1 1 1 Advantages/Disadvantages

2 Welding Position
Welding Process>>>>>Laser welding/Electron beam welding/MAG welding/Electroslag
3 welding
Arc welding Process>>>>>> Plasma welding/Gravity welding with cover electrode/MIG
4 welding/MAG Welding/TIG welding
Consumable electrode arc welding
5 process>>>>MMA/MAG/Electrogas/Electroslag/MIG/SAW
Gas shielded arc welding processes>>>>TIG/MAG/MIG/Electrogas welding/Plasma arc
6 welding
7

In the fusion welding,molten metal is shielded from air to get sound welds.Regarding
the shielding method.These are two typical methods principally,Gas Shielding and Flux
shielding.Flix welding process>>>>SAW/MMA/Electoslag welding/Self shielded tubular
8 cored arc welding
9 1 Pulsed MAG welding with solid wire >>> Shielding weld pool with active gas
2 MIG welding >>> Shielding weld pool with inert gas
3 Submerged arc welding >>> Shielding weld pool with flux(Slag)
4 Electroslag welding >>> Shielding weld pool with flux(Slag)
5 TIG welding >>> Shielding weld pool with inert gas
10 1 TIG welding >>> Tungsten Electrode
ESW >>> Resistance Heat
SAW >>> Granular flux
CO2 arc welding >>> Short circuiting transfer
Pulsered arc welding >>> Periodic change of current
11 1 SAW >>> High current welding with fused flux
2 CO2 arc welding >>> Grandular transfer
3 Pulsed MAG welding >>> Spray transfer
4 Plasma arc welding >>> Keyhole welding
5 TIG welding >>> alternating current welding of aluminium alloy

12 1 ESW >>> High efficiency welding process for vertical welding of thick steel plates

2 Arc stud welding >>> Arc welding process suitable to weld bolts on steel structures
Electron beam welding >>> Deep penetration welding process using elections
3 emitted in a vacuum and applicable to welding of active metal
TIG Welding >>> Non consumable electrode arc welding process shielded with inert
4 gas
Self shielded tubular cored arc welding >>> Welding process less influenced by wind
5 and applicable to site welding
13 1 Pulsed MAG welding >>> Spray transfer
Oxy fuel gas pressure welding(Oxy fuel gas welding with pressure) >>>
2 reducing(carburizing)flame
3 Resistance spot welding >>> pressure and copper electrode
4 Laser Welding >>> high energy density welding
5 Manuel metal arc welding >>> Covered electrode
14 1 Electroslag welding >>> Vertical single pass welding of thick steel plate
2 AC TIG welding >>> Welding of aluminium alloy
 3 Brazing >>> Wetting
4 Pulsed MAG welding >>> Periodical change of welding current
5 High frequency resistance welding >>> High speed seam welding of pipes
1 2 1 1
2
3
4
5
2 1 Electron carries arc current mainly.
2 Arc is composed of ionized high temperature gas.

3 Arc voltage change with decreasing arc current in the low current region to increase.

4 Arc voltage change with decreasing arc current in the high current region to increase.
Arc voltage change with varying arc length at the same arc current to change almost in
5 proportion to arc length.

When two electric conductors positioned in paralle carry currents in the same
direction,the force induced between the conductors by an electromagnetic effect is
3 1 attractive.

2 With an increase in welding current,the electromagnetic pinch effect becomes larger.

The characteristic of an arc that tends to extend strainghtly to the direction of electrode
3 axis is called arc stiffness.
With an increase in current density,the pressure of arc colum at the center as compared
4 with that at periphery becomes higher.
The gas flow caused by the pressure difference along arc column is called plasma
5 stream.
Compared with no load voltage,the arc reignition voltage in MMA welding using AC
4 1 current is lower.
The nature of an arc extended strainghtly in the electrode axis direction is called arc
2 stiffness.
3 As the thermal pinch effect becomes larger,the arc is constricted.
Regarding the current voltage phase relationship of AC arc welding,the phase of
4 welding current compared with that of no load voltage is lagged(delayed).

5 With an increase in welding current,the electromagnetic pinch effect becomes larger.

In welding of steel,arc is deflected by the electromagnetic force induced by welding
5 1 current and residual magnetism in base plate.
2 Magnetic arc blow is likely to occur at the start/end part.
3 Magnetic arc blow is likely to occur in DC arc welding.
4 Magnetic arc blow is caused by magnetic field.
One of countermeasures to prevent arc blow is to set the welding cable connection to
5 base metal at several points.
6 1 Reiginition of arc >>> Open circuit(No load)voltage,power factor
2 Cleaning action >>> Cathode spot,oxide film,aluminum
3 Plasma stream >>> Current density,pinch effect
Arc Blow >>> Start and end positions,residual magnetism,asymmetrical magnetic
4 field
 5 Metal transfer >>> Globular,spray,short circuiting

The polarity applied to TIG welding of stainless steel is DC electrode negative.In this
7 1 polarity,the penetration becomes deep because the arc is concentrated.
On the other hand,in TIG welding of aluminum alloy cleaning action is effective to
2 remove oxide film on the surface of material.Then,AC is applied.

In 100%CO2 Mag welding using solid wire in the low current and lowe voltage level,the
metal transfer mode becomes short circuiting transfer.And in the high current and high
8 1 voltage level the metal transfer mode becomes globulae transfer.
In 80% Ar-20%Co2 mixture gas MAG welding using solid wire with welding current over
2 350A,the metal transfer mode becomes spray transfer.

In GMA wellidng of stainless steel,a shielding mixture gas of Ar+2.5%O2 si used to keep
the arc stable.However,a shiedling gas of 100% Ar is applied to MIG welding of
3 aluminum alloy.

The molten metal droplet transfers along the arc cavity in the flux covering.This metal
9 1 transfer mode can be observed in SAW.(Flux wall guided transfer)

The molten metal droplet is punctured by rapid expansion of the internal gas generated
in the droplet.This metal transfer mode can be observed in MMA welding.(Explosive
2 tranfer)

The molten metal droplet size is larger than the electrode diameter.This metal transfer
3 mode can be observed in CO2 arc welding in high current.(Globular transfer)

The molten metal droplet of small size transfers in free flight in the arc.This metal
transfer mode can be observed in MAG welding in high current and Ar base shieding
4 gas(Ar-75% or more)(Spray transfer)

The molten metal droplet at the tip of electrode contacts with the weld pool and
transfers by the electromagnetic pinch force and the surface tension of the droplet.This
metal transfer mode can be observed in MAG welding in low current and low arc
5 voltage.

In MAG welding with Ar and CO2 mixed gas,the spray transfer mode is obtained when
the welding current is more than critical current and CO2 mixture ratio is less than
about 25%.If the welding current is under the level above mentioned,the spray transfer
10 1 mode can not be obtained because of a shortage of electromagnetic pinch force.
In order to obtain the spray transfer in pulsed MAG welding,it is necessary to keep
2 pulse current over the welding current mentioned in the paragraph.
11 1 CO2 arc welding in low current and low voltage >>> Short circuiting transfer
2 SAW >>> Flux wall guided transfer
3 CO2 arc welding in high current >>> Globular transfer
MAG weliding in high current and a mixed shiedling gas of 80%Ar+20%CO2 >>> Spray
4 transfer
5 MIG welding >>> Spray transfer
In short circuit welding,the spatter is made as molten is blown off by the
12 1 electromagnetic force and the arc reiginition force.
 To reduce the amount of spatter,an abrupt increase of short circuit is controlled by
reactor.Recently,high controllable and responsive power sources are developed to
2 reduce spatter.This type is inverter control.
In high welding current of golbular metal transfer,the size and amount of spatter are
3 large and many.
A wire is melted by the arc heat and Joule heat(Resistance heating) generated in the
13 1 wire extension.
2 The former is proportional to the arc current.
3 The latter is proportional to the square of welding current.
4 And the latter depends on both of wire diameter and wire extension.
Consequently in the case of wire feeding at constant speed,if the wire extrension is
5 incereased,welding current decerases.
When welding current increases in the condition of fixed arc voltage and welding
14 1 speed,the penetration depth increases.
When arc voltage increases in the condition of fixed welding current and welding
2 speed,the pentration fepth usually decreases.
When welding speed increases in the condition of fixed welding current and arc
3 voltage,the penetration depth decreases.
Compared with downhill welidng,the penetration depth of uphill welding is usually
4 deeper and its weld bead shape becomes narrower and more convex.
1 3 1
In MAG/MIG welding using a small-diameter wire,the welding wire is fed in high speed
2 1 and current density is high.
Then the welding power source is a type of DC constant voltage and the welding wire is
2 constant speed.
As a result of the previous paragraph(2),the arc length is controlled and arcs are
3 stabilized.This control function of the arc is called the self adjusting of arc.
The power source generally used in MMA welding is AC type with drooping
3 1 characteristics.
The power source generally used in TIG welding is DC type with constant current
2 characteristics.
The power source generally used in MAG welding is DC type with constant voltage
3 charactreristics.

4 The power source generally used in SAW is AC type with drooping characteristics.

5 The sheilding gas for MAG welding is a mixture of 80% argon and 20% carbon dioxide.
MAG welding process applies the self adjusting mechanism of arc length for wire
4 1 feeding.
DC type with constant voltage characteristics power source is used for self adjusting of
2 arc.
SAW with a large diameter wire process applies the arc voltage feedback control system
3 for wire feeding.
AC type with drooping characteristics power source is used for the arc voltage feedback
4 control system.
5 Constant speed feeding is suitable for the high speed wire feeding.
 In an arc welding power souce using in MMA welding,as shown in symbol A in
Fig(a),welding current increases or decreases by changing the position of moving
core.When the advice(Symbol A) is located in the position shown in Fig(b),magnetic
leakage flux,becomes large and welding current decreases.On the other hand,in the
5 1 case shown in Fig©,welding current increases.

The moving core type AC arc welding power source provides the drooping
characteristics by the reactance.Then the phase of welding current is delayed compared
with that of open circuit voltage.In the figure showing voltage current waveforms of AC
arc,curve(1) indicates op[en circuit voltage.Curve(2) indicated arc
voltage.Consequently,the moving core type AC arc welding power source provides low
6 1 power factor.
7 1
2
3
4 Not sure answer
8

When welding location is far away from a welding power source in MAG welding,a
welding cable is extended sometimes more than several ten meters.In this case,the arc
9 1 voltage decreases and the arc becomes unstable.

This state of arc is caused by the increase in electrical resistance of the extension
2 cable.Then the state of arc can be improved by increasing the output voltage.
However the arc can not be stabilized when the cable is wound in several turns.The
3 winding of cable causes the increase of reactance.

10 1 DC type constant current(dropping)characteristics) is used in stainless steel welding.

2 Tungsten is used as electrode.
3 High frequency AC is used to ignite an arc.
Electromagnetic noise are caused on electronic devices by the above arc ignition
4 method.
5 DC electrode negative is applied to welding of mild steel.

The duty circel of an arc welding power source is defined as the ratio of the loading
time to total time.In JIS,the loading time is adopted the sum of intermittent loading
11 1 time during the total time of 10 min.

In that time,the rated duty circle is defined as the percent ratio of the loading time of
rated output current.The allowable duty cycle is given by the following expression.
Xxxxxxxxxxxxxxx
2 A is the rated output current.B is the operating output current.

In the case of continuous welding(10 minutes or more)using the welding power source
with the rated output current of 350A and rated duty cycle of 60%,About 270A is the
12 1 allowable maximum weling current(If necessary,calculated as square root of 0.6=0.77)

In the case of continuous welding(10 minutes or more)using the welding power source
with the rated output current of 300A and rated duty cycle of 40%,185A is the
2 allowable maximum weling current(If necessary,calculated as square root of 0.4=0.63)
 In the case of continuous welding(10 minutes or more)using the welding power source
with the rated output current of 500A and rated duty cycle of 100%,500A is the
3 allowable maximum weling current.
The rated welding current and duty cycle of torch determine the allowable duty cycle of
4 welding torch except the operation welding current.

The inside of MAG welding power source is cooled by forced air,and therefore becomes
dusty.Then,it is necessary to clean the inside of power source by blowing of compressed
13 1 air.
If the groove of a wire feed roller is worn out,wire feeding becomes unsteady and
2 wire,slips.

3 In partly mechanized MAG welding,a conduit affects the smoothness of wire feeding.

4 In MAG welding,welidng current is transmitted to a welding wire through a constant tip.

14 1
 1
2

6
7

8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

24

25

26

27

28
29

30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

46

47

48

49

50

51

52

53

54

55
56

57

58

59
60
61
62

63
64
65
66

67
68

69

70

71

72

73

74

75

76

77

78

79

80
81
82
83

84
85

86
 87

88

89
90
91
92

93

94

95

96

97
98

99

100

101

102

103

104

105

106

107

108

109

110
111
112

113
114
115
116
117
118

119

120

121

122
123
124

125
126

127

128

129

130
131

132

133

134

135

136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
 171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
a
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
818
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
836
837
838
839
840
841
842
843
844
845
846
847
848
849
850
851
852
853
854
855
856
857
858
859
860
861
862
863
864
865
866
867
868
869
870
871
872
873
874
875
876
877
878
879
880
881
882
883
884
885
886
887
888
889
890
891
892
893
894
895
896
897
898
899
900
901
902
903
904
905
906
907
908
909
910
911
912
913
914
915
916
917
918
919
920
921
922
923
924
925
926
927
928
929
930
931
932
933
934
935
936
937
 AWE Chapter-1

1 1 1 1 2 3 4 5

2 1 2 3 4 5

3 1 2 3 4 5

4 1 2 3 4 5

5 1 2 3 4 5

6 1 2 3 4 5

7 1 2 3 4 5

8 1 2 3 4

9 1 2 3 4 5

10 1 2 3 4 5

11 1 2 3 4 5

12 1 2 3 4 5

13 1 2 3 4 5

14 1 2 3 4 5

Page 29 of 54
 AWE Chapter-1

1 2 1 1 2 3 4 5

2 1 2 3 4 5

3 1 2 3 4 5

4 1 2 3 4 5

5 1 2 3 4 5

6 1 2 3 4 5

7 1 2

8 1 2 3

9 1 2 3 4 5

10 1 2

11 1 2 3 4 5

12 1 2 3

13 1 2 3 4 5

14 1 2 3 4

Page 30 of 54
 AWE Chapter-1

1 3 1 1 2 3 4 5

2 1 2 3

3 1 2 3 4 5

4 1 2 3 4 5

5 1 2 3 4

6 1 2 3 4 5

7 1 2 3 4

8 1 2 3 4 5

9 1 2 3

10 1 2 3 4 5

11 1 2 3 4

12 1 2 3 4

13 1 2 3 4

Page 31 of 54
 AWE Chapter-1

1 4 1 1 2 3 4 5

2 1 2 3 4 5

3 1 2 3 4 5

4 1 2 3 4 5

5 1 2 3 4 5

6 1 2 3 4 5

7 1 2 3 4 5

8 1 2 3 4

9 1 2 3 4 5

10 1 2 3 4 5

11 1 2 3

12 1 2 3 4 5

Page 32 of 54
 AWE Chapter-1

1 5 1 1 2 3 4

2 1 2 3 4 5

3 1 2 3 4 5

Page 33 of 54
 AWE Chapter-1

1 6 1 1 2 3 4 5

2 1 2 3 4 5

3 1 2 3 4 5

4 1 2 3 4 5

5 1 2 3 4 5

6 1 2 3 4 5

7 1 2 3

8 1 2 3 4 5

9 1 2

10 1 2 3

11 1 2

Page 34 of 54
 AWE Chapter-2

2 1 1 1

2 1 2 1

2 1 3 1 2 3 4 5

2 1 4 1 2 3 4 5

2 1 5 1 2 3 4 5

2 1 6 1 2 3 4 5

2 1 7 1 2 3 4

2 1 8 1 2 3

2 1 9 1 2

2 1 10 1 2 3

2 1 11 1 2 3 4 5

Page 35 of 54
 AWE Chapter-2

2 2 1 1 2

2 2 2 1 2

2 2 3 1 2 3 4 5

2 2 4 1

2 2 5 1 2 3 4 5

2 2 6 1 2 3

2 2 7 1 2 3 4

2 2 8 1 2 3 4

2 2 9 1 2 3 4 5

Page 36 of 54
 AWE Chapter-2

2 3 1 1 2 3 4 5

2 3 2 1 2 3 4 5

2 3 3 1 2 3

2 3 4 1 2 3 4 5

2 3 5 1 2 3 4 5

2 3 6 1

2 3 7 1 2 3

2 3 8 1 2 3 4

2 3 9 1 2

2 3 10 1 2 3

2 3 11 1 2 3 4

2 3 12 1 2 3 4 5

Page 37 of 54
 AWE Chapter-2

2 4 1 1 2 3 4 5

2 4 2 1 2 3

2 4 3 1 2 3 4 5

2 4 4 1 2 3 4

2 4 5 1 2 3 4 5

2 4 6 1 2 3

2 4 7 1 2 3 4

2 4 8 1 2

2 4 9 1 2 3 4

2 4 10 1 2 3 4 5

2 4 11 1 2 3 4 5

2 4 12 1 2

2 4 13 1 2 3 4

Page 38 of 54
 AWE Chapter-2

2 5 1 1 2 3 4 5

2 5 2 1 2 3 4 5

2 5 3 1 2

2 5 4 1 2 3 4

2 5 5 1 2

2 5 6 1 2 3

2 5 7 1 2 3 4

2 6 1 1 2 3

2 6 2 1 2 3

2 6 3 1 2 3 4 5

2 6 4 1 2

Page 39 of 54
3 1 1 1 The force acting on a structure detail can be given by load.
The stress produced in a plane perpendicular to the direction of th external force is
2 normal stress.
the international unit(SI) of the stress is MPa(n/mm2).

When a round bar with the cross sectional area of 10mm2 is pulled by the force of
3 20kgf in the longitudinal direction,the stress in its direction is +19.6 Mpa.
When an external force acts on a component,the types of stress are tensile
4 stress,compression stress and shear stress.
3 1 2 1 The moment acting on a beam induces bending stress.
2 The stress required to elongate a material is tensile stress.
3 The stress existing in a member without external forces is called residual stress.
In a elastic region,the relation between stress and strain is given by xxx,where E is
3 1 3 1 modulus of elasticity.
2 Significant stress concentration occurs beside a hole in a plate.

For a widw plate with a hole subjected to uniform tension,the stress at the edge of the
3 hole is 3 times as large as the remote uniform stress area from the hole.
4 Among the followings,the stress concentration is the largest at the crack tip.
5 Stress concentration does not signigicantly affect static strength.

3 1 4 1 The static strength is obtained by tensile test under the a relatively small loading rate.

2 The absorbed energy is obtained by a Charpy test under at a drop weight loading rate.
3 The fatigue strength is obtained by a fatigue test, under a cyclic loading.
4 The creep strength is obtained by a creep test,under a constant load.
5 The hardness is closely related with tensile strength.
3 1 5 1 The strength of a weld joint is obtained by tensile test.
The property obtained is tensile strength and location of fracture.
The material properties differ from place to place in HAZ,because of different,thermal
2 history.
The material property in a weld joint locally varies.This variation is measured by the
3 hardness test.
Mechanical properties given in a tensile test are the yield strength,tensile strength and
3 2 1 1 elongation.
2 The tensile strength is closely related to the hardness.

In accordance with the international System of Units(SI units),the unit of stress in a

3 tensile test is defined as " load per sectional area",which is expressed by MPa(N/mm2).

When a steel bar is uniaxially loaded in a tensile test and is elongated by delta l from
the original length.Then the nominal strain of the steel bar in the axis direction is ∆l/l0.
4 (Need to check)

In a tensile test,there is a proprtional relation between the stress and strain under the
5 elastic condition.This proportional constant is called Young's modulus.
In a tensile test,the ductility is shown by elongation or the reduction of area of steel
3 2 2 1 materials.
 In a tensile test,some deformation still reamins after removing the load.This nature of
2 metals is defined as plasticity.
3 High strength steel is the steel material that has high tensile strength.

4 The yield ratio of high strength steel is generally larger than that of mild steel in general.
Compared with base metal,both microstructure and mechanical properties are changed
5 in HAZ.

3 2 3 1 One of the properties obtained in a tensile test of steel materials is yield strength.
2 One of the properties obtained in a hardness test of steel materials is HV.

3 One of the properties obtained in a bend test of steel materials is bending ductility.
One of the properties obtained in a Charpy impact test of steel materials is absorbed
4 energy.
One of the properties obtained in a constant amplitude fatigue test of steel materials is
5 S-N diagram.

3 2 4 1 In a tensile test of mild steel,a distinctive yielding phenomenon always appear.

In a tensile test of quenched-and-tempered high strength steel,a distinctive yielding
2 phenomenon,never appear.
In a tensile test of SUS304(Type 304) austenitic stainless steel,a distinctive yielding
3 phenomenon,never appear.

4 In a tensile test of pure aluminum,a distinctive yielding phenomenon,never appear.

5 High strength steel has almost the same Young's modulus as compared with mild steel.
3 2 5 1 The stress-strain curve of mild steel is Curve 1.
The point A,B and A' respectively indicate upper yield point,lower yield point and 0.2%
2 proof stress.
The point C and C' respectively indicates the points where load becomes the
3 maximum.The stress at these points is called tensile strength.
The strain to the points C and C' is uniform elongation beyond which necking occurs in
4 the spicemen.
The material fractures at the points D and D',and the points E and E' are called
5 elongation at the fracture.
The stress used in a stress-strain curve is the stress(normal stress)obtained by dividing
3 2 6 1 the tensile load by the cross sectional area before loading.

The strain used in a stress-strain curve is the stress(normal strain)obtained by dividing

2 the elongation of the guage lengjth by the gauge length before loading.
When the strain is small in the early stage of tensile test,a linear relation exists between
3 stress and strain.This region is called elastic region,
Although the micro-structure of steel varies by heat treatment or welding,modulus of
4 elasticity remains unchanged.
An alternative expression of the yield strength of high strength steel is 0.2% proof
5 stress.
3 2 7 1 The property obtained by a tensile test of weld joint is tensile strength.
2 It is generally required that the tensile strength.
 For the measurement of hardness in a narrow area such as HAZ,the Vicker's hardness
test is suitable.Because its indent made by a square pyramid diamond is deep.The
3 hardness obtained by this test is expressed by HV.

No significant macroscopic deformation is observed.The fracture surface is flat.The

fracture pattern is finely ripped or striated during the incremental propagation
3 3 1 1 stage,Fatigue fracture.

The fracture causes considerable deformation including reduced plate thickness and
2 contraction.The fracture surface is rough and dull,ductile fracture.

No significant macroscopic deformation is observed.The fracture surface is flat,bright

and crystalline.On the fracture surface,"chevron pattern" or "herringbone" is
3 observed,brittle fracture.

The fracture is caused under a combination of specific material and environment

subjected to a certain stress.This fracture mainly occurs in austenitic stainless
4 steel,stress corossion cracking.
The brittle fracture characteristic of low alloy steel is evaluated by toughness and this
3 3 2 1 fracture is more likely when the temperature decrease.
Brittle fracture is also known as unstable fracture,The crack propagating speed is fast,it
2 may cause a serious accident.
The steel material is more resistive to brittle fracture,as the ductile-brittle transition
3 temperature decrease.
3 3 3 1 When the transition temperature of a V-notch Charpy impact test,decrease.
2 The brittle fracture surface is almost perpendicular to the plate surface,
3 The reduction of thickness is very small.
Brittle fracture is more likely when the tensile stress is high,the crack size is large and
3 3 4 1 the temperature is low.
Brittle fracture usually occurs,when applied stresses is below the yield strength of
2 material, and the fracture surface shows chevron pattern.
Brittle fracture propagates much faster than fatigue fracture,and brittle fracture is
3 called unstable fracture.
The main three causes of brittle fracture in a weld joint are tensile stress,crack or notch
3 3 5 1 and low fracture toughness.
The fracture toughness of a weld joint is affected by the type of material,welding heat
2 input,thickness of a weld joint,temperature.
The fracture toughness of a weld joint decreases as the welding heat input becomes
3 excessive.
The fracture toughness of a weld joint decreases as the welding heat input becomes
excessive.
In the evaluation of a weld joint by the charpy impact test,the fracture toughness is
4 high when the energy transition temperature is low.
5 In a weld,the defect which affects brittle fracture most is crack.
The fracture toughness of the heat affected zone of a structural steel,varies with the
3 3 6 1 distance from the fusion line.

2 The worst fracture toughness appears,in the coarse grained heat affected zone.
The factor which does not affect the fracture toughness of the heat-affected zone is
3 height of weld reinforcement.
 The fracture toughness of HAZ of a multi-layer weld joint is affected by the multi-layer
4 thermal cycles.
Therefore,it is effective to inrease its toughness,to build-up passes,each reciving a
5 temper effect by the subsequent passes.

In general,the fatigue strength of weld joints is shown in the relationship between the
stress amplitude and the number of cycles to filure.This relationship is represented by
3 4 1 1 S-N curve.
The fatigue strength of as-welded joints is sensitive to stress concentration,and toe
2 shape of a weld.

In the fatigue test with constant amplitude,fatigue fracture does not occur under the
3 stress amplitude smaller than a certain limit.This limit stress is called fatigue limit.
3 4 2 1 The fatigue strength of weld joint is sensitive to toe shape of a weld.
Undercut is most influential to the fatigue strength,then the removal of this defect
2 leads to the reduction of stress concentration.
The fatigue strength is improved when the weld toe is smoothly finished by grinding or
3 by re-melting with TIG arc.
The fatigue strength can be improved by peening because compressive residual stresses
4 are induced in the vicinity of a weld toe.
A fatigue failure is cauesed by cyclic loading,under the applied stress which,may not be
3 4 3 1 higher than the yield strength.
2 The fatigue strength is sensitive to stress concentration.
The fatigue property is shown by a diagram called S-N diagram.In this diagram,as the
3 stress amplitude decreases,the number of cycles to failure.

A fatigue failure may not occur in a smooth specimen even if constant amplitude stress
of 10 million cycles is repeated.The upper limit of such a stress is called fatigue
limit.However,this limit may not appear clearly except for carbon steel.Moreover,this
3 4 4 1 limit for a smooth specimen is closely related to tensile sterngth.
The ratio of the minimum stress to the maximum is called stress ration in fatigue
2 tests.When this value is -1,the mean stress is 0.

When the external tensile force,P acts on the weld joint shown in the figure below,in
the case of butt joint(A),the highest stress concentration exists at the weld toe and in
3 4 5 1 the case of a non-load carrying fillet weld(B),it exists at the lower weld toe.
When the height of the weld reinforcement of a butt joint(A) increases,the stress
2 concentration at the weld toe increases.
As the curvature of a weld toe decreases,the stress concentration at the weld toe
3 4 6 1 increases.
2 The stress concentration at a weld toe does not affect statioc strength.
In the case of in plane loading,welding distortion such as angular distortion induces
3 bending stress and this stress decreases the fatigue cycle to failure.
3 4 7 1 Removing a weld reinforcement increases the fatigue strength.
An effective means to increase the high cycle fatigue strength of a weld joint is to
2 decrease the tensile reisdual stress.
The fatigue strength of a weld joint can be improved by smoothing the surface around a
3 weld toe.
 In the case that the fatigue limit does not appear in fatigue tests,the fatigue strength of
a steel weld joint is defined by the maximum stress amplitude at 2 million cycles,or is
4 evaluated by the stress amplitude at a specific cyclic number to failure.
3 5

In the relation between the residual stress in a weld joint and the welding heat
input,the peak value of the residual stress is almost independent of the heat
input.However,the width where the reisdual stress is tensile near a weld is wider as the
3 6 1 1 heat input is larger.
The residual stress in the welding direction of a mild steel plate is generally alnost the
2 same as the yield stress of the steel.
The residual stress along the weld line is almost constant as the weld length is
3 sufficiently long.
4 If the welding distortion is restrained,the residual stress generally increases.

One reason why the residual stresses is decreased by PWHT is the decrease of yield
strength of the material by elevating temperature.Another reason is a creep
3 6 2 1 phenomenon at the PWHT temperature.
The PWHT of mild steel is practiced by heating at a temperature of approximately,600
2 degree C for 25 mm of plate thickness.
3 6 3 1 One of the main purposes of PWHT is to reduce residual stress.
2 PWHT has a further effect of releasing hydrogen.
When PWHT is applied to QT high strength steel,the heating temperature shall not
3 exceed the tempering temperature.

Regarding the residual stress in a butt joint of mild steel,the highest stress exists in the
direction along the welding line, and the stress reashes almost 100% of the yield
3 6 4 1 strength.

2 Angular distortion significantly increases the stress concentration of a weld joint.

In overlay welding of austenitic stainless steel on a mild steel plate,the overlay weld is
distorted in a concave manner towards the overlay side after the completion of
3 welding.Then,tensile reisdual stress is generated in the stainless steel overlay weld.
In the butt joint of mild steel plates,the residual stress in the direction perpendicular to
3 6 5 1 the weld line is lower than the yield strength in general.
In multi-layer V groove welding,as the number of welding passes increases,angular
2 distortion,becomes larger.
The root gap changes during welding.This distortion in plane is called rotational
3 distrotion.
The distortion in fillet welding of T joint are angular distortion and longitudinal bending
4 distortion.
The shrinkage in the direction perpendicular to the welding line,which occurs in butt
5 joint welding,is called transverse shrinkage.
3 6 6 1 The welding distortion which induces bending stresses is angular distortion.
2 Tensile residual stresses hardly affect static strength.
3 Tensile residual stresses strongly affect britle fracture strength.
 Stress concentration and tensile residual stress decrease the fatigue strength of a weld
4 joint.
5 Compressive residual stresses in a sheet panel tend to genereate buckling.
Since the welding heat input strongly affects the welding distortion,the heat input
3 6 7 1 should be minimized as low as possible.
2 External restraint is not effective to reduce tensile residual stresses.
3 Progressive welding sequence is not usseful to reduce welding distortion.

The shrinkage in the direction perpendicular to the weld line is called transverse
3 6 8 1 shrinkage and that in the welding direction is called longitudinal shrinkage.
The out of plane distortion which often makes troubles in a fillet weld is angular
2 distortion and longitudinal bending distortion.
The root opening closes with the adverse of SMAW(MMA welding).This distortion is
3 called rotational distortion.
In order to reduce the angular distortion,it is effective,to decrease the amount of weld
3 6 9 1 metal.

2 One of the jigs for restraining angular distortion of a butt joint is to use a strongback.

3 As the number of weld passes increases,the angular distortion of a fillet weld increases.
In order to reduce the welding distortion of a fillet weld intermitted (skip) welding is
4 effective.

In the use of local heating for correcting welding distortion in QT high strength steel,the
5 maximum heating temperature shall not exceed tempering temperature.
3 6 10 1 When the welding heat input increases,the transverse shrinkage increase.
2 The buckling is likely to occur in thin plate.

Comparing the angular distortion of a V-grooved butt weld joint between many layers
piled up using small diameter electrodes and a few layers piled up with large diameter
3 edctrodes,the angular distortion is larger in former case.

4 Compared with a double V groove,a single V groove causes a larger angular distortion.
Compared with the transverse shrinkage between mild steel and austenitic stinless
5 steel,the transverse shrinkage is larger for austenitic stainless steel

The angular distortion of a butt weld joint is caused by the difference in transverse
shrinkage between the surface and back side of a plate.For this reason,the angular
distortion for one side multi pass welding tends to become large when a 60 degree V
3 6 11 1 groove is used.

In a bead on plate welding,when the welding heat input is small,the angular distortion
increases as the heat input increases.If the heat input is increased and through the
thickness penetration occurs,the angular distortion becomes the maximum at a certain
heat input followed by a gradual decrease as the heat input further increases.This owes
to the fact that when the welding heat input is sufficiently increased the difference in
2 shrinkage between the surface side and the back side is ignored.
 The amount of deposited metal is small compared with a double V groove,the welding
distortion is also small,and this groove is suitable for thick plates.The edge preparation
3 7 5 1 must be done by machining.(Double Sided U Groove)

The amount of deposited metal is small,the edge prepartation is easy and welding
distortion is small.But this groove can be applied to thin plates in MAG welding.(Square
2 Groove)

This groove is suitable for welding in the horizontal position and the edge preaparation
is easy.But the amount of deposited metal and the angular distortion are large when
3 applied to thick plates.(Single Bevel Groove)

The edge preparation is easy and it can be applied to the welding in all positions.But
the amount of deposited metal and the angular distortion are large when applied to
4 thick plates.(Single V Groove)

Compared with a single V groove,the edge preparation is not simple,but gas cutting can
be used.Also,the amount of deposited metal is small and this groove is applicable to
5 thick plates.(Double V Groove)
3 7 6 1 A groove for butt joint of 3mm thick plate in MMA welding is square groove.
A groove for butt joint of a 20mm thick plate to minimize angular distortion in MAG
2 welding is double V groove.
A groove for butt joint of a 10mm thick plate in horizontal welidng position is single
3 bevel groove.
A groove for butt joint of 1 40mm thick plate in horizontal welding position is double
4 bevel groove.

5 A groove for butt joint of 100mm thick plate in electroslag welding is square groove.

Thickness should be firstly taken into consideration in selecting a groove for a butt joint
3 7 7 1 of the steel,and the welding process and also the difficulity in edge preparation.
To reduce the welding distortion,a groove must be selected so that the deposited metal
2 is small in amount.

In the butt joint of steel plates unequla thickness,a transition with taper must be taken
3 to the thicker plate and the throat thickness is the thickness of the thinner plate.

When a weld groove is selected for the butt joint of a steel plate,welding process,
3 7 8 1 amount of deposited metal, thickness of steel, easiness of edge preparaion.
3 7 9
3 7 10
3 7 11
3 7 12
3 7 13
3 7 14
3 7 15
The allowable stress of a structural member subjected to a static load is generally given
3 8 1 1 as a fraction of yield strength or tensile strength.
2 The allowable shear stress is about 1/ root 3.
3 The allowable stress of a fillet weld is based on shear stress.
 4 Compared with the allowable static stress,the allowable fatigue stress is generally lower.

5 Lowering the allowable stress for the same weld joijt increases the safety factor.
3 8 2 1 The safety factor is defined ass referenced strength/allowable stress.
2 The fatigue strength of a weld joint is generally lower than the yield strength.
3 The allowable shear stress is lower than the allowable tensile stress.
When a welded member is reinforced with a cover plate,then the fatigue strength
4 decreases.
In the case of butt joints,the fatigue strength of partial penetration joints is generally
5 lower than that of full penetration joints.

3 8 3 1 The stress conccentration at the root or the weld toe is not taken into consideration.
2 Welding residual stress is not taken into consideration.
The designed cross-sectional area is given by the product of the throat thickness and
3 effective weld length.

In calculting the strength of a butt joint of unequal thickness,a transition with taper
4 must be thicker plate and the throat thickness is the thickness of the thinner plate.
5 The allowable stess for a fillet weld is based on shear strength.
In designing a welded structure,the strength required to the weld joint must be
3 8 4 1 understood the selection of material where the structure is applied.

When the static load can be considered as a main external force,the static strength of
the material used serves as the basis of allowable stress.In general,the allowable stress
2 can be determined as a fraction of yield point or proof stress or tensile strength.

When many uncertainies exist in the service conditions including load,the allowable
3 stress must be small that is factor of safety must be taken as a large value.
3 8 5 1 The throat thickness of the butt joint is 20 mm.
The effective sectional area of the throat is given by the product of the throat thickness
2 and 100mm.
3 Therefore,the sectional area of the joint is 2000mm2.
4 The allowable tensile stress for the weld joint of SM490 is 215 N/mm2.
5 Therefore,the allowable maximum load for the weld joint is 430KN.
3 8 6 1 The throat thickness of the weld joint is 5 mm for every weld.
If each weld length is assumed to be effective weld length,the total effective weld
2 length of the joint is 800mm.
The sectional area which holds the load is given by throat thickness x total effective
3 weld length.
4 The allowable stess is the stress allowed to shear.
Suppose that the allowable stress is 80N/mm2.Then the allowable maximum load is
5 320KN.
3 8 7 1 Since the size of the fillet weld is 10mm,the throat thickness is 7mm.

The effective weld length of one fillet weld is 100mm.Since load F is transmitted by a
couple of fillet welds on both left and right sides,the efective weld length of the weld
2 joint is 200mm.
 Since the efective sectional area of the throat is given by the product of the throat
3 thickness and the effective weld length,it becomes 1400 mm2.
4 The allowable stress for this weld joint of SM490 steel is 125 N/mm2.
5 Therefore,the allowable maximum load for the weld joint is 175KN.
3 8 8
3 8 9
3 8 10
3 8 11 1 As far as possible,the welding position is selected to be flat.
In addition to the plate thickness,the groove configuration must be selected according
2 to the welding process.
The codes and standards applied to the designing of weld joints of a structural member
3 shall be mandatory.

4 All of the weld joints of a structural member are not necessarily of full penetration.
The weld joint to which a non destructive examination cannot be applied must be
5 avoided.
3 9 2 1 The weld reinforcement height of double V butt joint is not included.
2 Metal backing should be the material equivalent to the base metal.

3 For a butt joint that requires the fatigue strength double side full penetration welding.
4 Residual stresses do not effect static strength.

The joint efficient is defined by the ratio of the strength of weld joint to that of base
metal.When the joint efficiency is 100% the strength of the weld joint is larger than that
of base metal.When it is,50% the strength of the weld joint is a half of that of base
3 9 3 1 metal.

If no defect exists in the weld joint,the butt weld joint loaded in the direction
perpendicular to the welding line generally fractures in the base metal.This owes to the
fact that the tensile strength of weld metal is to some extent lower than that of base
2 metal.
3 9 4 1 Fatigue failure of a weld joint strongly depends on the configuration of joint.
If an attachment or a cover plate is welded to a component,its fatigue strength
2 decreases.
In the butt joints with the same throat thickness,full penetration increases the fatigue
3 strenght in comparasion to the partial penetration.
In the but joint requiring fatige strength,backing strip welding from one side procedure
4 should be avoided.

In a cylindrical shell subjected to the internal pressure,the circumferential stress is 2

times as large as the axial stress.In calculation,therefore the circumferential stress of a
3 9 5 1 cylindrical shell is used as the applied stress.

The required wall thickness can be calculated by (allowable stess x joint

efficiency)≥(internal pressure x diameter)/(2x wall thickness),where 1 Mpa is equal to
2 1N/mm2.And the value substituted into the equation for 90% of joint efficiency is 0.9.

The calculation gives the result that the thickness of 14 mm is at least necessary if the
3 value below the decimal point is rounded up for safety purpose.
 AWE Chapter-3

3 1 1 1 2 3 4

3 1 2 1 2 3 4

3 1 3 1 2 3 4 5

3 1 4 1 2 3 4 5

3 1 5 1 2 3

3 2 1 1 2 3 4 5

3 2 2 1 2 3 4 5

3 2 3 1 2 3 4 5

3 2 4 1 2 3 4 5

3 2 5 1 2 3 4 5

3 2 6 1 2 3 4 5

3 2 7 1 2 3

Page 49 of 54
 AWE Chapter-3

3 3 1 1 2 3 4

3 3 2 1 2 3

3 3 3 1 2

3 3 4 1 2 3

3 3 5 1 2 3 4 5

3 3 6 1 2 3 4

3 4 1 1 2 3

3 4 2 1 2 3 4

3 4 3 1 2 3

3 4 4 1 2

3 4 5 1 2

3 4 6 1 2 3

3 4 7 1 2 3 4

3 5 1 1 2 3 4 5

Page 50 of 54
 AWE Chapter-3

3 6 1 1 2 3 4

3 6 2 1 2

3 6 3 1 2 3

3 6 4 1 2 3

3 6 5 1 2 3 4 5

3 6 6 1 2 3 4 5

3 6 7 1 2 3

3 6 8 1 2 3

3 6 9 1 2 3 4 5

3 6 10 1 2 3 4 5

3 6 11 1 2

Page 51 of 54
 AWE Chapter-3

3 7 1 1 2 3 4 5,6

3 7 2 1 2 3 4 5

3 7 3 1 2 3 4 5

3 7 4 1 2 3 4 5

3 7 5 1 2 3 4 5

3 7 6 1 2 3 5 5

3 7 7 1 2 3

3 7 8 1 2 3 4 5

3 7 9 1,2 3,4 5,6 7,8 9,10

3 7 10 1,2 3,4 5,6 7,8 9,10

3 7 11 1 2 3 4 5

3 7 12 1 2 3 4 5

3 7 13 1 2 3 4 5

3 7 14 1 2 3 4 5

3 7 15 1 2 3 4 5

Page 52 of 54
 AWE Chapter-3

3 7 16 1 2 3 4 5

3 8 1 1 2 3 4 5

3 8 2 1 2 3 4 5

3 8 3 1 2 3 4 5

3 8 4 1 2 3

3 8 5 1 2 3 4 5

3 8 6 1 2 3 4 5

3 8 7 1 2 3 4 5

3 8 8 1 2 3 4

3 8 9 1

3 8 10 1

3 9 1 1 2 3 4 5

3 9 2 1 2 3 4

3 9 3 1 2

3 9 4 1 2 3 4

Page 53 of 54
 AWE Chapter-3

3 9 5 1 2 3

Page 54 of 54