Welding Joint Design &

Welding symbols

Type of Weld joints

Weld strength
Extent of joint penetration
Strength of filler wire / weld metal
Discontinuities in the weld

Weld strength

Matching filler wire

Over-matched filler wire

Under matched filler wire

Weld Penetration

Partially
Penetrated
weld

Extent of fusion in the base material is weld

Penetration

Weld strength
Weld with
defects

Weld with
poor
contour

Weld strength
Using a filler metal that results in weld metal
with matching strength of base material.
Achieving full penetration of the thickness in
a groove weld and the required design size in
fillet welds
Obtaining a sound, defect free weld joint free
from fusion related discontinuities
Achieving a weld with smooth surface
contours and profiles without geometric
discontinuities

Need for Edge

Preparation

Penetration

SMAW PROCESS

Penetration

SMAW PROCESS

Penetration

P
P

SMAW PROCESS

Penetration

P1
P1

Full Penetration can be

achieved when welded
from both sides

SMAW PROCESS

Penetration

Full Penetration can be

achieved when the root
gap is increased by
providing a
backing plate

SMAW PROCESS

Penetration

Penetration

HEAT FLOW

Penetration

HEAT FLOW

HEAT FLOW

Due to small heat

sink the edges of the
plate is likely to get
burnt

Penetration

Providing a root face

increases the heat sink
area and prevents
burning of the edges

HEAT FLOW

Penetration

Wider included angles

increases the access of
arc to root face edges
and thereby increases
penetration.

Penetration

Edge Preparation
Full penetration is achieved by Providing
Root gap between joint edges
Chamfer at the joint edges to provide
approach / access to the arc
Suitable root face at the edges

Method of achieving
Full Penetration

Penetration

1.0 Weld from one side of the joint

Method of achieving
Full Penetration

Penetration

2.0 Back gouge / or grind/ from other side

Method of
achieving Full
Penetration

3.0 complete Welding on back gouged side

after LPT / or MPT

Method of
achieving Full
Penetration

Penetration

Use of consumable insert

Method of
achieving Full
Penetration

Penetration

Providing a backing strip

The backing strip can be made of metal or ceramic bead
embedded on adhesive tapes

Groove Dimensions
Included angle

Root Face

Root Gap

When welding can be done from both sides,

chamfer can be provided on both sides

Root Gap ( Rg)

Depends on
The heat input of the process
The diameter of the electrode
The thermal expansion/ contraction of
the material
Use of backing strip if any

Root Face (Rf)

Depends on
The heat input of the process
The thermal conductivity of the
material welded
The diameter of the electrode

Included Angle ()
Depends on
The diameter of the electrode
The position of welding
The thickness of the plates
The type of joint

Excess weld metal due increases with groove angle

Choice of type & dimensions of Groove

Choice of type & dimensions of Groove

Choice of Edge Preparation

Choice of type & dimensions of Groove

Choice of type & dimensions of Groove

Weld metal increases with groove angle

Choice of type & dimensions of Groove

Weld metal increases with root gap

Selection of Joint Groove Preparation

Thickness

Weight (gms)of Weld Metal required per metre

of weld length
Root Gap 1 mm
Thickness

Root Gap 2 mm

12

16

20

12

16

20

SV

790

1340

2050

840

1410

2120

DV

424

704

1062

502

830

1222

Design

Included angle - 60 deg.

Effect of Edge Preparation on distortion

Strong back
10

Distortion

Free
h1: h2 - 7:3

h1

h1: h2 - 6:4

h2

h1: h2 - 1:1
h1: h2 - 4:6
0

1/2

1 1/2

2
2 1/2
Plate thick in inches

Heat Input of welding

processes

Selection of Process

5
4

CO2

GTAW

SAW

SMAW

GW

Heat Input kJ/ mm

PAW

EBW

The choice of Groove type and angle depends on

welding process
Welding Position
Thickness of the section
The thermal properties of the material
The main objective is to achieve the required
penetration with minimum weld metal deposit

Symmetrical Single V-Groove preparation

For welding in down hand position

Asymmetric Groove angle for welding in Horizontal position

to reduce the gravitational effect on the weld pool

S2

s1

1
= 55
G = 1.6 3.15 mm
S = 1.6 - 3.15 mm

1= 10-15
2= 45-50

Groove angle formation by positioning the

members for welding

Groove angle for welding to avoid burning away outer corner

of vertical member

This Groove angle preparation is also used for

minimizing Lamellar tearing

Asymmetric Double-V Groove angle for welding in Fixed

position to reduce the gravitational effect on the weld pool
during welding in overhead position

d2

S
d1

Asymmetric Double-V Groove angle to facilitate welding in

the horizontal vertical position

1= 10-15
2= 45-40

Compound Groove angle for welding Fixed

in thicker sections
2

1 = 30 40
2 = 20

Symmetrical and Asymmetrical J-Groove type

weld preparations

Corner joint with different groove preparations

Recommended Groove angles in relation to

thickness
Thickness T inch

Groove type

T < 3/4
T - 1/2 to 2
T < 3/4
T - to 2

SV
DV
SB
DB

T - 3/4 to 1.5
T > 1.5

SJ
DJ

T - 3/4 to 1.5

SU

T > 1.5

DU

Fillet welds in T-joints

Convexity
Leg Size

Leg Size

Convex fillet weld

Actual throat

Convex
fillet weld

Effective throat

Theoretical throat

aa
Concavity
Actual throat
Leg Size
Effective throat

Convex fillet weld

Leg Size

Theoretical throat

Double
grooved fillet
weld
0.5 t

60

0.29 t

0.29 t

Combined Groove and filler welds with Partial Joint

Penetration but capable of full strength

Single fillet
weld
13 mm

Weld area = 80 mm 2

Single
grooved weld

13 mm

Weld area = 160 mm 2

Single
grooved
weld with
reinforcing
fillet

13 mm
45

Weld area = 80 mm 2

Single
grooved
weld with
reinforcing
fillet

13 mm
60

Weld area = 90 mm 2

Relative cost

20

Relative cost
of fillet

10

0.5

1.0

1.5

Plate Thickness in inches

2.0

Type of loads acting on welding joints

Welding Symbols as per ISO 2553)

Reference
line

Weld
symbol

Arrow line
Identifying
line
Joint

ELEMENTARY WELD SYMBOLS

Square Groove Weld
Single V Groove Weld
Single V Groove Weld
with Broad Root Face
Single bevel Groove
Weld
Single bevel Groove
Weld with Broad Root
Face

ELEMENTARY WELD SYMBOLS

Single U Groove Weld

Single J Groove Weld

Back Weld

Fillet Weld

ELEMENTARY WELD SYMBOLS

Plug / Slot Weld

Spot Weld

Seam Weld

Surfacing

SUPPLEMENTARY SYMBOLS
Weld
Profile

Flat

Peripheral Welds
(All around )

Site welds

Convex

Concave

EXAMPLES OF APPLICATION
Welding on the Arrow Side

Welding on the Other Side

DIMENSIONING OF WELDS
Groove welds

Fillet welds

z5

l
a5

DIMENSIONING OF WELDS
Spot
Weld

Plug
Weld
n (e)

Seam
Weld

n (e)

Slot Weld
d

n x l (e)

n x l (e)

Basic Joint Types

butt
tee

lap

corner
edge

Basic Weld Types

Groove welds

Fillet weld

Plug / slot weld

Spot / seam weld

Welding Positions Groove

1G

3G

2G
4G

Welding Positions Groove

1G

2G

5G

6G

45

Welding Position Fillet

1F
2F
3F

4F

Welding Position Fillet

1F
2F

5F

Shielding Gases for TIG Welding

TIG WELDING ELECTRODES

Size of Electrodes

Dia. - 0.3, 0.5, 1.0, 1.6, 2.0, 2.4, 3.0, 3.2, 4.0,
4.8, 5.0, 6.4, 8.0 mm
Length - 50, 75, 150, 175, 305, 455, 610 mm
Types of Electrodes and Colour Code
AWS
Classification
EWP
EWCe-2
EWla-1
EWla-1.5
EWla-2
EWTh-1
EWTh-2
EWZr-1

Colour *
Green
Orange
Black
Gold
Blue
Yellow
Red
Brown

Alloying
Element
---Cerium
Lanthanum
Lanthanum
Lanthanum
Thorium
Thorium
Zirconium

Alloying
Oxides
---CeO2
La2O3
La2O3
La2O3
ThO2
ThO2
ZrO2

Weight ( % ) of
Alloying Oxide
---1.8 2. 2
0.8 1. 2
1.3 1. 7
1.8 2. 2
0.8 1. 2
1.7 2. 2
0.15 0.4 0

TIG WELDING PROCESS PRINCIPLE

Filler wire is
added separately
in molten weld
metal pool
Independent
control on heat
input and filler
wire addition

GTAW Equipment
Power Source
Torch
HF Unit
Gas Cylinder
Tungsten Electrode

Gas Tungsten Arc Welding

SAFETY ACCESSORIES
>> Welding hand screens & helmet
>> Chipping goggles.
>> Apron
>> Jacket
>> Gloves
>> Sleeves
>>

Leggings

>>

Shoes

>>

Cap

CLASSIFICATION OF ELECTRODES (AWS 5.5)

Electrode
80,000 Psi
All position

E8018-B1H4R
Diff. H2
SUF

1-F,H,V,OH 2-F,H , 4-F,H,VD,OH

0

CELLULOSE SODIUM

CELLULOSE POTASSIUM

DCEP

AC/DCEP/DCEN

2 TITANIA SODIUM

AC/DCEN

3 TITANIA POTASSIUM

AC/DCEP

4 IRON POWDER TI

AC/DCEN/DCEP

5 LOW HYDROGN Na

DCEP

6 LOW HYDROGEN K

AC/DCEP

7 Fe POWDER Fe OXIDE AC/DCEP/DCEN

8 Fe POWDER LOW H2

AC/DCEP

%Mn

%Ni

Moisture
Resistant
%Cr

A1

%Mo

1/2

B1

B2

1-

B3

2-1/4 1

C1

2-1/2

C2

3-1/4

C3

D1&
D2

%V

1.2 2.00

0.50

0.15

.25 .35

0.30

0.20

0.10

CLASSIFICATION OF ELECTRODES (AWS 5.1)

E6010
Electrode
60 Ksi
70
80
90
100
110
120

Welding
position

Coating and
current conditions

COMPOSITION OF FLUX
7. Ionizing Substances
Used for stabilizing the arc
Substances : Chalk, Marble
8.Binding substance
Help the coating to grip firmly around the core wire
Substances: Sodium Silicate, Potassium Silicate

COMPOSITION OF FLUX
4.Iron powder
Gives good operating characteristics
Improves arc stability
Makes the coating electrically conducting

5.Oxidizing Substance
Makes the weld metal flow freely
Oxidizing substance are: iron oxide, Lamitite, Magnetite

6.Reducing Substances
They compensate for manganese Ferro Silicon
Substances: Ferro Manganese, Ferro Silicon, Ferro Titanium

contd

COMPOSITION OF FLUX IN THE COATING

1.

Organic substance or Cellulose material:

Wood, Flour & Cellulose
High arc force
Large volume of gas mostly hydrogen

2. Rutile:
Found in sand
Arc stabilizer
Good slag former
3. Ball Clay:
Compound of silica & alumina
Slag former & Gives plasticity in the wet paste
contd

PURPOSE OF FLUX COATING

>> Gas shielding of arc
>> Stabilizes the arc
>> Provides slag blanket
>> Alloying element will improve the mechanical
properties
>> Gives good appearance & penetration
>> Welding in all position is easy
>> Compensates for oxidation loss

CHARACTERISTICS OF ELECTRODES
Rutile Electrodes:
Electrode:

Cellulose

Quite & smooth arc

> Forceful &
noisy arc
> Excellent slag removal
> Friable slag
> Fine ripples
> Coarse ripples
> Medium penetration
> Deep
penetration
> Thick slag
> Thin
slag cover
> Good running
> More
gas shield
>
>

TYPES OF COVERING
Based on covering
>
>
>
>

Rutile electrodes
Basic coated electrodes
Cellulose coated electrode
Iron powder,iron oxide electrodes

Based on application:
>
>
>
>
>
>

carbon-manganese steel electrodes AWS A5.1

Stainless steel electrodes A5.4
Low alloy steel electrodes A5.5
Copper & Copper alloy electrodes A5.6
Aluminium & Aluminium alloy electrodes A5.10
Nickel & Nickel alloy covered electrodes A5.11

> Hardfacing electrodes A5.13

> Covered electrodes for cast iron A5.15

LIMITATIONS OF SMAW PROCESS

Less metal deposition Can not be

used for heavy fabrication welding . Less
Productivity due to fixed length of electrode

Requires more number of welders

Control of distortion is difficult
Continuous & automatic Welding is not
possible

More strain to the welders

>

Deslaging

Shielded Metal Arc

Welding
Process Capabilities:
Versatile process
Indoor & Outdoor welding
Multi-position welding
Equipment is simple &
portable
Universal process for repair