Joint design.
Edge prep.
Weld-friendly.
Welding design impacts strength, distortion, cost. Joint type, edge preparation, accessibility, post-weld machining all designed up front.
Key principles.
Per load
Butt joint: tensile strongest. Lap joint: easy to fit. T-joint: structural. Choose per loading.
For thickness
Square edges < 3 mm. V-groove 3-20 mm. Double-V > 15 mm. Per material thickness.
Tool path
Welder must reach joint. Access dimensions: 50 mm minimum tool clearance.
Match where possible
Welded sheets ideally same thickness. Mismatch causes thermal/strength mismatch.
Symmetric welds
Symmetric weld sequences balance heat distortion. Pre-fixturing helps.
Stack-up included
Welded assemblies typically need post-weld machining for precision features. Plan in DFM.
FAQ
Welding standards?
AWS D1.1: structural steel. AWS D1.2: aluminum. ASME IX: pressure vessels. Choose per application.
TIG vs MIG?
TIG: precision, slower, aerospace standard. MIG: production, faster, general industrial. Cost: TIG 2× MIG hourly.
Filler material?
Match base metal grade. ER70S-6 standard mild steel. ER308L for 304 stainless. ER316L for 316L. ER4043 for general aluminum.
Distortion?
Significant for thin material. Pre-fixturing, sequence, symmetric welds, post-weld machining all manage distortion.
Heat affected zone?
HAZ extends 5-15 mm from weld typically. Material properties altered. Plan precision features away from HAZ.
Inspection?
Visual standard. PT or MT for surface cracks. RT or UT for internal flaws. Per applicable code.
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