formulab 0.20.1 → 0.21.0

package/CHANGELOG.md

@@ -5,6 +5,27 @@ All notable changes to this project will be documented in this file.
 The format is based on [Keep a Changelog](https://keepachangelog.com/en/1.0.0/),
 and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0.html).
 
+## [0.21.0] - 2026-07-20
+
+### Added
+
+- **`metal/weldStrength`** — load-carrying capacity of an equal-leg fillet weld
+  (AISC 360 ASD / AWS D1.1). Given leg size, weld length/count, electrode class, and
+  applied shear load, it returns the effective throat (`0.707 × leg`), effective area,
+  allowable shear stress (`0.30 × FEXX`), allowable load (capacity), actual stress,
+  utilization, the minimum leg that carries the load, and an `isSafe` verdict.
+  - Electrode classes `E60`–`E110` map to their exact SI `FEXX` (1 ksi = 6.894757 MPa,
+    rounded to the nearest MPa: E70 = 483, E100 = 689, E110 = 758).
+  - **v1 scope is deliberately conservative** (matches the common baseline calculators),
+    documented in the JSDoc: ASD only (LRFD deferred), longitudinal/conservative
+    `0.30 × FEXX` with no directional strength increase, weld-metal check only
+    (base-metal rupture is the engineer's responsibility), and equal-leg 90° joints.
+    Each is an additive extension point for future demand.
+  - A hand-derived golden test pins the AISC ASD model (E70, leg 6 mm, L 100 mm,
+    P 50 kN → capacity 61.47 kN, utilization 0.8135, min leg 4.881 mm).
+  - `appliedLoad = 0` is a valid capacity-only query; throws `RangeError` on non-positive
+    leg/length, `weldCount < 1`, or negative load.
+
 ## [0.20.1] - 2026-07-20
 
 ### Fixed

package/README.md

@@ -11,12 +11,12 @@ A comprehensive collection of engineering formulas and calculations for manufact
 
 ## Features
 
-- **210 industrial calculations + 8 type guards** — OEE, Cpk, SPC control charts, Gage R&R, Weibull, metal weight, CNC machining, GD&T, pipe flow, CBM, NIOSH lifting, PMV/PPD, arc flash, battery SOH, GHG emissions, PID tuning, and more
+- **211 industrial calculations + 8 type guards** — OEE, Cpk, SPC control charts, Gage R&R, Weibull, metal weight, CNC machining, GD&T, pipe flow, CBM, NIOSH lifting, PMV/PPD, arc flash, battery SOH, GHG emissions, PID tuning, and more
 - **15 specialized domains** — Quality, Metal, Chemical, Electronics, Construction, Automotive, Logistics, Energy, Safety, Food, Utility, Battery, Environmental, Machining, Industrial Engineering
 - **Zero dependencies** — Lightweight and fast
 - **TypeScript first** — Full type definitions included
 - **Tree-shakeable** — Import only what you need
-- **2,906 tests** — Coverage thresholds: 90% lines, 95% functions, 85% branches ([CI pipeline](https://github.com/iyulab/formulab/actions/workflows/ci.yml))
+- **2,921 tests** — Coverage thresholds: 90% lines, 95% functions, 85% branches ([CI pipeline](https://github.com/iyulab/formulab/actions/workflows/ci.yml))
 - **Research-based** — Golden reference tests verified against NIOSH 94-110, AIAG/ASTM E2587, JIPM, ASME B16.5, ISO 22514-2, and more
 
 ## Verification Status
@@ -72,6 +72,7 @@ The following functions include tests verified against published reference value
 | `awgProperties()` | ANSI/AWG | AWG 0-40 diameter, resistance |
 | `pressFit()` | Shigley's Mechanical Engineering Design | Same-material solid-shaft interface pressure (39.36 MPa), nu-independence |
 | `spring()` | Shigley's Mechanical Engineering Design | Spring rate (Eq. 10-9), Wahl factor (Eq. 10-5), corrected shear stress (Eq. 10-7) |
+| `weldStrength()` | AISC 360 ASD / AWS D1.1 | Equal-leg fillet: throat 0.707·leg, allowable shear 0.30·FEXX (E70=144.9 MPa), capacity/utilization |
 
 ### Edge Case Handling
 
@@ -221,6 +222,7 @@ import { metalWeight, bendAllowance, cutting, bearing } from 'formulab/metal';
 | `vibration()` | Natural frequency analysis |
 | `weldHeat()` | Weld heat input calculation |
 | `welding()` | Welding parameters |
+| `weldStrength()` | Fillet weld strength / capacity (AISC ASD) |
 | `materialGradeConverter()` | ASTM/EN/JIS/GB/KS grade cross-reference |
 | `pipeSpec()` | ANSI/ASME pipe dimensions lookup |
 | `flangeSpec()` | ASME B16.5 flange dimensions lookup |

package/dist/metal/index.d.ts

@@ -1,4 +1,4 @@
-export type { MetalShape, MaterialName, MetalWeightInput, MetalWeightResult, BendingMaterial, ShapeType, BendAllowanceInput, BendAllowanceResult, SpringbackInput, SpringbackResult, FlatPatternInput, FlatPatternResult, KFactorReverseInput, KFactorReverseResult, PressOperation, BendType, PressTonnageInput, PressTonnageResult, BearingType, BearingInput, BearingResult, BoltCalculationMode, LubricationCondition, BoltInput, BoltResult, CuttingOperation, CuttingInput, CuttingResult, CuttingAlgorithm, CuttingPiece, CuttingStockInput, CuttingPattern, CuttingStockResult, GearCalculationMode, GearInput, GearResult, HardnessScale, HardnessInput, HardnessResult, MaterialCategory, MaterialInput, MaterialResult, MaterialSpec, PressFitInput, PressFitResult, RoughnessScale, RoughnessInput, RoughnessResult, PitchType, ScrewInput, ScrewResult, ScrewSpec, SpringMaterial, SpringInput, SpringResult, ThreadStandard, TapInput, TapResult, ThreadType, ThreadInput, ThreadResult, ThreadSpec, FitType, ToleranceInput, ToleranceResult, VibrationSystem, CrossSection, VibrationMaterial, VibrationInput, FrequencyMode, VibrationResult, WeldProcess, WeldBaseMetal, CrackingRisk, WeldPreheatSourceCode, WeldRecommendationCode, WeldRecommendation, WeldHeatInput, WeldHeatResult, WeldingBaseMetal, JointType, WeldPosition, WeldingInput, WeldingRod, WeldingResult, MaterialStandard, MaterialGradeConverterInput, MaterialGradeConverterResult, PipeStandard, PipeSchedule, PipeSpecInput, PipeSpecResult, FlangeStandard, PressureClass, FlangeSpecInput, FlangeSpecResult, } from './types.js';
+export type { MetalShape, MaterialName, MetalWeightInput, MetalWeightResult, BendingMaterial, ShapeType, BendAllowanceInput, BendAllowanceResult, SpringbackInput, SpringbackResult, FlatPatternInput, FlatPatternResult, KFactorReverseInput, KFactorReverseResult, PressOperation, BendType, PressTonnageInput, PressTonnageResult, BearingType, BearingInput, BearingResult, BoltCalculationMode, LubricationCondition, BoltInput, BoltResult, CuttingOperation, CuttingInput, CuttingResult, CuttingAlgorithm, CuttingPiece, CuttingStockInput, CuttingPattern, CuttingStockResult, GearCalculationMode, GearInput, GearResult, HardnessScale, HardnessInput, HardnessResult, MaterialCategory, MaterialInput, MaterialResult, MaterialSpec, PressFitInput, PressFitResult, RoughnessScale, RoughnessInput, RoughnessResult, PitchType, ScrewInput, ScrewResult, ScrewSpec, SpringMaterial, SpringInput, SpringResult, ThreadStandard, TapInput, TapResult, ThreadType, ThreadInput, ThreadResult, ThreadSpec, FitType, ToleranceInput, ToleranceResult, VibrationSystem, CrossSection, VibrationMaterial, VibrationInput, FrequencyMode, VibrationResult, WeldProcess, WeldBaseMetal, CrackingRisk, WeldPreheatSourceCode, WeldRecommendationCode, WeldRecommendation, WeldHeatInput, WeldHeatResult, WeldingBaseMetal, JointType, WeldPosition, WeldingInput, WeldingRod, WeldingResult, WeldElectrodeClass, WeldStrengthInput, WeldStrengthResult, MaterialStandard, MaterialGradeConverterInput, MaterialGradeConverterResult, PipeStandard, PipeSchedule, PipeSpecInput, PipeSpecResult, FlangeStandard, PressureClass, FlangeSpecInput, FlangeSpecResult, } from './types.js';
 export { isMetalWeightInput, isBoltInput } from './guards.js';
 export { metalWeight } from './metalWeight.js';
 export { bendAllowance } from './bendAllowance.js';
@@ -23,6 +23,7 @@ export { tolerance } from './tolerance.js';
 export { vibration } from './vibration.js';
 export { weldHeat } from './weldHeat.js';
 export { welding } from './welding.js';
+export { weldStrength } from './weldStrength.js';
 export { materialGradeConverter } from './materialGradeConverter.js';
 export { pipeSpec } from './pipeSpec.js';
 export { flangeSpec } from './flangeSpec.js';

package/dist/metal/index.d.ts.map

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package/dist/metal/index.js

@@ -24,6 +24,7 @@ export { tolerance } from './tolerance.js';
 export { vibration } from './vibration.js';
 export { weldHeat } from './weldHeat.js';
 export { welding } from './welding.js';
+export { weldStrength } from './weldStrength.js';
 export { materialGradeConverter } from './materialGradeConverter.js';
 export { pipeSpec } from './pipeSpec.js';
 export { flangeSpec } from './flangeSpec.js';

package/dist/metal/index.js.map

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package/dist/metal/types.d.ts

@@ -567,6 +567,31 @@ export interface WeldingResult {
     };
     notes: string[];
 }
+/**
+ * Weld Strength Types
+ *
+ * Filler-metal electrode classification. The numeric part is the minimum tensile
+ * strength of the deposited weld metal in ksi (E70 = 70 ksi). {@link weldStrength}
+ * maps each to an SI value; see FEXX table in weldStrength.ts.
+ */
+export type WeldElectrodeClass = 'E60' | 'E70' | 'E80' | 'E90' | 'E100' | 'E110';
+export interface WeldStrengthInput {
+    legSize: number;
+    weldLength: number;
+    weldCount?: number;
+    electrode: WeldElectrodeClass;
+    appliedLoad: number;
+}
+export interface WeldStrengthResult {
+    throat: number;
+    effectiveArea: number;
+    allowableShearStress: number;
+    allowableLoad: number;
+    actualStress: number;
+    utilization: number;
+    minRequiredLeg: number;
+    isSafe: boolean;
+}
 /**
  * Material Grade Converter Types
  */

package/dist/metal/types.d.ts.map

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package/dist/metal/weldStrength.d.ts

@@ -0,0 +1,36 @@
+import type { WeldStrengthInput, WeldStrengthResult } from './types.js';
+/**
+ * Calculate the load-carrying capacity of an equal-leg fillet weld (AISC ASD).
+ *
+ * # Formulas
+ * - Effective throat:      t = 0.707 x leg
+ * - Effective area:        Aw = t x L x n
+ * - Allowable shear stress: Fw = 0.30 x FEXX
+ * - Allowable load (capacity): Pallow = Fw x Aw
+ * - Actual shear stress:    tau = P / Aw
+ * - Utilization:            u = tau / Fw = P / Pallow
+ * - Minimum required leg:   leg_min = P / (Fw x 0.707 x L x n)
+ *
+ * Units are SI throughout: leg/length in mm give Aw in mm^2; Fw in MPa (= N/mm^2)
+ * gives Pallow directly in N. Cross-check: E70 -> Fw = 0.30 x 70 = 21 ksi, the
+ * classic AISC worked-example value (= 0.30 x 483 MPa = 144.9 MPa).
+ *
+ * # v1 scope (deliberately conservative — matches the common baseline calculators)
+ * These are recorded here so the boundary is explicit, not accidental:
+ * 1. **ASD only.** Allowable-stress design (0.30 x FEXX). LRFD (phi = 0.75,
+ *    Fnw = 0.60 x FEXX) is deferred until demanded via a `method` parameter.
+ * 2. **Longitudinal / conservative.** No directional strength increase. AISC allows
+ *    up to 1.5x for transverse loading (Fw = 0.60 x FEXX x (1 + 0.5 sin^1.5 theta));
+ *    omitting it is conservative and matches most basic calculators.
+ * 3. **Weld metal only.** Base-metal (shear rupture) checks are the engineer's
+ *    responsibility; a full design also verifies the connected material.
+ * 4. **Equal-leg, 90-degree joint.** t = 0.707 x leg assumes an equal-leg fillet on a
+ *    square (90-degree) joint. Unequal-leg / non-90-degree joints are deferred.
+ *
+ * Reference: AISC 360 (Steel Construction Manual), AWS D1.1 Structural Welding Code.
+ *
+ * @throws {RangeError} legSize or weldLength is not positive, weldCount < 1, or
+ *   appliedLoad is negative
+ */
+export declare function weldStrength(input: WeldStrengthInput): WeldStrengthResult;
+//# sourceMappingURL=weldStrength.d.ts.map

package/dist/metal/weldStrength.d.ts.map

@@ -0,0 +1 @@
+{"version":3,"file":"weldStrength.d.ts","sourceRoot":"","sources":["../../src/metal/weldStrength.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAEV,iBAAiB,EACjB,kBAAkB,EACnB,MAAM,YAAY,CAAC;AAyBpB;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;GAgCG;AACH,wBAAgB,YAAY,CAAC,KAAK,EAAE,iBAAiB,GAAG,kBAAkB,CA6CzE"}

package/dist/metal/weldStrength.js

@@ -0,0 +1,94 @@
+import { roundTo } from '../utils.js';
+/**
+ * Minimum tensile strength of deposited weld metal (FEXX), in MPa.
+ *
+ * The electrode class number is FEXX in ksi (E70 = 70 ksi). Values below are the
+ * exact SI conversion of the nominal ksi rating (1 ksi = 6.894757 MPa), rounded to
+ * the nearest MPa — NOT eyeballed. E100 = 100 x 6.894757 = 689.48 -> 689 (not 690);
+ * E110 = 758.42 -> 758 (not 760).
+ */
+const FEXX_MPA = {
+    E60: 414, // 60 ksi  = 413.69 MPa
+    E70: 483, // 70 ksi  = 482.63 MPa
+    E80: 552, // 80 ksi  = 551.58 MPa
+    E90: 621, // 90 ksi  = 620.53 MPa
+    E100: 689, // 100 ksi = 689.48 MPa
+    E110: 758, // 110 ksi = 758.42 MPa
+};
+/** Effective-throat factor for an equal-leg, 90-degree fillet weld: t = 0.707 x leg. */
+const THROAT_FACTOR = 0.707;
+/** AISC ASD allowable shear stress on the weld throat: Fw = 0.30 x FEXX. */
+const ASD_SHEAR_FACTOR = 0.30;
+/**
+ * Calculate the load-carrying capacity of an equal-leg fillet weld (AISC ASD).
+ *
+ * # Formulas
+ * - Effective throat:      t = 0.707 x leg
+ * - Effective area:        Aw = t x L x n
+ * - Allowable shear stress: Fw = 0.30 x FEXX
+ * - Allowable load (capacity): Pallow = Fw x Aw
+ * - Actual shear stress:    tau = P / Aw
+ * - Utilization:            u = tau / Fw = P / Pallow
+ * - Minimum required leg:   leg_min = P / (Fw x 0.707 x L x n)
+ *
+ * Units are SI throughout: leg/length in mm give Aw in mm^2; Fw in MPa (= N/mm^2)
+ * gives Pallow directly in N. Cross-check: E70 -> Fw = 0.30 x 70 = 21 ksi, the
+ * classic AISC worked-example value (= 0.30 x 483 MPa = 144.9 MPa).
+ *
+ * # v1 scope (deliberately conservative — matches the common baseline calculators)
+ * These are recorded here so the boundary is explicit, not accidental:
+ * 1. **ASD only.** Allowable-stress design (0.30 x FEXX). LRFD (phi = 0.75,
+ *    Fnw = 0.60 x FEXX) is deferred until demanded via a `method` parameter.
+ * 2. **Longitudinal / conservative.** No directional strength increase. AISC allows
+ *    up to 1.5x for transverse loading (Fw = 0.60 x FEXX x (1 + 0.5 sin^1.5 theta));
+ *    omitting it is conservative and matches most basic calculators.
+ * 3. **Weld metal only.** Base-metal (shear rupture) checks are the engineer's
+ *    responsibility; a full design also verifies the connected material.
+ * 4. **Equal-leg, 90-degree joint.** t = 0.707 x leg assumes an equal-leg fillet on a
+ *    square (90-degree) joint. Unequal-leg / non-90-degree joints are deferred.
+ *
+ * Reference: AISC 360 (Steel Construction Manual), AWS D1.1 Structural Welding Code.
+ *
+ * @throws {RangeError} legSize or weldLength is not positive, weldCount < 1, or
+ *   appliedLoad is negative
+ */
+export function weldStrength(input) {
+    const { legSize, weldLength, electrode, appliedLoad } = input;
+    const weldCount = input.weldCount ?? 1;
+    // Validation
+    if (legSize <= 0) {
+        throw new RangeError('legSize must be greater than 0');
+    }
+    if (weldLength <= 0) {
+        throw new RangeError('weldLength must be greater than 0');
+    }
+    if (weldCount < 1) {
+        throw new RangeError('weldCount must be at least 1');
+    }
+    if (appliedLoad < 0) {
+        throw new RangeError('appliedLoad must not be negative');
+    }
+    const fexx = FEXX_MPA[electrode];
+    // Geometry and capacity
+    const throat = THROAT_FACTOR * legSize; // mm
+    const effectiveArea = throat * weldLength * weldCount; // mm^2
+    const allowableShearStress = ASD_SHEAR_FACTOR * fexx; // MPa
+    const allowableLoad = allowableShearStress * effectiveArea; // N (MPa x mm^2)
+    // Demand
+    const actualStress = appliedLoad / effectiveArea; // MPa
+    const utilization = appliedLoad / allowableLoad; // ratio
+    // Smallest equal leg that carries appliedLoad (inverts throat + capacity):
+    // leg_min = P / (Fw x 0.707 x L x n). Denominator is always > 0.
+    const minRequiredLeg = appliedLoad / (allowableShearStress * THROAT_FACTOR * weldLength * weldCount);
+    return {
+        throat: roundTo(throat, 3),
+        effectiveArea: roundTo(effectiveArea, 2),
+        allowableShearStress: roundTo(allowableShearStress, 2),
+        allowableLoad: roundTo(allowableLoad, 1),
+        actualStress: roundTo(actualStress, 2),
+        utilization: roundTo(utilization, 4),
+        minRequiredLeg: roundTo(minRequiredLeg, 3),
+        isSafe: utilization <= 1,
+    };
+}
+//# sourceMappingURL=weldStrength.js.map

package/dist/metal/weldStrength.js.map

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package/package.json

@@ -1,7 +1,7 @@
 {
   "name": "formulab",
-  "version": "0.20.1",
-  "description": "Manufacturing & Engineering calculation formulas library - 210 industrial calculations across 15 domains for OEE, Cpk, SPC, FMEA, Nelson Rules, metal weight, CNC machining, GD&T, battery, environmental, pipe flow, logistics, IE time study, and more",
+  "version": "0.21.0",
+  "description": "Manufacturing & Engineering calculation formulas library - 211 industrial calculations across 15 domains for OEE, Cpk, SPC, FMEA, Nelson Rules, metal weight, CNC machining, GD&T, battery, environmental, pipe flow, logistics, IE time study, and more",
   "type": "module",
   "main": "./dist/index.js",
   "types": "./dist/index.d.ts",