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1 21 Steel Design GuideWelded Connections A Primer for 16/21/2006 8:21:32 AM21 Steel Design GuideWelded Connections A Primer For EngineersDUANE K. MILLER, , Lincoln Electric CompanyCleveland, OhioAMERICAN INSTITUTE OF STEEL CONSTRUCTION, 2006byAmerican Institute of Steel Construction, rights reserved. This book or any part thereofmust not be reproduced in any form without thewritten permission of the information presented in this publication has been prepared in accordance with recognized engineering principles and is for general information only. While it is believed to be accurate, this information should not be used or relied upon for any specific application without compe-tent professional examination and verification of its accuracy, suitablility, and applicability by a licensed professional engineer, designer, or architect. The publication of the material contained herein is not intended as a representation or warranty on the part of the American Institute of Steel Construction or of any other person named herein, that this information is suitable for any general or particular use or of freedom from infringement of any patent or patents.

2 Anyone making use of this information assumes all liability arising from such must be exercised when relying upon other specifications and codes developed by other bodies and incorporated by reference herein since such material may be modified or amended from time to time subsequent to the printing of this edition. The Institute bears no responsi-bility for such material other than to refer to it and incorporate it by reference at the time of the initial publication of this in the United States of AmericaFirst Printing: June 2006 Design Guide 21 / WELDED CONNECTIONS A PRIMER FOR ENGINEERS/ iiiAcknowledgmentsThe author would like to thank The Lincoln Electric Com-pany for the use of many of the figures provided in this document and the following reviewers for their insightful comments and suggestions:Brad DavisFred BreismeisterRoger L. BrockenbroughCharles J. CarterJason EricksenStephen M. HerlacheWladyslaw Jaxa-RozenLawrence KloiberChristopher HewittKeith LandwehrMichael MayesRon MengDavis ParsonsDean PhillipsDavid T.

3 RickerThomas J. SchlaflyBill SeguiRobert E. Shaw, Jr. Victor ShneurRaymond TideGary VioletteKenneth WiesnerDESIGN Guide 21 / WELDED CONNECTIONS A PRIMER FOR ENGINEERS/ vTable of Contents1. INTRODUCTION .. IMPORTANCE OF WELDING .. SCOPE OF WELDING .. WELDING-RELATED CODES AND AISC Specification for Structural Steel Buildings .. AWS Structural Welding Code Steel .. AISC Seismic Provisions for Structural Steel Buildings .. AWS Structural Welding Code Seismic Supplement .. AWS Structural Welding Code Sheet Steel .. Other AWS D1 Codes ..32. WELDING AND THERMAL CUTTING PROCESSES .. INTRODUCTION .. Requirements for Welding .. Arc Welding as Compared to Other Welding Processes .. Process Issues and Concerns for the Engineer .. SMAW .. Fundamentals .. Equipment .. Consumables .. Electrode Classification System .. Low-Hydrogen SMAW Electrodes.

4 Care and Storage of Low-Hydrogen Electrodes .. Process Advantages/Limitations .. Applications .. FCAW .. Fundamentals .. Equipment .. Consumables .. Electrode Classification .. FCAW Advantages and Limitations .. FCAW-G Advantages and Limitations .. FCAW-G Applications .. FCAW-S Advantages and Limitations .. FCAW-S Applications .. FCAW-S Intermix Concerns .. SAW .. Fundamentals .. Equipment .. SAW Consumables .. Electrode and Flux Classification .. Flux Recovery .. Crushed Slag .. Process Advantages and Limitations .. Applications .. GMAW .. Fundamentals .. Equipment .. Consumables .. Electrode Classification System .. Shielding Gas .. Modes of Transfer .. Process Advantages and Limitations .. Applications .. ESW/EGW .. Fundamentals .. Equipment .. Consumables .. Electrode Classification.

5 Process Advantages and Limitations .. Applications .. GTAW .. ARC STUD WELDING .. THERMAL CUTTING PROCESSES .. Oxyfuel Gas Cutting and Gouging .. Plasma Arc Cutting and Gouging .. Air Carbon Arc Gouging and Cutting ..303. WELDED CONNECTIONS .. JOINTS .. WELD TYPES GENERAL .. COMPLETE JOINT PENETRATION (CJP) GROOVE WELDS .. CJP Groove Weld Backing .. Single-Sided vs. Double-Sided Welds .. Groove Weld Preparations .. Spacer Bars .. PA RTIAL JOINT PENETRATION (PJP) GROOVE WELDS .. Effective Throats for PJP Groove Welds .. Minimum PJP Groove Weld Sizes .. Restrictions on the Use of PJP Groove Welds .. Required Filler Metal Strength for PJP-Groove Welds .. Flare-V and Flare-Bevel Groove Welds .. Single-Sided vs. Double-Sided Welds .. PJP-Groove Weld Details .. FILLET WELDS .. Minimum Size of Fillet Welds .. Maximum Size of Fillet Welds.

6 Minimum Fillet Weld Lengths .. Maximum Fillet Weld Lengths .. Intermittent Fillet Welds .. Penetration in Fillet Welds .. Longitudinal vs. Transverse Fillet Welds .. Combined Longitudinal vs. Transverse Welds .. End Returns (Boxing) .. Weld Termination (Fillet Welds) .. Fillet Welds and Fitup .. PLUG/SLOT WELDS .. INTERACTION OF JOINT TYPES AND WELD TYPES .. SELECTION OF WELD TYPES .. WELD DETAILS .. Weld Tabs .. Weld Access Holes .. Fillers .. Welds and Mechanical Fasteners .. Strength of Welds in Combinations .. k-Area Detailing .. LAMELLAR TEARING AND JOINT DETAILS .. REQUIRED FILLER METAL STRENGTH .. Matching Filler Metal .. Undermatching Filler Metal .. Overmatching .. DETERMINING WELD STRENGTH .. CJP Groove Welds .. PJP Groove Welds .. Fillet Welds .. Plug/Slot Welds .. SPECIAL WELDS .. Arc Spot Welds (Puddle Welds, Deck Welds).

7 Repair Welds .. Seal Welds .. Tack Welds .. Temporary Welds .. Compatibility of Weld Metals .. SPECIFIC REQUIREMENTS FOR VARIOUS JOINTS .. Butt Joints .. Corner Joints .. T-Joints .. Lap Joints .. WELDING SYMBOLS .. SAMPLE CALCULATIONS ..574. METALLURGICAL ISSUES .. INTRODUCTION .. STEEL PROPERTIES OF INTEREST .. DESCRIPTIONS OF STEEL GROUPS .. AWS Prequalified Steels .. AWS Approved Steels .. AWS Unlisted Steels .. AISC Specification Treatment of Unidentified Steels ..60vi/DESIGNGUIDE21/ WELDED CONNECTIONS A PRIMER FOR ENGINEERSDESIGN Guide 21 / WELDED CONNECTIONS A PRIMER FOR ENGINEERS/ WELDING REQUIREMENTS FOR SPECIFIC STEELS .. Weathering Steels .. Quenched and Tempered Steels .. Historical (Obsolete) Steels .. WELDING NONSTRUCTURAL STEELS .. Anchor Rods .. Bolts and Nuts .. Stainless Steel to Steel .. Cast Iron .. Wrought Iron.

8 Steel Castings ..655. WELD CRACKING .. INTRODUCTION .. SHRINKAGE AND RESTRAINT .. Shrinkage .. Constraint .. TYPES OF WELD CRACKS .. Centerline Cracking .. Heat-Affected Zone Cracking .. Transverse Cracking .. LAMELLAR TEARING .. REDUCING SHRINKAGE STRESSES .. REDUCING RESTRAINT .. POST-WELDING STRESS REDUCTION MEASURES ..786. DISTORTION .. INTRODUCTION .. CAUSES OF DISTORTION .. DISTORTION CONTROL .. General .. Angular Distortion .. Transverse Shrinkage .. Longitudinal Shortening .. Twisting .. Longitudinal Sweep or Camber .. Buckling and Warping .. Rotational Distortion .. SPECIALIZED DISTORTION CONTROL MEASURES .. Adding Restraint .. Weld Placement .. Welding Sequence ..867. WELDING PROCEDURE SPECIFICATIONS .. INTRODUCTION .. WRITING WELDING PROCEDURE SPECIFICATIONS .. USING WELDING PROCEDURE SPECIFICATIONS .. PREQUALIFIED WELDING PROCEDURE SPECIFICATIONS.

9 QUALIFIED WELDING PROCEDURE SPECIFICATIONS .. EFFECTS OF WPS VARIABLES .. Amperage .. Arc Voltage .. Travel Speed .. Wire Feed Speed .. Electrode Extension .. Contact Tip to Work Distance .. Electrode Diameter .. Polarity .. Heat Input .. Preheat and Interpass Temperature .. Post-Heat .. Stress Relief ..948. WELD QUALITY .. INTRODUCTION .. TYPES OF WELD DISCONTINUITIES .. Planar Discontinuities Weld and Base Metal .. Volumetric Discontinuities Specific to the Weld .. Volumetric Discontinuities External to the Weld .. Metallurgical Deficiencies ..100viii/DESIGNGUIDE 21 / WELDED CONNECTIONS A PRIMER FOR ENGINEERS9. WELD INSPECTION .. INTRODUCTION .. VISUAL INSPECTION (VT) .. Visual Inspection Before Welding .. Visual Inspection During Welding .. Visual Inspection After Welding .. NONDESTRUCTIVE TESTING GENERAL.

10 PENETRANT TESTING (PT) .. MAGNETIC PARTICLE INSPECTION (MT) RADIOGRAPHIC INSPECTION (RT) .. ULTRASONIC INSPECTION (UT) ..10410. SEISMIC WELDING ISSUES .. INTRODUCTION .. SPECIFICATIONS AND CODES .. SEISMIC WELDING TERMINOLOGY .. SPECIAL CONNECTION DETAILS .. FILLER METAL REQUIREMENTS .. WELDER QUALIFICATION TESTS .. NONDESTRUCTIVE TESTING ..11111. FATIGUE CONSIDERATIONS .. INTRODUCTION .. STRESS RANGE .. CONNECTION GEOMETRY .. COMPUTATIONS .. INSPECTION ISSUES .. SPECIAL FABRICATION/ERECTION REQUIREMENTS ..11912. SPECIAL WELDING APPLICATIONS .. WELDING ON ANCHOR RODS .. General .. Extending Anchor Rods .. Welding Anchor Rod to Base Plates .. WELDING ON COATED STEELS .. General .. Galvanized Materials .. Testing .. Ventilation .. WELDING ON HEAVY SECTIONS .. WELDING ON HEAVILY RESTRAINED MEMBERS .. WELDING HSS .. Introduction .. Connections and HSS Member Size.