VI Classifications of Weldments

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1 VI Classifications of Weldments Good Bad AM 11/03 1

2 Outline TWI Classification system AISC classification system An alternative classification system AM 11/03 2

3 B - Longitudinal butt AM 11/03 3

4 C - longit. Butt w/ Reinforcement AM 11/03 4

5 C - Transverse Butt, Machined AM 11/03 5

6 D - Long. Butt w/ Start-stop AM 11/03 6

7 D - Butt weld w/ good toe AM 11/03 7

8 E - Butt weld w/ bad toe AM 11/03 8

9 F2 - Trans. butt in rolled section AM 11/03 9

10 F - Trans. Butt w/ backing strip AM 11/03 10

11 F - Attachments on plate face AM 11/03 11

12 F - Groove welded cruciform AM 11/03 12

13 G - Attachments near edge AM 11/03 13

14 F2 - Load carrying fillet weld AM 11/03 14

15 W - Fillet weld metal AM 11/03 15

16 TWI - Classification system AM 11/03 16

17 Application of TWI system AM 11/03 17

18 Application of TWI system AM 11/03 18

19 TWI rules AM 11/03 19

20 Outline TWI Classification system AISC classification system An alternative classification system AM 11/03 20

21 AISC classification system 100 Weld Category A B 10 C D E F Fatigue Life, N (cycles) AM 11/03 21

22 AISC category B and C 10 3 S = * N^ , r = , s = % survival with 50% confidence 99% survival with 95% confidence The good welds! failures run-outs logn = *logS, r = , s = Fatigue life, N (cycles) AM 11/03 22

23 AISC category D and E 10 3 failures run outs 10 2 S = * N^ , r^2 = 0.173, s = % survival with 50% confidence 99% survival with 95% confidence logn = *logS, r = , s = The bad welds! Fatigue life, N (cycles) AM 11/03 23

24 AISC category best fit lines to data % survival with 95% confidence A B A-S99% B-S99% C-S99% D-S99% E-S99% F-S99% C 10 1 D E F Fatigue life, N (cycles) AM 11/03 24

25 6.3 A Suggestion for the Classification of Weldments Good Bad AM 11/03 25

26 Weld stress concentrations Personal view Termination Ripple Toe Root AM 11/03 26

27 Ripple Ripple Groove Welds Non-Load-Carrying Fillet Welds Load-Carrying Fillet Welds Terminations Fatigue Life, N (cycles) Nominal Stress Range, DS (MPa) AM 11/03 27

28 Groove welded butt joints Ripple Groove Welds Non-Load-Carrying Fillet Welds Load-Carrying Fillet Welds Terminations Fatigue Life, N (cycles) Nominal Stress Range, DS (MPa) AM 11/03 28

29 Non-load-carrying fillet welds Ripple Groove Welds Non-Load-Carrying Fillet Welds Load-Carrying Fillet Welds Terminations Fatigue Life, N (cycles) Nominal Stress Range, DS (MPa) AM 11/03 29

30 Transverse attachments Ripple Groove Welds Non-Load-Carrying Fillet Welds Load-Carrying Fillet Welds Terminations Fatigue Life, N (cycles) Nominal Stress Range, DS (MPa) AM 11/03 30

31 Longitudinal attachments Ripple Groove Welds Non-Load-Carrying Fillet Welds Load-Carrying Fillet Welds Terminations Fatigue Life, N (cycles) Nominal Stress Range, DS (MPa) AM 11/03 31

32 Good, bad, maverick S (MPa) Ripple Groove Welds Non-Load-Carrying Fillet Welds Load-Carrying Fillet Welds Terminations Fatigue Life, N (cycles) AM 11/03 32

33 Good welds, Bad welds, Mavericks Nominal Stress Range, S (ksi) Non-Load-Carrying Fillet Bad Good Fatigue Life, N (cycles) Ripple 500 Transverse Groove Welded Butt 100 Terminations Maverick Termination Partial Penetration Load-Carrying Fillet AM 11/ Nominal Stress Range, S (MPa)

34 The good welds: weld toe failures C Detail #3 Kf = 1.87 ²S design = 27.0 ksi. C Full-Penetration Groove Weld: Detail #10 Kf =2.12 ²S design = 23.3 ksi. C Non-Load Carrying Fillet Weld: Detail #25 Kf =2.23 ²S design = 22.1 ksi. AM 11/03 34

35 The bad welds: terminations C,Cs Load Carrying Fill et Weld: Detail #20 Kf =3.12 ²S design = 17.5 ksi. C Weld Termination: Detail #30 Kf =3.27 ²S design = 14.5 ksi. AM 11/03 35

36 Fatigue severity of terminations C Starts and stops introduce weld discontinuities. Residual stresses very high. 3-D stress concentrations effects. AM 11/03 36

37 Examples of terminations C C C L P L-P L-P C C b a C AM 11/03 37

38 The mavericks: something undefined P C Partial penetration weldment. The amount of penetration is generally unknown. C, Cs C, Cs Undercut. Failu re occurs at the undercut on wrap-around weld where the arris of the plate is melted. the amount of the undercut is generally unknown. AM 11/03 38

39 The mavericks: complex components C C Multiple failure sites. The stress distribution in the joint changes as fatigu e cracks initiate and grow at various locations. L L-P L-P P C Local stresses uncertain because of structural redundancy AM 11/03 39

40 Summary Viewed from the perspective of crack initiation site, weldments could be grouped into four categories: ripple, toe, root, and terminations. This classification scheme leads to the conclusion that there are Good and Bad weldments and Mavericks - weldments for which a critical piece of information is unavailable and hence their behavior is undefined. AM 11/03 40

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