To prevent part deformation during welding it is common practice to design a
flange at the weld surface. Due to the weld, a loss in the overall length of
0.2-0.4 mm (0.01-0.02 in) should be taken into account when designing the
component. Correct alignment of the components is important. Gusset plates
can be added on the flange of the part for improved torque transmission.
Gusset plates for improved torque transmission
A simple butt joint is possible. However, the figures A and B show some
typical welding designs, which are stronger and self-centering.
Proper welds will always show flash. For aesthetic purposes the part can be
designed to hide the weld (figure C) or flash traps can be used(figure D).
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