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Chapter Objectives Welding was first used as a means of patching and re-
pairing. It was rarely employed as a means of fabricat-
ing pressure vessels, pipelines, and other structures such
After completing this chapter, you will be able to:
as buildings and bridges that would be a hazard to life
28-1 Describe the various types of weld joint designs. and property if they failed. As welding began to be used
28-2 Understand the implications of doing code welding. as a fabrication process, it became essential for welded
28-3 Describe various nondestructive weld test methods. joints to be strong enough to meet the service require-
28-4 Describe various destructive weld test methods. ments for which they were designed (fitness for purpose).
Methods for testing the quality of the weld, the ability of
28-5 Demonstrate the ability to do groove and fillet weld
the welder, as well as the ability of the inspector had to be
soundness tests.
devised.
28-6 Describe and conduct visual weld inspection.
For a long time it had been considered necessary only
28-7 Explain the various gauges used for weld inspection. to look at a completed weld in order to judge its quality
and the welder’s ability. If carried out by a competent
inspector and/or welder, visual inspection may be sat-
isfactory for welds that are designed primarily to hold
parts together and that are not subject to high stress in
service. This kind of inspection is limited since there
is no way of knowing if the weld metal has internal de-
fects. The outer appearance of the weld may be entirely
satisfactory, and yet it may be porous, contain cracks,
and lack both complete fusion and penetration. The
weld metal may have serious defects due to poor weld-
ing technique.
Critical welding demands that the weld metal and joint
be tested for strength, soundness, and other physical qual-
ities required in the design. The reliability of the welded
891
joint can be determined by the degree to which the weld
metal is kept free of foreign materials such as slag, poros-
ity, cracks, and by the degree to which it is fused to the
base material.
45°
0 to 3/16 1 May Be Less with Wider Root Opening.
3/8 60°
to 1
0 to 1/8
Single Bevel 1/2 to 2 0 to 1/8
0 to 3/16
60°
A
1/4 to 3/4
0 to 1/8
0 to 3/16
Single V B
Fig. 28-5 Proportions for single V-groove butt joints. Fig. 28-7 Double V-groove butt joint.
1 to 3/8 0 to 1/16
0 to 1/8 A
60°
1/8 to 3/8
1/4 to 3/4 B
0 to 1/8
A
welded from both sides (Fig. 28-11C), and on joints with a
backup strip (Fig. 28-11D), than on joints welded from one
side only (Fig. 28-11B). The joint is usually welded with
free-flowing electrodes.
B
B
Fig. 28-14 Double J-groove butt joint.
Fig. 28-12 Double U-groove butt joint.
are used on work similar to
that requiring U-groove butt
1/2R
joints, but when load con-
15° ditions are not as demand- Single Fillet
1/2
ing. The cost of preparation
to 11/2 A
1/8
is less since only one plate
0 to 1/16 edge must be prepared. Less
Single J filler metal is required to fill
A the groove. It is difficult to
secure good fusion and thor-
Double Fillet
ough penetration because of
B
the perpendicular wall of the
B square member. Fig. 28-15 Lap joints
with fillet welds.
Lap Joints
Lap joints are used frequently
on all kinds of work. There
C
is no plate preparation in-
volved. The single-fillet lap
joint (Fig. 28-15A), while not
as strong as the double-fillet
lap joint (Fig. 28-15B), is
D
more often used on noncode
Fig. 28-13 Single J-groove butt joints. work. Single-fillet lap joints
should not be used if the root
A
of the joint is to be subjected
are greater and welding can be done from both sides. to bending. In both cases fu-
Plate thicknesses range up to 3⁄4 inch. Although the cost of sion to the root of the joint is
preparation is greater than for single U-groove butt joints, necessary. The welder must
double joints may be welded with fewer electrodes. Weld- make sure that the edge of
ing from both sides permits a more even distribution of the upper plate is not burned
stress and reduces distortion. away. A lap joint should never
The choice between double-U and double V-groove replace the butt joint on work
butt joints should be made on the basis of the relative costs under severe load.
of metal preparation and welding. B
Slot and Plug Welds on a Lap
J-Groove Butt Joints Single J-groove butt joints, Joint The slot and plug weld Fig. 28-16 Slot and plug
Fig. 28-13, and double J-groove butt joints, Fig. 28-14, on a lap joint, Fig. 28-16, welds on lap joints.
Dim. T Dim. R
1/8 Max. O VI Double-V Groove Welds Welded from Both Sides
1/8 to 1/4 T/2 Max. 1/16 Max.
60° Min.
1/8 to 1/4
III Square Groove Welds Welded from One Side with Backing 60° Min.
T T R Min.
R Min.
10° to 15° *1/16 to 1/8
1/8 – 1/4 1/16 Max.
IV Single-V Groove Welds Welded from One or Both Sides VII Single-bevel Groove Welds Welded from
1/8 One or Both Sides
60° Min. 60° Min.
1/8 Max. Max. 45° Min. 1/16 Max. 45° Min.
1/16 Max.
1/16 Max. 60° 1/16 Max.
1/8 – 1/4
3/16
Min. 45° Min. 1/8
Fig. 28-23 Recommended dimensions of grooves for shielded metal arc welding, gas metal arc welding, and gas welding
(except pressure gas welding). Note: Dimensions marked * are exceptions that apply specifically to designs for gas metal arc
welding.
AWS D17.1 covers fusion welding for aerospace appli- it. The welder should, however, have a good understand-
cations. This specification represents the most signifi- ing of the different weld tests and know what to look for
cant change to aviation welding standards in more than in any visual inspection.
three decades and is being adopted by many aerospace There are two broad categories of welding tests. A
companies. It is being looked at to replace government- procedure qualification test is a test conducted for the
sponsored standards. The structural codes for steel, purpose of determining the correctness of the method
aluminum, stainless steel, and sheet metal, and specifi- of welding for a specific welding project. The American
cations for the welding of hygienic piping and aerospace Welding Society and various code authorities have es-
systems can be obtained through the American Welding tablished standard procedures for welding. The weld-
Society. ing procedure meets specifications for base metal filler
The welder does not have to be thoroughly informed metal, joint preparation, position of welding, the weld-
about the details of all the existing codes. The employer, ing process, and welding techniques. Such requirements
through the engineering and production departments, as current setting, electrode size, electrode manipulation
makes sure that the work meets the standards required for and preheat, interpass, and postheat temperatures are