Welds

Lecture 33 Engineering 473 Machine Design

What is welding?
Welding is a fusion process, in which metal parts are heated to the melting point and fused together, usually with a filler of the same material melted along with the parent material.
Temperature control is the most important parameter associated with obtaining a good weld.

Haynes Welding Manual, 10445(2110)

Ancient Welding Processes

Welding was using in ancient (3,000 years ago) times by pouring molten metal into a cast located on another metal part. Sand casting is still used today.

Sand Cast

Arc Welding Instructions for the Beginner, Lincoln Arc Welding Foundation, Fig. 6

Modern Welding Processes

Oxy-acetylene Gas Welding Tungsten Inert Gas (TIG) or Gas Tungsten Arc Welding (GTAW) Metal Inert Gas (MIG) or Gas Metal Arc Welding (GMAW)

Arc Welding There are many welding processes. The ability to produce pure oxygen @1900 was important to the development of welding.

Arc Welding
Electric current flowing through a high resistance air gap generates an intense arc with temperatures ranging from 6,000 to 10,000 oF.

Arc welding is the most common method used with structural steel welding.
Arc Welding Instructions for the Beginner, Lincoln Arc Welding Foundation, Fig. 9&13

MIG or GMAW
Argon and CO2 are common inert gases used in the MIG process. A mixture of 75% Argon and 25% CO2 (C-25) is also very common.

Small commercial MIG welder.

www.hobartbrothers.com

Continuously fed filler wire makes MIG welding suited to high volume, machine assisted industrial welding applications.
Haynes Welding Manual, 10445(2110)

TIG or GTAW
The shielding gas in the TIG process is Helium. This gives rise to the term heli-arc welding. The TIG process is considered the most precise, most controllable, and cleanest method of welding. The TIG process can be used to make welds of great strength and quality in thin, light, and dissimilar materials.
Haynes Welding Manual, 10445(2110)

Soldering and Brazing

Soldering and brazing are common methods of joining two metals. Soldering and brazing are not welding processes because they do not melt the parent material. In soldering and brazing, the parent metal is heated and the the filler metal is melted into the joint where it cools. Lead based filler metals are used in soldering and brass based filler metals are used in brazing.

Filler Metals
Filler metal rods and wires are designated by a system established by the American Welding Society (AWS).

AWS Designation System Electrode E70XX Minimum yield strength Type of process of the completed weld (ksi). The static strength of a good weld is often higher than the base material. Position of the weld

Residual Stresses
The uneven heating and cooling in welding operations gives rise to significant residual stresses in the vicinity of the weld. The residual stresses may distort the part. The residual stresses and discontinuities in a weld have a significant influence on the fatigue life of a part. The fatigue life of a weld is often less than the base material. Residual stresses are influenced by the % carbon found in the material being joined. Residual stresses may be removed by annealing.

Butt Welds

Design Criteria

P Syp Lt N fs

Welds Loaded in Shear

Fillet Weld Geometry Real Surface Weld Throat Potential Shear Failure Planes Theoretical Surface

A s = cos 45 h L = 0.7071 h L

h
Deutschman, Fig. 17-5

Welds Loaded in Shear

(Continued)

Design Criteria two shear planes

Weld Shear Area

Sys P = 2A s N fs Sys 0.6Syt

Deutschman, Fig. 17-5

A s = cos 45 h L = 0.7071 h L

Assignment
Read sections 9-1 through 9-3 in Shigley. The figure shows a horizontal steel bar, 3/8 in thick, loaded in tension and welded to a vertical support. Find the load F that will cause a shear stress in the welds of 20 kpsi.

Assignment
(Continued) A 5/16 in steel bar is welded to a vertical support as shown. What is the shear stress in the welds if the force is F=32 kip?