9/4/2023

Introduction
• Welcome Back to 3rd Year!

• Fall 2022 Course Delivery for this entire course is on

campus!

Introduction & Review

Week 1
WELD 3070 - Welding Design I

Jim Galloway

J. Galloway – WELD3070

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Course Objective Course Objective (cont’d)

• This course is intended to provide a broad overview and • The Welding Engineering Technologist requires a
introduction to welding design principles for the fundamental knowledge of basic weld design
Engineering Technologist. concepts in order to effectively participate in these
sorts of projects in industry:
• The course builds upon and may require you to apply
material already introduced in the following courses • New product development;
(without additional in class review): • Welding procedure development;
• DRWG1497 – Eng. Drawing Interpretation
• WELD1700 – Weld Quality & Inspection
• Weld cost reduction projects;
• WELD2155 – Welding Codes & QC • Specifying welding consumables;
• MATH2285 – Technical Math III • Welding inspection;
• WELD2175 – Welding Metallurgy I
• Welding failure analysis.
• WELD2115 – Welding Mechanics

J. Galloway – WELD3070 J. Galloway – WELD3070

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Course Objective (cont’d) Course Delivery

• This course is not intended to replace any particular • This course will be delivered on campus for Fall 2022
welding design standard or code, and we will
discuss a variety of them. This is critical: • Lecture notes from these presentations and a series of
“Review Problems” will be provided
• Always consult the most current edition of the welding • Selected problems will be taken up in class as time permits
design standard, code, or industrial specification that • Plan now to commit at least 2-hrs each week outside of class
applies to the job that you are working on before to thoroughly learn this material and do the study guide and
undertaking the work. review problems.

• Design authority: • AWS WHB, 9th Ed., Vol. 1. is referenced &/or readings
• Engineering technologists should only be making may be assigned
recommendations on weld designs under the • This is available for online viewing if you have not purchased
supervision of the responsible professional engineer (or a hardcopy. Relevant Figures/Tables will be provided in
advance if required for tests
architect).
J. Galloway – WELD3070 J. Galloway – WELD3070

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Introduction Introduction
• The Instructional Plan is available on E-Conestoga. • This lecture will review basic material properties
• WELD 3070 – Evaluation Summary: that are used to characterize metals and
Grade Item: Weighting weldments
Assignment A – Low Temperature Application 5%
Assignment B – Weld Design Review Calculations 5%
Mid-term Exam 35%
Note: This should all be review. All of it will be needed
Assignment C – Truck Beam 10%
to solve more complex design problems throughout this
Assignment D – Treating the Weld as a Line 10% course.
Final Exam 35%
Total 100%

• Due dates are listed in Instructional Plan and the eConestoga course calendar. In case of discrepancy, please
notify the instructor ASAP for clarification

• Please Note: Midterm & Final Exams are scheduled to be written on campus, during scheduled class time.

J. Galloway – WELD3070 J. Galloway – WELD3070

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Review – Strength of Materials Review - Stress

• Before proceeding to ‘weld design’ you must have a • Stress is the measure of force applied to a material
thorough understanding of the basic concepts in that accounts for the size (cross-sectional area) of
the Strength of Materials: the material
• Stress • Strength is a materials ability to resist an applied
• Strain stress
• Young’s Modulus of Elasticity
• Mathematically we define stress as the force
• Ultimate Tensile Strength
divided by the cross-sectional area
• Yield Strength
• Hardness 𝑷 Where:
• Ductility 𝝈= • σ is the unit stress in the material (lb/in2, psi …. or N/mm2, MPa);
• Toughness
𝑨𝒐 • P is the applied load or force (lb-f or N);
• Ao is the original cross-sectional area.

J. Galloway – WELD3070 J. Galloway – WELD3070

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• A 1.00” diameter 1020 carbon steel round bar in the normalized condition

Review Problem- Stress has a minimum yield strength of 43,000 psi and an ultimate tensile
strength of 66,000 psi. What load in pounds will cause it yield? Convert
the answer to N

• A 1.00” diameter 1020 carbon steel round bar in

the normalized condition has a minimum yield
strength of 43,000 psi and an ultimate tensile
strength of 66,000 psi. What load in pounds will
cause it yield? Convert the answer to N

J. Galloway – WELD3070 J. Galloway – WELD3070

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• A 1.00” diameter 1020 carbon steel round bar in the normalized condition
has a minimum yield strength of 43,000 psi and an ultimate tensile
strength of 66,000 psi. What load in pounds will cause it yield? Convert
the answer to N
Review – Strain
• Strain is the deformation of a solid due to an
applied stress.

∆𝒍
•𝜺=
𝒍𝒐
Where:
• 𝜺 is the measure of strain (% or no units – mm/mm, in/in);
• Δl is the change in length under stress (in or mm);
• lo is the original length of the sample (in or mm).

J. Galloway – WELD3070 J. Galloway – WELD3070

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Review - Stiffness Review – Young’s Modulus

• Stiffness in the field of mechanics of materials can • Engineering Stress-Strain Curve:
be quantified by the Young’s Modulus of Elasticity
of the material (in the elastic range).
𝑷
𝝈 𝝈 𝑨𝒐 𝑷 𝑳𝒐
•𝜺= ∴𝑬= = ∆𝒍 =
𝑬 𝜺 𝒍𝒐 ∆𝒍 𝑨𝒐

Where:
• 𝜺 is the measure of strain (% or no units – can be thought of as mm/mm);
• E is the Young’s Modulus of Elasticity of the material (lb/in2 or N/mm2 or MPa);
• P is the applied load or force (lb-f (lb) or N);
• Δl is the change in length under stress (in or mm);
• lo is the original length of the sample (in or mm);
• σ is the unit stress in the material (lb/in2 or N/mm2 or MPa);
• Ao is the original area of the sample (in2 or mm2).
J. Galloway – WELD3070 J. Galloway – WELD3070

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Review – Elastic-Plastic Behaviour Review – Young’s Modulus

• Before the Yield Stress level (proportional limit) is
• Each common engineering alloy has a specific
reached, most engineering materials behave like an
Young’s Modulus value:
elastic and follow Hooke’s Law (spring-like).
• Beyond the Yield Stress the • Steel alloys
material behaves plastically and • 29,000,000 lb/in2 or
will not return to its original 200,000 MPa (N/mm2)
shape. • Titanium alloys
• A structure loaded to ‘plastic behaviour’ • 16,000,000 lb/in2 or
will be considered damaged
110,000 MPa
• ductile materials can absorb significant
energy before catastrophic failure • Aluminum alloys
• Absorbed energy is measured by the • 10,000,000 lb/in2 or
area under the stress-strain curve 69,000 MPa

J. Galloway – WELD3070 J. Galloway – WELD3070

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Review – Young’s Modulus vs. Strength Review – Stiffness vs. Strength

• The point at which an alloy reaches Yield or UTS is • Higher ‘strength’ alloys have the same ‘stiffness’,
the ‘strength’ of the alloy and is independent of the they just reach Yield and UTS at higher stress levels.
‘stiffness’.

J. Galloway – WELD3070 J. Galloway – WELD3070

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Review - Strength Review –Yield Strength

• Ultimate Tensile Strength (UTS) is the maximum • For consistency, the standard method for
stress level (or load) reached over the original area determining the Yield Strength of engineering
of the material. (σu) alloys uses the “0.2% (strain) Offset Method”:

• Yield Strength (YS) is the stress required to produce

permanent plastic deformation. (σy)

J. Galloway – WELD3070 J. Moulton – WELD3070

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Review – UTS vs. YS Review – Strength:

• Typically in steels as the strength increases, the • In welding design for structural applications we
difference (Δ) between the YS and the UTS are primarily concerned with the minimum:
decreases; this is an indication of lower ductility:
• UTS of the electrode
classification (Xu)

• YS of the base metal

grade (Fy)

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Review – Tensile Testing: Review – Base Metal Tensile:

• In our industry there are three common reasons • The UTS, YS, and ductility of base metal is
for (or types) of tensile tests conducted: typically determined using a standard ‘round-bar’
1. Base Metal Tensile Tests or ‘505’ test coupon in a tensile test.
• To determine the UTS, YS, and ductility of the base metal.
• Sheet, plate
2. All- Weld Metal Tests (electrode qualifications)
• Machined from weld metal deposited into a groove weld.
• To determine the UTS, YS, and ductility of the weld metal. A ‘505’ Test
• Normally a round ‘505’ type specimen. Specimen and the
3. Weld Procedure Qualification Testing Test Setup with
• Transverse (across the entire weld from plate, pipe or tubes). Extensometer
• Longitudinal specimens (down the length of the weld).
• To determine the UTS.
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Review – All-Weld Metal Tensile Review – Tensile Test Results

• The UTS, YS, and ductility of weld metal is also • The UTS of the sample can be calculated based
determined through ‘505’ test coupons, however upon the original area of the sample and the peak
these samples are machined entirely from weld load readout determined in the tensile test (to
metal (from a standard qualification test plate). failure).
• The YS of the sample is determined from the stress-
strain curve generated from the force read-out vs.
the strain (measured by the extensometer); the
0.2% offset method is required most commonly.
• The Ductility is normally determined by comparing
A ‘505’ Test the original gauge-length of the sample to the post
Specimen Removed test gauge length…this is % Elongation.
from Weld Metal

J. Galloway – WELD3070 J. Galloway – WELD3070

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Review – Ductility (% Elongation) Review – % Elongation

• The % Elongation is the standard method for • The % Elongation is a unit-less value (ratio)
determining ductility from tensile testing. calculated as follows:
• Most standard test samples have an original Gauge Percent Elongation = × 100
Length (G.L.) of 2.00” (or 50mm).
Where:
• lx is the final Gauge Length of the sample (in or mm).
• lo is the original Gauge Length of the sample (in or mm).
The % Elongation
(Before vs. After
Tensile Testing) • Note: To be valid, this measure of ductility must
always be specified over the Original Length:
• E.g. – “22% Elongation on a 50mm GL”

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Review – Ductility Review – Transverse Weld Tensile:

• Ductility is a measure of the material’s ability to • For welding procedure qualifications the most
undergo plastic deformation before final fracture. common tensile test is the ‘transverse’ test (across
• Ductility is an extremely important material the weld and HAZ).
property in the welding industry.
• Other common ways to quantify ductility are:
• Lateral Expansion (in a Charpy impact test);
• % Shear (in a Charpy impact test); Reduced Section
Transverse Tensile
• % Reduction in Area (in a tensile test). Testing Coupon

J. Galloway – WELD3070 J. Galloway – WELD3070

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Review –Weld Tensile Testing Review – Hardness

• Because tensile tests cross welds are testing a non- • Hardness is a measure of a material's resistance to
homogenous material (Base Metal, HAZ, and Weld deformation by surface indentation or by abrasion.
Metal) the deformation is commonly very localized. • This property correlates approximately to the UTS.
• Subsequently these tests do not normally provide • There are several standard tests and scales for this
useful data beyond the UTS (for comparison to the property used in the welding industry:
base metal minimum strength). • Vickers (Hv)
• The location and ‘characteristic’ of the failed • Brinell (Hb)
specimen is also recorded on the standard PQR • Rockwell (HRb) B – scale (for mild steels)
forms, but the key PASS/FAIL determination is • Rockwell (HRc) C – scale (for hardened steels)
based upon the UTS.

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Weld Procedure Qualifications Summary

• The most common testing required by welding • The Welding Design I (WELD3070) course has been
codes and standards for procedure qualifications introduced.
evaluate weld quality and these properties: • Review of the Strength of Materials:
• Weld Soundness (e.g., guided bend, nick-break); • Stress & Strain
• Weld Fusion, Shape, & Penetration (e.g., macro • Young’s Modulus of Elasticity
sectioning);
• UTS & YS
• Tensile (UTS) (e.g., transverse reduced section samples);
• Ductility
• Impact Toughness (e.g., Charpy V-Notch);
• Tensile Testing
• Hardness (e.g., HAZ Vickers micro-hardness);
• Hardness Testing
• Microstructure (e.g., for duplex stainless steel).

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