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Weld joint design evaluation

Weld joint design evaluation

Weld joint design evaluation

I have a seam that is edge welded kinda like so: |L, where the weld is at the top of the two members.  The final structure is a sort of like a rectangular tube, rolled the easy way, with welds on the inner upper and lower corners: |].
I am considering changing this to more like [], where the inner (left) part is enough wider for the outer to nest inside and use a lap weld.
The disadvantage of the current design is that it takes a lot of time to align the two edges and is not automated welding friendly.  The advantage is that it allows for a fair amount of variation in braking of the outer part.
The pros/cons of the proposed joint are just the opposite.
This assembly is used in a heat exchanger so is subject to thermal cycling.  
Material varies for several models from .06" aluminized steel to .09" HR or Aluminized.


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