Note:

The following definitions are taken from BS 499-1:1991 “Welding terms and
symbols – Glossary for welding, brazing and thermal cutting”

Welding:
An operation in which two or more parts are united by means of heat,
pressure or both, in such a way that there is continuity in the nature of the
metal between these parts.

Brazing:
A process of joining generally applied to metals in which, during or after
heating, molten filler metal is drawn into or retained in the space between
closely adjacent surfaces of the parts to be joined by capillary attraction. In
general, the melting point of the filler metal is above 450°C but always below
the melting temperature of the parent material.

Braze welding:
The joining of metals using a technique similar to fusion welding and a filler
metal with a lower melting point than the parent metal, but neither using
capillary action as in brazing nor intentionally melting the parent metal.

Weld:
A union of pieces of metal made by welding.

Joint:
Connection where the individual components, suitably prepared and
assembled, are joined by welding or brazing.

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Terms and Definitions
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 Type of joint Sketch Definition
Butt joint A connection between the ends
or edges of two parts making an
angle to one another of 135° to
180° inclusive in the region of the
joint
T joint A connection between the end or
edge of one part and the face of
the other part, the parts making
an angle to one another of more
than 5° up to and including 90° in
the region of the joint

Corner joint A connection between the ends

or edges of two parts making an
angle to one another of more
than 30° but less than 135° in the
region of the joint

Edge joint A connection between the edges

of two parts making an angle to
one another of 0° to 30° inclusive
in the region of the joint

Cruciform joint A connection in which two flat

plates or two bars are welded to
another flat plate at right angles
and on the same axis

Lap joint A connection between two over-

lapping parts making an angle to
one another of 0° to 5° inclusive
in the region of the weld or welds

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Terms and Definitions
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1 Types of Welds
1.1 From configuration point of view

Butt weld Fillet weld

In a butt joint

Butt weld In a T joint

In a corner joint

Autogenous weld:
A fusion weld made without filler metal. Can be achieved by TIG, plasma
electron beam, laser or oxy-fuel gas welding.

Slot weld:
A joint between two overlapping components made by depositing a fillet
weld round the periphery of a hole in one component so as to join it to the
surface of the other component exposed through the hole.

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Terms and Definitions
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 Plug weld:
A weld made by filling a hole in one component of a workpiece with filler
metal so as to join it to the surface of an overlapping component exposed
through the hole (the hole can be circular or oval).

1.2 From the penetration point of view

Full penetration weld:
A welded joint where the weld metal fully penetrates the joint with complete
root fusion. In US the preferred term is complete joint penetration weld or
CJP for short (see AWS D1.1.)

Partial penetration weld:

A welded joint without full penetration. In US the preferred term is partial
joint penetration weld or PJP for short.

2 Types of Joint (see BS EN ISO 15607)

Homogeneous joint:
Welded joint in which the weld metal and parent material have no significant
differences in mechanical properties and/or chemical composition. Example:
two carbon steel plates welded with a matching carbon steel electrode.

Heterogeneous joint:
Welded joint in which the weld metal and parent material have significant
differences in mechanical properties and/or chemical composition. Example:
a repair weld of a cast iron item performed with a nickel base electrode.

Dissimilar joint:
Welded joint in which the parent materials have significant differences in
mechanical properties and/or chemical composition. Example: a carbon
steel lifting lug welded onto an austenitic stainless steel pressure vessel.

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3 Features of the Completed Weld
Parent metal:
Metal to be joined or surfaced by welding, braze welding or brazing.

Filler metal:
Metal added during welding, braze welding, brazing or surfacing.

Weld metal:
All metal melted during the making of a weld and retained in the weld.

Heat-affected zone (HAZ):

The part of the parent metal that is metallurgically affected by the heat of
welding or thermal cutting, but not melted.

Fusion line:
Boundary between the weld metal and the HAZ in a fusion weld. This is a
non-standard term for weld junction.

Weld zone:
The zone containing the weld metal and the HAZ.

Weld face:
The surface of a fusion weld exposed on the side from which the weld has
been made.

Root:
The zone on the side of the first run farthest from the welder.

Toe:
Boundary between a weld face and the parent metal or between runs. This
is a very important feature of a weld since toes are points of high stress
concentration and often they are initiation points for different types of cracks
(eg fatigue cracks, cold cracks). In order to reduce the stress concentration,
toes must blend smoothly into the parent metal surface.

Excess weld metal:

Weld metal lying outside the plane joining the toes. Other non-standard
terms for this feature: reinforcement, overfill.

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Terms and Definitions
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 Parent Weld
Weld
metal zone
face Toe
Parent
metal

HAZ
Weld
metal Fusion
Root Excess
line
weld metal
Excess
weld metal

Butt weld

Parent
metal
Excess
weld metal
Weld
zone
Toe
Fusion
line
Weld
face

Root Parent
Weld HAZ metal
metal
Fillet weld

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Terms and Definitions
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4 Weld Preparation
A preparation for making a connection where the individual components,
suitably prepared and assembled, are joined by welding or brazing.

4.1 Features of the weld preparation

Angle of bevel:
The angle at which the edge of a component is prepared for making a weld.
In case of a V preparation for a MMA weld on carbon steel plates, this angle
is between 25-30°. In the case of a U preparation for an MMA weld on
carbon steel plates, this angle is between 8-12°. In case of a single bevel
preparation for an MMA weld on carbon steel plates, this angle is between
40-50°. In case of a single J preparation for a MMA weld on carbon steel
plates, this angle is between 10-20°.

Included angle:
The angle between the planes of the fusion faces of parts to be welded. In
the case of single V, single U, double V and double U this angle is twice the
bevel angle. In case of single bevel, single J, double bevel and double J, the
included angle is equal to the bevel angle.

Root face:
The portion of a fusion face at the root that is not bevelled or grooved. Its
value depends on the welding process used, parent material to be welded
and application; for a full penetration weld on carbon steel plates, it has a
value between 1-2mm (for the common welding processes).

Gap:
The minimum distance at any cross section between edges, ends or
surfaces to be joined. Its value depends on the welding process used and
application; for a full penetration weld on carbon steel plates, it has a value
between 1-4mm.

Root radius:
The radius of the curved portion of the fusion face in a component prepared
for a single J, single U, double J or double U weld. In case of MMA,
MIG/MAG and oxyfuel gas welding on carbon steel plates, the root radius
has a value of 6mm in case of single and double U preparations and 8mm in
case of single and double J preparations.

Land:
The straight portion of a fusion face between the root face and the curved
part of a J or U preparation, can be 0. Usually present in case of weld
preparations for MIG welding of aluminium alloys.

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Terms and Definitions
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4.2 Types of preparation
Open square butt preparation

This preparation is used for welding thin components, either from one or
both sides. If the root gap is zero (ie if components are in contact), this
preparation becomes a closed square butt preparation (not recommended
due to the lack of penetration problems!).

Single V preparation

Included angle

Angle of
bevel

Gap Root face

The V preparation is one of the most common preparations used in welding;

it can be produced using flame or plasma cutting (cheap and fast). For
thicker plates a double V preparation is preferred since it requires less filler
material to complete the joint and the residual stresses can be balanced on
both sides of the joint resulting in lower angular distortion.

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Terms and Definitions
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 Double V preparation

The depth of preparation can be the same on both sides (symmetric double
V preparation) or deeper on one side (asymmetric double V preparation).
Usually, in this situation the depth of preparation is distributed as 2/3 of the
thickness of the plate on the first side with the remaining 1/3 on the
backside. This asymmetric preparation allows for a balanced welding
sequence with root back gouging, giving lower angular distortions. Whilst
single V preparation allows welding from one side, double V preparation
requires both sides access (the same applies for all double side
preparations).

Single U preparation

Included angle

Angle of
bevel

Root
radius

Gap Root
Land face

U preparation can be produced only by machining (slow and expensive).

However, tighter tolerances obtained in this case provide for a better fit-up
than in the case of V preparations. Usually it is applied for thicker plates
compared with single V preparation (requires less filler material to complete
the joint and this lead to lower residual stresses and distortions). Similar with
the V preparation, in case of very thick sections a double U preparation can
be used.

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Terms and Definitions
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 Double U preparation

Usually this type does not require a land (exception: aluminium alloys).

Single V preparation with backing strip

Backing strips allow the production of full penetration welds with increased
current and hence increased deposition rates/productivity without the
danger of burn-through. Backing strips can be permanent or temporary.
Permanent types are of the same material being joined and are tack welded
in place. The main problems related with this type of weld are poor fatigue
resistance and the probability of crevice corrosion between the parent metal
and the backing strip. It is also difficult to examine by NDT due to the built-in
crevice at the root of the joint. Temporary types include copper strips,
ceramic tiles and fluxes.

Single bevel preparation

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Terms and Definitions
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 Double bevel preparation

Single J preparation

Double J preparation

All these preparations (single/double bevel and single/double J) can be used

on T joints as well. Double preparations are recommended in case of thick
sections. The main advantage of these preparations is that only one
component is prepared (cheap, can allow for small misalignments).

For further details regarding weld preparations, please refer to BS EN ISO

9692 standard.

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 5 Size of Butt Welds
Full penetration butt weld

Actual throat Design throat

thickness thickness

Partial penetration butt weld

Actual throat Design throat

thickness thickness

As a general rule:

Actual throat thickness = design throat thickness + excess weld metal.

Full penetration butt weld ground flush

Actual throat thickness

= design throat
thickness

Butt weld between two plates of different thickness

Actual throat thickness =

Design throat thickness
maximum thickness
= thickness of the
through the joint
thinner plate

Run (pass):
The metal melted or deposited during one passage of an electrode, torch or
blowpipe.

Single run weld Multi run weld

Layer:
A stratum of weld metal consisting of one or more runs.

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Terms and Definitions
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 Types of butt weld (from accessibility point of view):

Single side weld Double side weld

6 Fillet Weld
A fusion weld, other than a butt, edge or fusion spot weld, which is
approximately triangular in transverse cross section.

6.1 Size of fillet welds

Unlike butt welds, fillet welds can be defined using several dimensions.

Actual throat thickness:

The perpendicular distance between two lines, each parallel to a line joining
the outer toes, one being a tangent at the weld face and the other being
through the furthermost point of fusion penetration

Design throat thickness:

The minimum dimension of throat thickness used for purposes of design.
Also known as effective throat thickness. Symbolised on the drawing with
‘a’.

Leg length:
The distance from the actual or projected intersection of the fusion faces
and the toe of a fillet weld, measured across the fusion face. Symbolised on
the drawing with ‘z'.

Actual throat
thickness
Leg length

Design throat
thickness
Leg length

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6.2 Shape of fillet welds
Mitre fillet weld:
Flat face fillet weld in which the leg lengths are equal within the agreed
tolerance. The cross section area of this type of weld is considered to be a
right angle isosceles triangle with a design throat thickness ‘a’ and a leg
length ‘z’. The relation between design throat thickness and leg length is:

a = 0,707 × z. or z = 1,41 × a.

Convex fillet weld:

Fillet weld in which the weld face is convex. The above relation between the
leg length and the design throat thickness written in case of mitre fillet welds
is also valid for this type of weld. Since there is an excess weld metal
present in this case, the actual throat thickness is bigger than the design
throat thickness.

Concave fillet weld:

Fillet weld in which the weld face is concave. The above relation between
the leg length and the design throat thickness written in case of mitre fillet
welds is not valid for this type of weld. Also, the design throat thickness is
equal to the actual throat thickness. Due to the smooth blending between
the weld face and surrounding parent material, the stress concentration
effect at the toes of the weld is reduced compared with the previous type.
This is why this weld is highly desired in case of applications subjected to
cyclic loads where fatigue phenomena might be a major cause for failure.

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Terms and Definitions
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 Asymmetrical fillet weld:
Fillet weld in which the vertical leg length is not equal with the horizontal leg
length. The relation between the leg length and the design throat thickness
written in case of mitre fillet welds is not valid for this type of weld because
the cross section is not an isosceles triangle.

Horizontal
leg size

Vertical
leg size

Throat
size

Deep penetration fillet weld:

Fillet weld with a deeper than normal penetration. It is produced using high
heat input welding processes (ie SAW or MAG with spray transfer). This
type of weld uses the benefits of greater arc penetration to obtain the
required throat thickness whilst reducing the amount of deposited metal
needed, thus leading to a reduction in residual stress level. In order to
produce a consistent and constant penetration, the travel speed must be
kept constant, at a high value. As a consequence, this type of weld is
usually produced using mechanised or automatic welding processes. Also,
the high depth-to-width ratio increases the probability of solidification
centreline cracking. In order to differentiate this type of welds from the
previous types, the throat thickness is symbolised with ‘s’ instead of ‘a’.

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Terms and Definitions
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6.3 Compound of butt and fillet welds
A combination of butt and fillet welds used in case of T joints with full or
partial penetration or butt joints between two plates with different thickness.
Fillet welds added on top of the groove welds improve the blending of weld
face towards parent metal surface and reduce the stress concentration at
the toes of the weld.
Bevel
weld Fillet
weld

Double bevel compound weld

7 Welding Position, Weld Slope and Weld Rotation

Weld position:
The orientation of a weld expressed in terms of working position, weld slope
and weld rotation (for further details, please see ISO 6947).

Weld slope:
The angle between root line and the positive X axis of the horizontal
reference plane, measured in mathematically positive direction (ie counter-
clockwise).

Weld rotation
The angle between the centreline of the weld and the positive Z axis or a
line parallel to the Y axis, measured in the mathematically positive direction
(ie counter-clockwise) in the plane of the transverse cross section of the
weld in question.

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Terms and Definitions
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 Welding position Sketch Definition
Flat A welding position in which
the welding is horizontal,
with the centreline of
the weld vertical. Symbol
according ISO 6947 – PA.
Horizontal-vertical A welding position in which
the welding is horizontal
(applicable in case of fillet
welds). Symbol according
ISO 6947 – PB

Horizontal A welding position in which

the welding is horizontal,
with the centreline of the
weld horizontal. Symbol
according ISO 6947 – PC

Vertical up A welding position in which

the welding is upwards.
Symbol according ISO 6947
PG – PF.
Vertical down A welding position in which
the welding is downwards.
Symbol according ISO 6947
PF – PG

Overhead A welding position in which

the welding is horizontal and
overhead, with the centre-
line of the weld vertical.
Symbol according ISO 6947
– PE.
Horizontal- A welding position in which
overhead the welding is horizontal and
overhead (applicable in
case of fillet welds). Symbol
according ISO 6947 – PD.

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 Tolerances for the welding positions

8 Weaving
Transverse oscillation of an electrode or blowpipe nozzle during the
deposition of weld metal. This technique is generally used for vertical up
welds.

Stringer bead:
A run of weld metal made with little or no weaving motion.

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