groove) 404.4.1.4 Effective Area of Groove Welds 404.5 Weld Grooves 424.5.1 Square Groove Welds 424.5.2 Single Bevel Groove Welds 434.5.3 Double Bevel Groove Weld 434.5.4 Single-V-Groove Weld 434.5.5 Double-V-Groove Welds 444.5.6 Single or Double-J-Groove Weld 444.5.7 Single or Double-U-Groove Weld 444.6 Fillet Welds 444.6.1 Definitions Applicable to Fillet Welds 454.6.1.1 Effective Length (Straight) 454.6.1.2 Effective Length (Curved) 454.6.1.3 Minimum Length 454.6.1.4 Intermittent Fillet Welds (Minimum Length) 454.6.1.5 Maximum Effective Length 454.6.1.6 Calculation of Effective Throat 454.6.1.7 Reinforcing Fillet Welds 464.6.1.8 Maximum Weld Size in Lap Joints 464.6.1.9 Effective Area of Fillet Welds 464.7 About Fillet Weld 464.7.1 Filet Weld Defined and Explained 474.7.1.1 Single Fillet Welds 524.7.1.2 Double Fillet Welds 524.7.1.3 Combined Groove and Fillet Welds 524.8 Weld Design and Loading 544.8.1 Common Conditions to Consider When Designing Welded Connections 554.8.2 Marking the Fabrication and Construction Drawings 554.8.3 Effective Areas 574.8.4 Effective Area of Groove Welds 574.9 Sizing Fillet Welds 594.9.1 Effective Length of Straight Fillet Welds 594.9.2 The Determination of Effective Throat of a Fillet Weld 594.9.2.1 Fillet Welds Joining Perpendicular Members 594.9.2.2 Fillet Weld in Acute Angle 604.9.2.3 Fillet Welds That Make Angle Between 60 o and 80 o 604.9.2.4 Fillet Welds That Make Acute Angle Between 60 o and 30 o 614.9.2.5 Reinforcing Fillet Welds 614.9.3 Fillet Welds - Minimum Size 614.9.4 Maximum Weld Size in Lap Joints 624.9.5 Skewed T-Joints 634.9.5.1 T–Joint Welds in Acute Angles Between 80° and 60° and in Obtuse Angles Greater Than 100° 634.9.5.2 T-Joint Welds in Angles Between 60° and 30° 634.9.5.3 T-Joint Welds in Angles Less than 30° 634.9.5.4 Effective Length of Skewed T-Joints 644.9.5.5 Effective Throat of Skewed T-Joints 644.9.5.6 Effective Area of Skewed T-Joints 644.10 Fillet Welds in Holes and Slots 644.10.1 Slot Ends 644.10.2 Effective Length of Fillet Welds in Holes or Slots 644.10.3 Effective Area of Fillet Welds in Holes or Slots 644.10.4 Diameter and Width Limitations 644.10.5 Slot Length and Shape 654.10.6 Effective Area of Plug and Slot Welds 654.11 Designing Calculations for Skewed Fillet Weld 654.12 Treating Weld as a Line 664.12.1 Calculation Approach 674.12.2 Finding the Size of the Weld 674.12.3 Calculated Stresses 734.12.4 Stress in Fillet Welds 734.12.5 Joint Configuration and Details 744.12.6 Compression Member Connections and Splices 754.12.7 Where There is an Issue of Through-Thickness Loading on the Base Plate 754.12.8 Determining the Capacity of Combinations of Welds 754.12.9 Corner and T-Joint Surface Contouring 754.12.10 Weld Access Holes 754.12.11 Welds with Rivets or Bolts 764.12.12 Joint Configuration and Details 764.12.12.1 Groove Welds - Transitions in Thicknesses and Widths 764.12.12.2 Partial Length CJP Groove Weld Prohibition 764.12.12.3 Flare Welds, Flare Groove and Intermittent PJP Groove Welds 764.12.12.4 Joint Configuration and Details 774.12.12.5 Termination of Fillet Welds 774.12.12.6 Fillet Welds in Holes and Slots 784.13 Design of Tubular Connections 804.13.1 Weld Joint Design 824.13.2 Uneven Distribution of Load 884.13.3 Collapse 914.13.4 Lamellar Tear and Lamination 914.13.5 Fatigue 924.14 Design for Cyclic Loading 934.14.1 Improving Fatigue Performance of Welds, and Evaluation of S-N Curves for Design 1054.14.1.1 Typical Weld Flushing Plan 1074.15 Aluminum 1074.15.1 Aluminum Alloys and Their Characteristics 1084.15.1.1 Aluminum Alloys Series 1xxx 1084.15.1.2 Aluminum Alloy Series 2xxx 1094.15.1.3 Aluminum Alloy Series 3xxx 1094.15.1.4 Aluminum Alloy Series 4xxx 1094.15.1.5 Aluminum Alloy Series 5xxx 1094.15.1.6 Aluminum Alloy Series 6xxx 1104.15.1.7 Aluminum Alloy Series 7xxx 1104.15.2 The Aluminum Alloy Temper and Designation System 1104.15.3 Wrought Alloy Designation System 1114.15.4 Cast Alloy Designation 1114.15.5 The Aluminum Temper Designation System 1124.16 Welding Aluminum 1144.16.1 Aluminum Welding Electrodes 1154.16.2 Electrical Parameters 1154.17 Design for Welding Aluminum 1164.17.1 Effect of Welding on the Strength of Aluminum and its Alloys 1174.17.2 Effect of Service Temperature 1194.17.3 Type of Weld Joints for Aluminum Welding 1204.17.3.1 Butt Joints 1204.17.4 Lap Joint for Aluminum Welding 1214.17.5 Use of T-Joints in Aluminum Welding 1214.18 Distribution of Stress in Aluminum Weld Design 1224.18.1 Shear Strength of Aluminum Fillet Welds 1234.18.2 Fatigue Strength in Aluminum Welds 1234.19 Heat and Distortion Control 1244.19.1 Angular Distortion 1254.19.2 Longitudinal Distortions 1265 Introduction to Welding Processes 1315.1 Introduction 1315.2 Shielded Metal Arc Welding (SMAW) 1345.3 Gas Tungsten Arc Welding 1395.4 Gas Metal Arc Welding 1425.5 Flux Cored Arc Welding (FCAW) 1455.6 Submerged Arc Welding (SAW) 1455.7 Electroslag Welding (ESW) 1465.8 Plasma Arc Welding 1465.9 Stud Welding 1465.10 Oxyfuel Gas Welding 1475.11 Hyperbaric Welding 1525.12 Application of Welding Processes 1536 Welding Symbols 1556.1 Introduction 1556.2 Common Weld Symbols and Their Meanings 1566.2.1 The Basic Structure of Welding Symbol 1566.2.2 Types of Welds and Their Symbols 1576.3 Fillet Welds 1586.3.1 The Length of the Fillet Weld 1596.4 Groove Welds 1606.4.1 Square Groove Welds 1616.4.2 V-Groove Welds 1616.5 Bevel Groove Welds 1626.5.1 U-Groove Welds 1636.5.2 J-Groove Welds 1636.5.3 Flare-V Groove Welds 1646.5.4 Flare Bevel Groove Weld 1646.6 Plug and Slot Welds 1667 Structural Design and Welding Specifications, and Other Useful Information 1697.1 Introduction 1697.2 Structural Welding Codes 1697.3 Useful Engineering Information 174Index 201