Practical Ideas for the Design Professional by Duane K. Miller, Sc.D., P.E.
When fillet welds exceed a certain leg size to length ratio, and when such welds are “end loaded,” they can become “too long.” That is, the added length may not add strength that is proportional to the increase in length. This situation rarely occurs, as will be seen, but the designer should be aware of when it occurs, why the capacity is diminished, and how to mitigate the effects.
The distribution of stress at the end of welds, such as the one shown in Figure 1, is far from uniform. The relative stiffness of the weld versus the two lapped members may be significantly different. Shear lag further complicates the stress distribution. Due to these factors, and perhaps oth- ers as well, the full length of the weld may not be uniformly loaded. At some length, it becomes unconservative to assume the full length of the weld is equally effective in transferring stress. For the purposes of this article, it is at that point that the weld is considered to be “too long.”
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