Fatigue strength assessment of laser stake‐welded T‐joints subjected to reversed bending

The paper investigates the fatigue strength of laser stake‐welded T‐joints subjected to reversed bending. The fatigue tests are carried out with the load ratio, R ≈ ?0.8. The experimental data is firstly analysed using the nominal stress approach and then by the J‐integral as the local fatigue strength parameter in the finite element (FE) assessment. The nominal stress approach demonstrated that the fatigue strength of the investigated T‐joints is lower than encountered for any other steel joint under reversed tensile loading. The results also showed that the fatigue strength of this joint under the load ratio R ≈ ?0.8 increases with respect to R = 0 bending by 22.6% in the case of the nominal stress approach and 13% in the case of the J‐integral approach. However, the slopes of the fatigue resistance curves for different load ratios appear very similar, suggesting that the load ratio has an insignificant influence to the slope. In contrast to the similar slopes, the scatter indexes were different. The nominal stress approach shows that the scatter index is 3.4 times larger for R ≈ ?0.8 than R = 0 bending. The J‐integral approach showed that the scatter index for R ≈ ?0.8 is only 67% larger than in the R = 0 case because the weld geometry is modelled in the FE analysis.     

Fatigue reliability analysis of kiln welded shell

This paper presents a probabilistic reliability method for the welded shell during crack growth. The crack growth model incorporated with a failure assessment diagram, which provides a better estimation of the critical crack depth, is developed to describe fatigue failure. All variables used of particular welded joints are studied. The stress variables are based on resultant stress calculated by using the finite element (FE) code ANSYS. Fatigue reliability analysis of the welded shell is performed by using the Monte Carlo simulation method. It is demonstrated that fatigue reliability analysis is significantly useful for the repair schedule of shell cracks.     

Fatigue design of welded double‐sided T‐joints and double‐sided cruciform joints in steel marine structures: A total stress concept

Fatigue is a governing design limit state for marine structures. Welded joints are important in that respect. The weld notch stress (intensity) distributions contain essential information and formulations have been established to obtain a total stress fatigue damage criterion and corresponding fatigue resistance curve; a total stress concept. However, the involved weld load carrying stress model does not provide the required estimates and trends for varying geometry dimensions and loading & response combinations. A new one has been developed and performance evaluation for T‐joints and cruciform joints in steel marine structures shows that in comparison with the nominal stress, hot spot structural stress and effective notch stress concept based results up to 50% more accurate fatigue design life time estimates can be obtained. Taking advantage of the weld notch stress formulations, the effective notch stress concept performance has improved adopting a stress‐averaged criterion rather than a fictitious notch radius‐based one.     

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.     

An examination of load shedding during fatigue fracture

The existence of fatigue markings across the entire fracture surface of certain failed components implies that load shedding had occurred during the course of the fracture process. In order to examine the role of load shedding, a sample containing three parallel load paths with the central path being cracked was tested in fatigue using fixed grips. Loads in the three load paths, measured with strain gauges, were observed to be in good agreement with values predicted by theoretical analysis, based upon compliance calculations. Measured fatigue crack propagation rates also agreed well with those predicted from theoretical calculations.     

Fatigue life prediction for butt‐welded joints considering weld‐induced residual stresses and initial damage,relaxation of residual stress,and elasto‐plastic fatigue damage

Fatigue damage of butt‐welded joints is investigated by a damage mechanics method. First, the weld‐induced residual stresses are determined by using a sequentially coupled thermo‐mechanical finite element analysis. The plastic damage of material is then calculated with the use of Lemaitre's plastic damage model. Second, during the subsequent fatigue damage analysis, the residual stresses are superimposed on the fatigue loading, and the weld‐induced plastic damage is considered as the initial damage via an elasto‐plastic fatigue damage model. Finally, the fatigue damage evolution, the relaxation of residual stress, and the fatigue lives of the joints are evaluated using a numerical implementation. The predicted results agree well with the experimental data.     

Fatigue failure transition analysis in load‐carrying cruciform welded joints based on strain energy density approach

This paper details a study of the application of notch stress intensity theory to the fatigue failure mode analysis of the transition in load‐carrying cruciform welded joints. The weldment fatigue crack initiation point is difficult to predict precisely because it usually occurs in the vicinity of the weld toe or weld root. To investigate the relationship between fatigue failure location and the geometry of the weldments, we analysed the weld toe and root asymptotic notch stress fields were analysed using the notch stress intensity factors on the basis of the Williams' solution in Linear Elastic Fracture Mechanics (LEFM). Numerous configurations of cruciform joints of various plate thicknesses, transverse plate thickness, weld sizes and incomplete penetration size were used to investigate the location of the fatigue failure. The strain energy density (SED) surrounding the notch tip was introduced to unify the scalar quantity and preclude the inconsistency of the dimensionality of the notch stress intensity factors for various notch opening angles. The results of the investigation showed that the SED approach can be used to determine the transition zone for a variety of joint geometries. The validity of the SED criteria was verified by comparing the experimental results of this study with the complied results for load‐carrying cruciform welded joints reported in literature.     

Experimental study of the fatigue characteristics and reliability of continuous welded rails

In recent years, joint types in railway superstructure have shifted to continuous welded rails (CWRs), which can be constructed by various welding techniques to form uninterrupted rails several kilometres long. Because of the numerous advantages of this method, CWR systems are highly preferred today for the construction of new railway lines. The increase in the number of trains in operation is inducing fatigue damages, linking to life‐threatening risks in the rails as well as in trains' wheels and axles. In this study, CWR specimens formed by the flash butt‐welding process are investigated. Specimens extracted from rail sections are subjected to four‐point bending fatigue tests to establish S–N curves under various loading levels. The surfaces of those specimens which fail are then investigated in detail in order to determine the initiation points of the failures. The findings provide experimental data on the dynamic life cycle of CWR and identify the failure mechanism of the CWR system.     

Probabilistic prediction of high cycle fatigue reliability of high strength steel butt‐welded joints

The aim of this paper is to develop a probabilistic approach of high cycle fatigue (HCF) behaviour prediction of welded joints taking into account the surface modifications induced by welding and the post‐welding shot peening treatment. In this work, the HCF Crossland criterion has been used and adopted to the case of welded and shot peened welded parts, by taking into account the surface modifications which are classified as follows: (i) the compressive residual stresses, (ii) the surface work‐hardening, (iii) the geometrical irregularities and (iv) the superficial defects. The random effects due to the dispersions of: (i) the HCF Crossland criterion material characteristics (ii) the applied loading and (iii) the surface modifications parameters are introduced in the proposed model. The HCF reliability has been computed by using the ‘strength load’ method with Monte Carlo simulation. The reliability computation results lead to obtain interesting and useful iso‐probabilistic Crossland diagrams (PCD) for different welding and shot peening surface conditions. To validate the proposed method, the approach has been applied to a butt‐welded joint made of S550MC high strength steel (HSS). Four types of specimens are investigated: (i) base metal (BM), (ii) machined and grooved (MG) condition, (iii) As welded (AW) condition and (iv) as welded and shot peened (AWSP) condition. The comparison between the computed reliabilities and the experimental investigations reveals good agreement leading to validate the proposed approach. The effects of the different welded and post‐weld shot peened specimen's surface properties are analysed and discussed using the design of experiments (DoE) techniques.     

Fatigue of welded hybrid‐joints

Only for steels up to grade S690QL the well‐known fact is confirmed that the fatigue strength of welded joints is independent of the material. For higher strength steels a remarkable reduction of the fatigue strength is found. Some advice is given for designers in which situations the one or the other of the various approaches for the assessment of the fatigue strength of welds could be applied. In complex, real situations even the highly sophisticated effective notch stress approach might loose its applicability. A new alternative approach is proposed for these situations. It is based on stresses in real notches and an example is presented for the familiar case of a start‐stop position.     

Fatigue residual life estimation of jib structure based on improved v‐SVR algorithm obtaining equivalent load spectrum

Fatigue tests of truck crane jib structure have great difficulty, long testing cycle, and high cost. Therefore, with the portfolio strategy for “collection, prediction, measurement and simulation” being introduced, an improved support vector regression (v‐SVR) algorithm is proposed to predict the equivalent load spectrum based on the small measured load spectrum and the fatigue residual life evaluation model is built. First, the v‐SVR algorithm corrected in kernel function, decision function, and parameter optimization is utilized to acquire the equivalent load spectrum. Second, the distribution of critical points is determined by the case‐based reasoning technique. The simulation model of first main stress‐time histories for critical points is established, and the two‐dimensional stress spectrum is obtained by the rain‐flow counting method. Finally, the fatigue residual life of jib structure is estimated by the Forman formula. Taking ZLJ5551JQZ110V truck crane jib structure as an example, the effectiveness of the above method is validated.     

Fatigue strength of fillet‐welded joints at subzero temperatures

Ships and offshore structures may be operated in areas with seasonal freezing temperatures and extreme environmental conditions. While current standards state that attention should be given to the validity of fatigue design curves at subzero temperatures, studies on fatigue strength of structural steel at subzero temperatures are scarce. This study addresses the issue by analysing the fatigue strength of welded steel joints under subzero temperatures. Although critical weld details in large welded structures are mostly fillet‐welded joints, most published data are based on fatigue crack growth rate specimens cut out of butt‐welded joints. This study analyses fillet‐welded specimens at ?20°C and ?50°C against controls at room temperature. Significantly higher fatigue strength was measured in comparison to estimates based on international standards and data from design codes even at temperatures far below the allowed service temperature based on fracture toughness results.     

A structural stress‐based critical plane method for multiaxial fatigue life estimation in welded joints

This paper aims at proposing a new fatigue life estimation model that is preferably adapted to welded joints subjected to multiaxial loading. First, a mesh‐size insensitive structural stress is defined that enables to characterize the stress concentration effect appropriately. Second, the multiaxial stress state and loading path influence are taken into account in the lifetime prediction model by adopting a suitable critical plane method, originally proposed by Carpinteri and co‐authors. Experimental verification is conducted for a given welded joint geometry under different loading conditions, including uniaxial, torsional and multiaxial loads. The reliability and effectiveness of the new method are validated through substantive fatigue testing data.     

Fatigue fracture behaviour of spot welded B1500HS steel under tensile‐shear load

The microstructural characterizations, micro‐hardness measurements and fatigue tests of B1500HS steel spot welded tensile‐shear specimens were performed. The high hardness values of base material (470 HV) and nugget (515 HV) are closely related to the dominant formation of martensitic microstructures, while the occurrence of soft zone is the result of the formation of ferrite phases in inter‐critical heat‐affected zone (HAZ), as well as martensite tempering in sub‐critical HAZ. The fatigue failure modes involve the fracture along the circumference or along the direction of width. The fatigue property of spot welded B1500HS is found to be better than that of spot welded M190 because of the thicker sheet and suitable nugget size, which follows the standard rule of 5t^0.5, where t is the sheet thickness.     

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.     

高速列车荷载作用下铸钢焊接节点的疲劳分析

钢结构特别是焊接钢结构对动荷载特别敏感。武广客运专线武汉火车站采用了新型的“桥建合一”的结构型式,在长期往复动荷载作用下,上部大跨度钢结构的疲劳寿命令人关注。论文建立了铸钢节点包括焊缝的精细有限元模型,基于热点应力法和Miner线性累积损伤理论,分析了武汉站上部大跨度钢结构10管相贯焊接铸钢节点的疲劳寿命。分析结果表明：列车振动荷载引起的动应力对铸钢节点的疲劳寿命影响不大,满足结构使用寿命100年的要求。分析方法可为国内今后类似结构的疲劳寿命分析提供参考。     

Experimental study on the whole‐life heterogeneous ratchetting and ratchetting‐fatigue interaction of SUS301L stainless steel butt‐welded joint

Uniaxial fatigue tests of butt‐welded joint, made from SUS301L stainless steel, were carried out under asymmetric stress‐controlled cyclic loading conditions in this work. The effects of stress amplitude and mean stress on the whole‐life heterogeneous ratchetting and fatigue life of the butt‐welded joint were investigated, respectively, for the specified subzones. The experimental observations show that the whole‐life inhomogeneous ratchetting strain concentrating in a specific fusion zone (denoted as the FZ‐1 subzone) of the welded joint becomes more significant as the stress level increases; the fatigue failure also occurs in the FZ‐1 subzone, and the fatigue life depends on both the applied mean stress and stress amplitude and is determined by the combination of ratchetting damage and fatigue one in the localized FZ‐1 subzone.     

Simulation in fracture of welded structures with developing damages

The main features of durability design of weld structures containinginitial technological defects are considered. Among these features are:(1)~structural analysis of welded structures; (2)~simulation of limit statesand evaluation of reliability of welds and, (3) optimisation and ensuring agiven reliability of structures. The main results of simulation are givenfor: fatigue curves, reliability functions, complete probabilistic lifediagrams, diagrams of defect standardisation and probabilistic durabilitysurfaces.     

Fatigue reliability assessment of turbine discs under multi‐source uncertainties

Hot section components of aircraft engines like high pressure turbine (HPT) discs usually operate under complex loadings coupled with multi‐source uncertainties. The effect of these uncertainties on structural response of HPT discs should be accounted for its fatigue life and reliability assessment. In this study, a probabilistic framework for fatigue reliability analysis is established by incorporating FE simulations with Latin hypercube sampling to quantify the influence of material variability and load variations. Particularly, variability in material response is characterized by combining the Chaboche constitutive model with Fatemi‐Socie criterion. Results from fatigue reliability and sensitivity analysis of a HPT disc indicated that dispersions of basic variables must be taken into account for its fatigue reliability analysis. Moreover, the proposed framework based on the strength‐damage interference provides more reasonably correlations with its field number of flights rather than the load‐life interference one.     

考虑载荷作用次数的机械零部件可靠性灵敏度分析方法

 为了研究载荷多次作用时,机械零部件的可靠度及可靠性灵敏度变化规律,从灵敏度角度修改零件的设计参数,降低制造成本,建立一种可靠性模型结合了随机摄动法、Edgeworth级数技术,并考虑了载荷的作用次数．摄动法和Edgeworth级数可以在基本随机参数的前4阶矩已知的情况下,研究具有任意分布参数的机械零件的可靠性灵敏度设计问题,顺序统计量理论考虑了载荷作用次数在可靠度和灵敏度计算中的影响．使用这种模型计算出的可靠度会随着载荷作用次数而变化,这与静态的可靠度计算方法存在差别．以某一型号的螺栓为算例,应用此模型计算了其可靠度、随机变量均值和方差的可靠性灵敏度．由提出的方法得到了可靠度和可靠性灵敏度值及其随载荷作用次数变化的曲线．可靠度及可靠性灵敏度随载荷作用次数变化的规律是：载荷作用次数增加,可靠度值降低,变化趋势单调;载荷作用次数达到最大时,可靠度达到最小;随机变量均值和方差的灵敏度随载荷作用次数变化出现不同的变化趋势,其中螺栓截面直径的均值和方差灵敏度随载荷作用次数的变化最大,随作用次数的增加,螺栓截面直径的参数将对螺栓的可靠性起主要的决定作用．