5 Types of Welding Joints Explained

Welding might sound like a fairly simple process, but in reality, it’s a technical craft that requires a specific skill set; including high levels of attention to detail and precision.

What’s more, the individual performing the process needs to be aware of what welding joints to use so that they can guarantee a high-quality weld. Since there are several different types of welding joints to choose from, it’s important to pick the right one for your weld, since different ones offer different qualities. 

That’s why we’ve highlighted the five most common welding joints in our blog below. Read on to find out what they are, their applications, and how to choose the right one for your project…

Interested in our welding services? Get in touch at 01484 843599 to find out what we can offer your business.

1. Butt joint weld

Starting with one of the most common types of joints – the butt joint weld is where two flat pieces of metal are aligned in the same plane at an angle before the weld begins. Butt joint welds have many variations, including:

• Square
• V-groove
• Single bevel

What variation a welder chooses for this joint depends on the type of weld being produced. For example, square groove welds are better for materials being welded which are moderately thick.

Pros:

• Stronger than other weld joints
• Easy to machine and inspect

Cons:

• Not suitable for thin materials, such as welding certain types of stainless steel
• Can experience cracking and porosity 

What are the common applications of a butt joint weld?

Butt joint welds are most commonly used in sheet metal fabrication, in the fabrication of structures, such as bridges and parking garages, as well as piping systems. They are also used in the transportation industry for the manufacturing of car frames and exhaust systems.

2. Lap joint weld

A lap joint weld is a similar process to a butt joint weld, but instead of joining the metals side by side, they are placed so they overlap each other. With these types of weld, you can either provide a full lap joint or a half lap joint.

In a full lap joint, no materials are removed from the piece joined – meaning the weld is a combination of both materials’ thicknesses. With a halving laps joint, material is removed from both pieces, so they can join together to create a thickness uniform with the rest of the weld.

Pros:

• Better for aesthetic purposes as provides a neater finish
• Have a large surface area for the weld

Cons:

• The overlapping metals might not be suitable for all types of aesthetic applications
• Correct welding speed must be used otherwise it can be prone to cracking

What are the common applications of a lap joint weld?

Lap joint welds are commonly used in sheet metal fabrication projects, as well as in the repair of metal structures. They are also used within the aircraft and spacecraft sector, to form structural components.

3. Corner joint weld

To count as a corner joint weld, two pieces of material in a weld must be joined at a right angle. This is so the materials ultimately form an L-shape.

To be classed as a corner joint weld, the metals must be joined together at a 90 degree angle. Any other angle would be considered a fillet weld.

Pros:

• Can withstand a variety of materials
• Offers a clean appearance so suitable for aesthetic projects

Cons:

• Require careful welding techniques to provide correct fusion 
• Can experience more bouts of wear and tear at its seams

What are the common applications of a corner joint weld?

Corner joint welds have proven popular in the sheet metal fabrication industry because they act as a focal point of stress, which makes them perfect for making boxes and frames.

4. Edge joint weld

Edge joint welds are similar to corner joint welds in that they help join two metals together. However, edge joints join the metal side-by-side. Depending on the application, the joint can be angled.

They’re often considered to be easy to assemble and a better alternative to corner welds – if an accurate fit is necessary.

Pros:

• Fairly easy to assemble and master 
• No need to prepare materials before welding as the edges used are typically already smooth and even 

Cons:

• Can’t withstand heavy loads
• Weld can struggle to penetrate all the way

What are the common applications of an edge joint weld?

As they are similar to corner joint welds, they have similar applications too. Edge joint welds are used in sheet metal projects, as well as piping where accuracy is essential.

5. Tee joint weld

A tee joint weld gets its name from assuming the shape of the letter ‘T’, and involves welding two perpendicular pieces of metal together.

They’re considered to be a type of fillet weld, and are faster and easier to produce than other welding joints in the list.

Pros:

• Simple and quick to create
• Can withstand stronger materials

Cons:

• Must prepare edges if materials are thicker
• Are more prone to corrosion

What are the common applications of a tee joint weld?

Tee joint welds are most commonly used in equipment manufacturing – for example, within packaging machinery. They are especially useful for those working with thin materials such as plates or sheets.

Types of welding joints: FAQs

What exactly are welding joints?

Welding joints refer to the point or edge where two (or more) metals are fused together.

The process of welding dates back to 3000 B.C., so it makes sense that within this time we’ve developed higher standards around the process. That’s why small details, such as choosing the right welding joint are very important, as they can impact the quality of the weld.

How do you choose the right welding joint for your project?

To choose the right welding joint for your project, ensure you consider the following factors:

• Materials: Assess the materials you will use in your weld. This will indicate what strength of weld joint you need. For example, if you’re using thicker materials, you might need to use a butt joint as they have good mechanical strength.
• Welding process: You should also consider the welding process when you choose a weld joint. This is because some joints are more suitable for welding in certain positions than others.
• Accessibility: Evaluate what the process of your weld will entail before choosing your weld joint. For example, if you have poor weld area accessibility, it’s best to pick a weld joint that is easier to access, such as the butt joint.

Are you looking for a full-service sheet metal fabrication company?

Since our inception in 1968, we’ve been a part of a variety of different sheet metal fabrication projects. So when it comes to choosing the right materials – from the most suitable type of metal right down to the correct welding joint – we know exactly what will work best for your specific project.

Using our variety of sheet metal fabrication services, including welding and CAD design, as well as laser cutting, we’ll get to work on providing you with a high-quality, cost-effective result that exceeds your expectations.

For more information about our extensive range of services here at Salamander Fabrications, speak to a member of our expert team today.