Weld Sizes

The ultimate result of increasing the weld area will be a larger weld area.

You need to try to be clearer in your questions if you want really useful answers.

Why you intend to increase weld area? Be more clear, please!

Larger welds don't always make for stronger connections. Check out this article in Welding Magazine.

Larger Welds will provide increased strength. The strength of the weld varies greatly with the skills and abilities of the welder, the material being welded, and the welding procedure required to meet the strength criteria.

While the above respondent states that larger welds do not always make for stronger connections, that is a specific condition of circumferential welds loaded in torsion. So be careful to fully analyze critical welds for their design and actual strength characteristics.

Another outcome of larger welds is increase labor and material costs - so oversizing welds just to be sure, is an added cost in time and money that may not be required.

More filler metal, more cost, more time, more distortion.

The amount of weld required depends on the situation. There are times that more weld is good. Other times it causes problems. A good butt weld should not create a large stress riser. The joint should be able to behave close to the same way as the base metal. Other wise cracks will begin to develop in or along the weld joint. A Tee joint with a fillet weld should have a minimum leg length equal to the thickness of the thinnest member. Depending on the use and clearance issues a larger weld is sometimes preferred here for a safety margin.

larger weld doesnt always create good strength, if too high can build stresss consentration on the toe than can result crack

- Increased stress.

-Increased Distortion

- Increased HAZ

- May be increased strength (but then the component may fail somewhere else)

I was reading the machine design by Nystrom the other day - _{I still get the fun in reading and learning} where in the second chapter or so, he had explained a fatigue failure due to a construction weld (and no, not due to any of the above, it was due to modified stress distribution.)