Chapter 9

ME 307: Machine Design I
Mohiuddin, M. Taher Chapter9: Welding, Bonding, and the Design of Permanent Joints CH-9 LEC 40 Slide 1
Mohiuddin, M. Taher Chapter9: Welding, Bonding, and the Design of Permanent Joints
Introduction
Welding is the process of joining two pieces of
metal together by hammering, pressure or fusion.

Filler metal may or may not be used.
The strongest and most common method of

permanently joining steel components together.
Arc welding is the most important since it is

adaptable to various manufacturing environments
and is relatively cheap.
A weldment is fabricated by welding together a

collection of metal shapes.
Introduction
A pool of molten metal in which the components
and electrode material coalesce, forming a
homogeneous whole (ideally) when the pool later
re-solidifies.
The materials of components and electrode must be

compatible from the point of view of strength,
ductility and metallurgy.
Welded joints and their advantages:
Welding is a very commonly used permanent joining process.

Thanks to great advancement in welding technology, it has
secured a prominent place in manufacturing machine
components.
A welded joint has following advantages:
(i) Compared to other type of joints, the welded joint has
higher efficiency. An efficiency > 95 % is easily possible.
(ii) Since the added material is minimum, the joint has
lighter weight.
(iii) Welded joints have smooth appearances.
(iv) Due to flexibility in the welding procedure, alteration
and addition are possible.
(v) It is less expensive.
(vi) Forming a joint in difficult locations is possible through
welding.
Mohiuddin, M Taher Chapter9: Welding, Bonding, and the Design of Permanent Joints CH-9 LEC 40 Slide 5
Applications
The advantages have made welding suitable for
joining components in various machines and

structures. Some typically welded machine
components are listed below.
Pressure vessels, steel structures.
Flanges welded to shafts and axles.
Crank shafts
Heavy hydraulic turbine shafts
Large gears, pulleys, flywheels
Gear housing
Machine frames and bases
Housing and mill-stands.
Basic types of welded processes:
Welding can be broadly classified in two groups
1) Liquid state (fusion) welding where heat is added

to the base metals until they melt. Added metal
(filler material) may also be supplied. Upon cooling
strong joint is formed. Depending upon the method
of heat addition this process can be further
subdivided, namely
Electrical heating: Arc welding
Resistance welding
Induction welding
 Chemical welding: Gas welding
Thermit welding
 Laser welding
 Electron beam welding
Basic types of welded processes:
2) Solid state welding: Here mechanical

force is applied until materials deform to
plastic state. Bonds are then formed
through molecular interaction. Solid state
welding may be of various kinds, namely,
Cold welding
Diffusion welding
Hot forging
The form of a welded joint is dictated largely by the

layout of the joined components.
Two most common forms are:

1. the butt joint
2. the fillet joint
9-1 Welding Symbols
A weld is fabricated by welding together a collection of
metal shapes, cut to particular configurations.
The weld must be precisely specified on working drawing

and this is done by welding symbol, Fig. 9-1.
The arrow of this symbol points to the joint to be welded.
The body of the symbol contains as many of the following

elements as are deemed necessary:
Reference line Supplementary symbols
Arrow Finish symbols
Basic weld symbols in Fig. 9-2 Tail
Dimensions and other data Specification or process.
ME 307: Machine Design I Welding Symbols
WELD
Types of Welding
There 2 general types of welds:
1. Fillet
Fillet welds
welds for general machine elements.
2. Butt or groove
groove welds
welds for pressure vessels, piping systems,...
There are also others such as: Bead , Plug or slot
Plug groove
Bead Fillet or
slot
Figure 9-2
Arc and gas-weld symbols
Figure 9-3
Fillet welds
Figure 9-4
The circle on the weld symbol indicates that the welding
is to go all around.
Figure 9-5
Figure 9-6
9-2 Butt and Fillet Welds
where h is the weld throat and l is the length of the weld. Notice
that the value of h does not include the reinforcement.
Stresses in Welds: The approach has been to:
Consider the external loading to be carried by shear forces on

the throat area of the weld. By ignoring the normal stress on the
throat, the shearing stresses are inflated sufficiently to render
the model conservative.
Use the distortion energy for significant stresses
Circumscribe typical cases by code
For this model, the basis for weld analysis or design employs
F 1.414 F
  (9.3)
0.707hl hl
which assumes the entire force F is accounted for by a shear
stress in the minimum throat area.
Notice that this inflates the maximum estimated shear stress by
a factor of 1.414/1.207=1.17.
Further, consider the parallel fillet welds shown in Fig. 9-11

where, as in Fig.9-8, each weld transmits a force F. However,

in the case of Fig. 9-11, the maximum shear stress is at the
minimum throat area and corresponds to Eq. (9-3).
Under circumstances of combined loading we:
Examine primary shear stresses due to external forces.
Examine secondary shear stresses due to torsional and bending

moments.
Estimate the strength(s) of the parent metal (s).
Estimate the strength of the deposited weld metal.
Estimate the permissible load(s) for parent metal(s).
Estimate permissible load for deposited weld metal.
9-3 Stresses in Welded Joints in Torsion
Figure 9-12 illustrates a cantilever of length l welded to a column by
2 fillet welds.
The reaction at the

support of a cantilever
always consists of shear
force V and a moment
reaction M.
The shear force produces

a primary shear in the
welds of magnitude
V
 ' (9.4)
A
where A is the throat
area of the welds.
The moment at the support
produces secondary shear or

torsion of the welds, and this
stress is given by
Mr
" (9.5)
J
where
r: distance from the
centroid of the weld group to
the point in the weld of
interest.
J: second polar moment of

area of the group about the
centroid of the group.

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ME 307: Machine Design I

metal together by hammering, pressure or fusion.

The strongest and most common method of

Arc welding is the most important since it is

A weldment is fabricated by welding together a

The materials of components and electrode must be

Welding is a very commonly used permanent joining process.

joining components in various machines and

1) Liquid state (fusion) welding where heat is added

2) Solid state welding: Here mechanical

The form of a welded joint is dictated largely by the

Two most common forms are:

metal shapes, cut to particular configurations.

The weld must be precisely specified on working drawing

The arrow of this symbol points to the joint to be welded.

The body of the symbol contains as many of the following

Consider the external loading to be carried by shear forces on

Use the distortion energy for significant stresses

Circumscribe typical cases by code

Further, consider the parallel fillet welds shown in Fig. 9-11

where, as in Fig.9-8, each weld transmits a force F. However,

Examine primary shear stresses due to external forces.

Examine secondary shear stresses due to torsional and bending

Estimate the strength(s) of the parent metal (s).

Estimate the strength of the deposited weld metal.

Estimate the permissible load(s) for parent metal(s).

Estimate permissible load for deposited weld metal.

The reaction at the

The shear force produces

produces secondary shear or

J: second polar moment of

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