Weld design (double fillet, lap/tee joint): Using the conventional leg size s and weld length l, the tensile strength (capacity) of a double-fillet welded joint is approximated as:

Difficulty: Medium

Correct Answer: 2 s * l * σt

Explanation:


Introduction / Context:
Design of fillet welds often uses simplified strength expressions in terms of leg size s and weld length l for quick sizing. For symmetric double-fillet joints (e.g., lap or tee with fillets on both sides), the effective area is roughly doubled compared to a single fillet, leading to a doubled tensile capacity under direct load sharing.


Given Data / Assumptions:

  • Double fillet of leg size s on both sides, length l.
  • Allowable tensile stress for weld metal = σt.
  • Conventional simplified design (leg-size basis), ignoring detailed throat coefficient in this question's formulation.


Concept / Approach:
In basic textbook treatments aligned with these options, the tensile capacity is taken proportional to weld effective area. For a single fillet, capacity is approximately s * l * σt; for a double fillet, area doubles, so capacity ≈ 2 * s * l * σt. (More rigorous practice uses the throat thickness t_throat = 0.707 s, giving 2 * 0.707 s * l * σ_allow, but such detail is not reflected in the given options.)


Step-by-Step Solution:

Single fillet capacity (simplified) ≈ s * l * σt.Double fillet → two such areas in parallel → 2 * s * l * σt.Therefore, the tensile strength of the double-fillet joint is 2 s * l * σt.


Verification / Alternative check:
Throat-based check: using t_throat = 0.707 s gives capacity ≈ 2 * 0.707 s * l * σ_allow = 1.414 s l σ_allow, close to but slightly less than 2 s l σt when σ_allow definitions differ. The problem's answer set aligns with the simplified leg-size expression.


Why Other Options Are Wrong:

  • 0.5 s l σt and s l σt correspond to smaller capacities (single fillet or half value).
  • 0.707 s l σt is a single-fillet throat approximation, not double fillet.
  • 2.0 s l σt duplicates option C; both indicate the same correct value.


Common Pitfalls:
Confusing leg size with throat thickness; mixing allowable weld metal stress with base metal allowable; forgetting that two fillets share the load.


Final Answer:
2 s * l * σt

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