Estimation of three‐dimensional stress intensity factor for structural ‘T’ details

Three‐dimensional (3D) opening mode stress intensity factors (SIFs) for structural steel‐welded ‘T’ details were investigated by the finite element method. A 3D shape‐dependent correction factor is proposed for semi‐elliptical surface cracks. The aspect ratio (a/c) of a semi‐elliptical crack plays a key role in the approximation of 3D‐SIF values, and in the present study, it was estimated for a 3D crack analysis. The estimated 3D‐SIF was determined through a correlation between the a/c ratio and the two‐dimensional SIF for semi‐elliptical cracks in the thickness direction adjacent to the web‐flange junction of a welded ‘T’. The resulting equation can be used to estimate the 3D‐SIF values from the two‐dimensional SIF without much ambiguity.     

Experimental and analytical investigation of fatigue crack propagation of T‐welded joints considering the effect of boundary condition

T‐welded joints are commonly employed in ship and ocean structures. The fatigue failure of structure components subjected to cyclic loading always occurs in T‐welded joints because of the metallurgical differences, tensile residual stress fields and stress concentrations. The former researches about T‐welded joints fatigue have in common that the boundary condition needs to be taken into account as an influencing parameter to predict the crack propagation during cyclic loading. In this paper, the crack growth behaviour in T‐welded joint processed with Q345D steel (Pingxiang Iron & Steel Co., Ltd, Hukou, Jiangxi Province in China) under the fatigue loading was analysed via analytical model and verified via experiment. The results show that the influence of boundary condition should be considered in T‐welded joint structure during crack propagation in weld toe area. The correction factor concerning the effect of boundary condition and modified Paris' equation was proposed according to the experimental results and verified by the following repeated experiments.     

Weld magnification factors for semi-elliptical surface cracks in fillet welded T-butt joint models

The weld magnification factor method has been widely used in the determination of the stress intensity factor (SIF) for weld-toe cracks in welded structural components. Weld magnification factors M _kare normally derived from two-dimensional crack models with fillet weld profiles to take account of the effect of weld-notch stress concentration at the deepest point of the crack front. This paper presents a detailed three-dimensional analysis of weld-toe surface cracks in fillet welded T-butt joint models using the finite element method. Effects of the weld notch and the welded attachment stiffness on the SIFs of the weld-toe surface cracks have been studied quantitatively. Weld magnification factors applying to the whole surface crack fronts have been estimated. Numerical results show two contradictory effects; that the effect of weld notch increases SIF values throughout the shallow surface crack fronts which are in the region of notch stress concentration, while the effect of local structural constraint reduces the SIF values. The increase in the SIF values mainly depends upon the relative crack front depth and the decrease in the SIF values mainly depends upon the crack shape aspect ratio for a specific weld profile. Both effects on the weld magnification factors can be estimated separately. A simple approach for deriving the weld magnification factors for various weld-toe surface crack problems is proposed for engineering applications.     

The Prediction of Fatigue Crack Initiation Life in Spot Welds

Abstract: In this paper, strain‐based fatigue life prediction method has been used to estimate the fatigue crack initiation life of spot‐welded joints of Mild Steel JSC270D and Ultra‐High Strength Steel JSC980Y. To do so, the joints were simulated using three‐dimensional finite‐element (FE) models, and then nonlinear FE analysis was performed to obtain the local stress and strain ranges and finally, the Morrow equation was applied to estimate the crack initiation lives. The results have been compared with those obtained from experimental crack growth morphology. In addition, the difference between fatigue limits for smooth specimens and spot‐welded joints for mentioned materials has been briefly discussed. It has been shown that mean stress values in the Ultra‐High Strength Steel can significantly decrease the fatigue limit of spot‐welded joint because even at very low load level the stresses exceed the yield point at the root of nugget of spot‐welded joint, while the amount of mean stress in the Mild Steel for the same load level is much less than that of Ultra‐High Strength Steel. The comparison between numerical results of fatigue crack initiation lives and experimental data provided good agreement between numerical predictions and crack growth morphology observations. The results also shows that in some cases, depending on the joint type, the life spent in the nucleation phase can be an important part of the final failure lifetime.     

Stress-intensity factors for circular hollow section V-joints with a rack-plate chord

This study investigates the fatigue crack‐driving force, measured by the linear‐elastic stress‐intensity factors (SIFs), for a surface crack at the root of the welds in a thick‐walled, circular hollow section (CHS) V‐shape joint, typically installed in modern offshore jack‐up platforms. The primary (chord) member of the V‐joint consists of two half CHSs welded to both sides of a thick rack plate, while the secondary (brace) member adopts thick‐walled CHSs. The surface‐breaking crack considered in this study locates at the interface between the rack plate and the weld metal joining the half CHS, and represents an initial flaw introduced by lack of penetration in the welding procedure. The finite‐element model incorporates a very detailed, local crack‐front mesh in a global continuous mesh through a mesh‐tying procedure, which ensures displacement continuity between the independent master surface and the dependent slave surface. A simple plate model verifies the mesh‐tying procedure in computing the linear‐elastic stress‐intensity factors for two remote loading conditions. The computation of the stress‐intensity factors employs a linear‐elastic interaction integral approach. The comparison of the computed SIF values with a previous experimental measurement for a CHS T‐joint verifies the accuracy and feasibility of the interaction integral approach in computing SIF values for surface cracks in welded tubular connections. Subsequent numerical analysis on the gapped V‐joints examines the mixed‐mode SIF values for different loading conditions and includes an array of practical joint geometric parameters and crack sizes. The nondimensional mode I stress‐intensity factors generally increases with the following variations in the joint geometric parameters: an increase in the chord radius to the wall thickness ratio (γ=d₀/2t₀) , an increase in the brace diameter to the chord diameter ratio (β=d₁/d₀) , a decrease in the crack depth ratio (a/t) or an increase in the crack length c. The current study identifies a practical group of V‐joints that requires detailed treatment in the fatigue assessment procedure. These V‐joints adopt a large β ratio and demonstrate high mode‐mixity angles [ψ= tan^?1(K_II/K_I)] with correspondingly high mode I and mode II stress‐intensity factors.     

Probabilistic fatigue crack growth analysis of spot‐welded joints

This paper presents a probabilistic fatigue crack growth life prediction methodology for spot‐welded joints under variable amplitude loading history. The loading is multi‐axial and is obtained from transient response analysis of a vehicle model using finite‐element analysis. A three‐dimensional (3D) finite element model of a simplified joint with four spot welds is developed, and the static stress analysis of this joint is performed. Then the fatigue crack inside the base material sheet is modelled as a surface crack. Probabilistic crack growth model is combined with the stress analysis result to develop a probabilistic fatigue crack growth life prediction methodology for spot welds. This new method is implemented with MSC/NASTRAN and MSC/FATIGUE and is useful for the reliability assessment of spot‐welded joints against fatigue crack growth.     

Stress intensity factor solution for a semi-elliptical crack in an arbitrarily distributed stress field

An equation for the stress intensity factor (SIF) for semi-elliptical crack has been developed. It is based on the Newman-Raju's solution for the crack in a plate under bending or tension. The equation can be applied when a stress distribution is described by a power function. Using the approach outlined, the SIF for a surface crack in a T-butt welded connection has been estimated. The results obtained can be used in a fracture-mechanics-based fatigue analysis.     

A notch stress intensity approach applied to fatigue life predictions of welded joints with different local toe geometry

In the Notch Stress Intensity Factor (N‐SIF) approach the weld toe region is modelled as a sharp V‐shaped corner and local stress distributions in planar problems can be expressed in closed form on the basis of the relevant mode I and mode II N‐SIFs. Initially thought of as parameters suitable for quantifying only the crack initiation life, N‐SIFs were shown able to predict also the total fatigue life, at least when a large part of the life is spent as in the propagation of small cracks in the highly stressed region close to the notch tip. While the assumption of a welded toe radius equal to zero seems to be reasonable in many cases of practical interest, it is well known that some welding procedures are able to assure the presence of a mean value of the weld toe radius substantially different from zero. Under such conditions any N‐SIF‐based prediction is expected to underestimate the fatigue life. In order to investigate the degree of conservatism, a total of 128 fillet welded specimens are re‐analysed in the present work by using an energy‐based N‐SIF approach. The local weld toe geometry, characterised by its angle and radius, has been measured with accuracy for the actual test series. The aim of the work is to determine if the N‐SIF‐based model is capable of taking into account the large variability of the toe angle, and to quantify the inaccuracy in the predictions due to the simplification of setting the toe radius equal to zero.     

Fracture analysis of dissimilar Al‐Al friction stir welded joints under tensile/shear loading

In this research, fracture of dissimilar friction stir welded (FSWed) joint made of Al 7075‐T6 and Al 6061‐T6 aluminum alloys is investigated in the cracked semi‐circular bend (CSCB) specimen under mixed mode I/II loading. Due to the elastic‐plastic behavior of the welded material and the existence of significant plastic deformations around the crack tip at the propagation instance, fracture prediction of the FSWed specimens needs some failure criteria in the context of the elastic‐plastic fracture mechanics which are very complicated and time‐consuming. For this purpose, the Equivalent Material Concept (EMC) is used herein by which the tensile behavior of the welded material is equated with that of a virtual brittle material. By combining EMC with the 2 brittle fracture criteria, namely the maximum tangential stress (MTS) and mean stress (MS) criteria, the load‐carrying capacity (LCC) of the FSWed CSCB specimens is predicted. Comparison of the experimental results and theoretical predictions from the 2 criteria showed that both criteria could accurately predict the LCC of the cracked specimens. Moreover, as the contribution of mode II loading increases, the size of the plastic region around the crack tip at failure increases, leading to increasing the LCC.     

圆钢管混凝土T型焊接节点应力强度因子计算方法研究

主管内填充混凝土的圆管桁架是一种新型结构,鉴于断裂力学评估这种结构疲劳性能的需要,该文探讨了圆钢管混凝土T型焊接节点在支管轴拉力作用下的应力强度因子计算方法.首先,根据节点的热点应力分布和疲劳裂纹试验结果,提出了节点断裂力学分析的半椭圆表面裂纹模型.其次,推导了主管、支管及混凝土等部分的参数变换公式,并通过ANSYS软...     

Determination of crack-tip stress intensity factors in complex geometries by the composition of constituent weight function solutions

Linear elastic fracture mechanics (LEFM) is the science frequently used to understand the stable and progressive fatigue crack growth that often occurs in engineering components under varying applied stress. The stress intensity factor (SIF) is its basis and describes the stress state at the crack tip. This can be used with the appropriate material properties to calculate the rate at which the crack will propagate in a linear elastic manner. Unfortunately, the SIF is difficult to compute or measure, particularly if the crack is situated in a complex three‐dimensional geometry or subjected to a non‐simple stress state. This is because the SIF is not only a function of the crack and component geometry but is also dependent on the applied stress field. In the last 20 years, the SIF weight function has gained prominence as a method for calculating and presenting SIFs independent of applied stress. This paper demonstrates that the real promise of the SIF weight Function lies in its use to rapidly generate SIF solutions for cracks in complex geometries by simple composition of geometric influences from reference constituent solutions.     

Structural integrity of pipelines: T-stress by line-spring

The elastic T‐stress is an important constraint parameter for characterizing elastic–plastic crack‐tip fields and in fracture assessment procedures. However, many of the methods reported in the literature for estimating T‐stress are not easily suited for surface‐cracked pipes because these are three‐dimensional in nature. Here, the line‐spring method is demonstrated to be an efficient and accurate tool for the constraint estimation in surface‐cracked pipes. Detailed three‐dimensional analyses are performed to verify the line‐spring results. Using the line‐spring method, the effects of different crack geometries and diameter‐to‐thickness ratio on stress‐intensity factor (SIF) and T‐stress in circumferentially surface‐cracked pipes are examined. Further, a compendium of normalised SIF and T‐stress values for surface‐cracked pipes in remote tension and bending, calculated from a total of 1000 analyses, is tabulated. Finally, the application of an ‘elastic–plastic’ T‐stress under large‐scale plasticity is explored.     

The effect of microstructures on fatigue crack growth in Q345 steel welded joint

It is a traditional that the fatigue crack growth behavior is sensitive to microstructure in threshold regime, while it is sensitive to R‐ratio in Paris regime. Fatigue test is carried out for welded joints of a Q345 steel where the compact tension specimens with 3.8 and 12.5 mm thickness are used, and comparisons of fatigue crack growth behavior between base metal and a few different locations in the welded joint are considered in Paris regime. Welding residual stresses are removed by heat treatment to focus the study on the microstructural effect. It is shown that fatigue crack growth rate (FCGR) in the base metal is not sensitive to R‐ratio, but the FCGR increases in the overheated zone, the fusion zone and the weld metal zone with R‐ratio increasing. To the low R‐ratio, FCGR in the three zones is smaller than that in the base metal, but they approximate the same with base metal under the high R‐ratio. The mechanism of fatigue crack growth is analyzed through crack path in microstructures and SEM fractograph. The coarse‐grained ferrite in the base metal is of benefit to relaxation of the average stress at the crack tip, and the fatigue crack growth predicts branching and deflection within above different locations in the welded joint. These tortuous crack paths with crack branching and deflection will promote crack closure as well as crack‐tip stress shielding and then resulted in higher crack growth resistance.     

Crack closure in friction stir weldment using non‐linear model for fatigue crack propagation

The fatigue crack propagation in a friction stir‐welded sample has been simulated herein by means of two 3‐dimensional finite element method (FEM)‐based analyses. Numerical simulations of the fatigue crack propagation have been carried out by assuming a residual stress field as a starting condition. Two initial cracks, observed in the real specimen, have been assessed experimentally by performing fatigue tests on the welded sample. Hence, the same cracks have been placed in the corresponding FE model, and then a remote load with boundary conditions has been applied on the welded specimen. The material behaviour of the welded joint has been modelled by means of the Ramberg‐Osgood equation, while the non‐linear Kujawski‐Ellyin (KE) model has been adopted for the fatigue crack propagation under small‐scale yielding (SSY) conditions. Owing to the compressive nature of the residual stress field that acts on a part of the cracked regions, the crack closure phenomenon has also been considered. Then, the original version of the KE law has been modified to fully include the closure effect in the analysis. Later, the crack closure effect has also been assessed in the simulation of fatigue propagation of three cracks. Finally, an investigation of the fracture process zone (FPZ) extension as well as the cyclic plastic zone (CPZ) and monotonic plastic zone (MPZ) extensions have been assessed.     

Fatigue strength assessment of partial and full‐penetration steel and aluminium butt‐welded joints according to the peak stress method

In fatigue design of welded joints, the local approach based on the notch stress intensity factors (NSIFs) assumes that the weld toe profile is a sharp V‐notch having a tip radius equal to zero, while the root side is a pre‐crack in the structure. The peak stress method (PSM) is an engineering, FE‐oriented application of the NSIF approach to fatigue design of welded joints, which takes advantage of the elastic peak stresses from FE analyses carried out by using a given mesh pattern, where the element type is kept constant and the average element size can be chosen arbitrarily within a given range. The meshes required for the PSM application are rather coarse if compared with those necessary to evaluate the NSIFs from the local stress distributions. In this paper, the PSM is extended for the first time to butt‐welded joints in steel as well as in aluminium alloys, by comparing a number of experimental data taken from the literature with the design scatter bands previously calibrated on results relevant only to fillet‐welded joints. A major problem in the case of butt‐welded joints is to define the weld bead geometry with reasonable accuracy. Only in few cases such geometrical data were available, and this fact made the application of the local approaches more difficult. Provided the local geometry is defined, the PSM can be easily applied: a properly defined design stress, that is, the equivalent peak stress, is shown (i) to single out the crack initiation point in cases where competition between root and toe failure exists and (ii) to correlate with good approximation all analysed experimental data.     

基于失效评定图(FAD)研究含疲劳裂纹T型圆钢管节点的安全性

失效评定曲线(FAD)常用来评价焊接结构在出现裂纹后的安全性,为了验证这种曲线在评价焊接管结构在节点部位出现疲劳裂纹后安全性的适用性,采用实验测试和有限元分析的方法研究了3个含疲劳裂纹的T型管节点试件在静力作用下的极限承载能力及破坏过程。3个T型管节点试件首先进行疲劳实验在焊趾处产生表面裂纹,然后通过在支管端部施加轴向拉力作用检测节点的破坏过程。基于自行开发的含表面裂纹T型管节点的有限元网格自动产生程序以及ABAQUS分析软件,研究了在管节点破坏过程中表面裂纹最深点的应力强度因子大小,并通过实验的荷载-位移曲线确定了T节点试件的塑性极限承载力。在这些结果的基础上,验证了FAD在评价含疲劳裂纹的焊接管节点安全性方面的适用性。研究结果标明:FAD在评价含疲劳裂纹管节点的安全性方面是安全可靠的,但偏于保守。     

Crack retardation equations for the propagation of branched fatigue cracks

The stress intensity factors (SIF) associated with branched fatigue cracks can be considerably smaller than that of a straight crack with the same projected length, causing crack growth retardation or even arrest. This crack branching mechanism can quantitatively explain retardation effects even when plasticity induced crack closure cannot be applied, e.g. in high R-ratio or in some plane strain controlled fatigue crack growth problems. Analytical solutions have been obtained for the SIF of branched cracks, however, numerical methods such as Finite Elements (FE) or Boundary Elements (BE) are the only means to predict the subsequent curved propagation behavior. In this work, a FE program is developed to calculate the path and associated SIF of branched cracks, validated through experiments on 4340 steel ESE(T) specimens. From these results, semi-empirical crack retardation equations are proposed to model the retardation factor along the crack path. The model also considers the possible interaction between crack branching and other retardation mechanisms.     

Neural approach to estimate the stress intensity factor of semi‐elliptical cracks in rotating cracked shafts in bending

In the last decades, neural network approach has often been used to study various and complex engineering problems, such as optimization or prediction. In this paper, a methodology founded on artificial neural networks (ANNs) was used to calculate the stress intensity factor (SIF) in different points of the front of a semi‐elliptical crack present in a rotating shaft, taking into account the shape and depth of the crack, the angle of rotation, and the location of the point in the front. In the event of rotating machines, such as shafts, it is crucial to know the SIF along the crack front because this parameter, according to the Paris Law, is related to the performance of the crack during its propagation. Previously, it was necessary to achieve the data for the ANN training, for this a quasi‐static numerical model was made, which simulates a rotating cracked shaft with a semi‐elliptical crack. The numerical solutions cover a wide range of crack depths and shapes, and rotation angles. The values of the SIF estimated by the ANNs were contrasted with other solutions available in the literature finding a good agreement between them. The proposed neural network methodology is an alternative that offers a very good option for the SIF estimation, because it is efficient and easy to use, does not require high computational costs, and can be used to analyse the propagation of cracks contained in rotating shafts by means of the Paris Law taking into account the nonlinear behaviour of the shaft.     

Effects of divider orientation split‐out on fracture toughness

The Split‐out phenomenon is a sudden instability, which takes place near the crack tip, and is generated by a rapid growth and arrest of a crack at the divider orientation. This phenomenon is related to stress triaxiality in the front of the crack tip when the structure is under plane strain conditions, plus the existence of weak interfaces oriented normal to the thickness direction. The weak interfaces can be generated as a result of some metallurgical process such as hot‐rolling lamination in materials with a high level of impurities, as well as steels where the structure results in a strong banding of ferrite and pearlite. When a cracked structure is loaded, the high σ_z stresses related to the plain strain state can lead to a split‐out brought about by delamination of the weak interfaces. During a fracture toughness test, this is noticed as a drop in the load‐displacement record, which is similar to that produced by the well‐known pop‐in instability in welded joints. Although the load drops are very similar in both phenomena, their etiologies are completely different, since the pop‐in is produced by an unstable crack growth and its ulterior arrest, due to local brittle zones located generally at the heat affected zone (HAZ) at or near a welded joint. As the split‐out has been less studied than the pop‐in, and due to the similarities between both load‐displacement records, it is very common to consider both instabilities under the same failure acceptance criteria. In this way, the split‐out is usually treated as a critical event, and therefore, many materials are rejected when split‐outs occur in fracture testings. However, when a split‐out occurs, the σ_z stress is drastically reduced, leading to a condition close to a plane stress situation (in fact, the σ_z stress reduces to 0 at the crack surfaces of the split‐out). The aim of this work was to study the effect of the split‐out in the fracture toughness of hot laminated steels working in the upper‐shelf region. In order to achieve this, the fracture toughness was evaluated by means of the resistance curve J‐R of the material, using a single specimen test method. The occurrence of load drop and displacement increase in the test record are explained based on a constant main plane crack length hypothesis.     

The effect of residual stress due to interference fit on the fatigue behavior of a fastener hole with edge cracks

The fatigue property of riveted lap joint is greatly related to the riveting-induced residual stress. However, an accurate study of the fatigue property considering the influence of residual stress quantitatively can be very difficult. A 3D interface element based on the virtual crack closure technology (VCCT) was developed to calculate the stress intensity factor (SIF) for through cracks at the hole edge. The riveting process was analyzed prior to the tensile test in the finite element code, so that the residual stress can be taken into account to get the eventual value of SIF. The result shows that, with the presence of fatigue cracks, the initial stress-strain state in the structure would change, especially near the crack tip, where great compressive stress can be found. The eventual residual stress cannot be derived by simply superimposing the riveting-induced residual stress with the crack-induced residual stress. The 3D-VCCT interface element shows strong ability to solve the SIFs. The FE analysis results agree well with the reported models both in the fatigue crack growth rate (FCGR) and in the shape of the crack front. However, when the crack is extremely short, not only the reported models, but also the present numerical model would fail. Besides, unlike Elber's model and Schijve's model, this study shows that the crack opening stress should not be a function of the stress ratio solely, but also with the crack length included.