It is easy to fall into a designer’s bubble and not take the time to fully understand the industry that will be building your designed part. In engineering, and arguably in every industry, words are very loaded, and people do not take the time to fully understand their impact on outcomes. Designing a welded joint is not a simple matter, and in many cases an over-engineered joint can result in a poorly built product.

The term weld brings with it weld process, type of weld joint, filler metal, heat affected zone and material temper, porosity, distortion, material shrinkage, structural integrity, etc. Most of these terms and potential issues will be taken care of by the manufacturing factory involved in the project, but it is important for a design engineer to understand the process.

In the design engineer’s mind, they should be also focused on the next higher assembly, interface/interference analysis, type of weld joint that will comply with requirements while reducing preparation time and potential fixture development, machinability, environmental effects on the part, etc.

Designing a welded assembly or part to be used by the public must follow stringent standards developed for safety by organizations and governments worldwide. These standards offer peace of mind by manufacturers and to designers by providing easy-to-follow welding guidelines that will result in properly engineered joint construction. Although designers must choose the proper materials for the application and perform a subsequent structural analysis of the product, the standards make it possible to design welded joints with the understanding that the theoretical engineering will not be lost between groups involved.