Welds Simple Methods

Fatigue of Welds
Professor Darrell F. Socie

2010-2014 Darrell Socie, All Rights Reserved
Weld Fatigue Problems
Fatigue of Welds
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More Problems
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Two Similar Shapes
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Fatigue Analysis
This one is difficult
This one is easy

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Fatigue Analysis
Material
Data
Component
Geometry
Analysis
Fatigue
Life Estimate
Service
Loading
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Nominal Stress
Nominal stress approaches are based on
extensive tests of welded joints and
connections. Weld joints are classified by
type , loading and shape. For example, a
transversely loaded butt weld. It is
assumed and confirmed by experiments that welds of a
similar shape have the same general fatigue behavior so
that a single design SN curve can be employed for any
weld class. The designer need only determine the nominal
stress and select a weld class. There is no need to directly
consider the stress concentration effects of the weld.
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Structural Stress
Structural stress approaches are often
referred to as "hot-spot methods". The
structural stress includes the
macroscopic stress concentrating
effects of the weld detail but not the
local peak stress caused by the notch
at the weld toe. There are various methods used to
determine the structural stress. They involve
extrapolating the computed or measured stresses from
two points near the weld to a structural stress at the weld
toe. This method works in situations where there is no
clear definition of the nominal stress.
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Local Stress Strain

Local stress or strain approaches
include both the macroscopic
stress concentration due to the
weld shape and the local stress
concentration at the weld toe. To
apply traditional methods of fatigue analysis to
welds, an appropriate value of the stress
concentration factor and residual stress must be
selected. Although the smallest radius produces the
largest stress concentration factor, its effect in
fatigue is smaller because of the gradient effect. As
a result there is a critical radius for fatigue that can
be used to compute the fatigue notch factor.
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Crack Growth
Many weld details have planar
lack of fusion defects. This is
particularly true of fillet welds. In
this case fracture mechanics
models for crack growth are the most appropriate
fatigue technology.
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Similitude
Local stresses and strains

control the fatigue life
Lifetime to about a 1mm crack
Crack initiation
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Similitude (continued)
Nominal stresses and crack

Length control the fatigue life
Crack propagation
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Vehicles Are Frequently Overloaded
Occasional plastic deformation strain life analysis

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Strain-Life Fatigue Analysis

Cyclic stress strain curve
Material
Data
7,7'
n'
=
+ '
E K
8
2,2'
6
4
Component
Geometry
log (/2)
Strain-life curve
Service
Loading
f
'
f
=
2N f
2
E
+ 'f 2 N f
f/E
e/
E
e= /
Fatigue of Welds
1,1'
5,5'
2N
log (2Nf)
2Ne
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Gradient Effects
Material
Data
Component
Geometry
Service
Loading
Neubers Rule
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Analytical
Material
Data
Component
Geometry
Structural Loads
Experimental
Service
Loading
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Crack Growth Fatigue Analysis

Material
Data
Component
Geometry
Service
Loading
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Material
Data
(x)
Component
Geometry
Service
Loading
Fatigue of Welds
Stress distribution along crack path

in an un-cracked body
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Analytical
Material
Data
Component
Geometry
Structural Loads
Experimental
Service
Loading
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Why Are Welds Difficult to Analyze?
This one is difficult
This one is easy

Fatigue of Welds
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Welds Have Distortions
What is the real stress at a weld toe?
Fatigue of Welds
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Loading Conditions
How is the weld loaded ?

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Many Possible Failure Locations
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So Many Possibilities !
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What is KT?
Tight fit-up
KT = 3
Fatigue of Welds
Loose fit-up
KT = 7
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What Is The Weld Shape ?
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Weld Quality ?
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Mean Stress ?
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Material Properties ?
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Summary
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Summary (continued)
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Fatigue Analysis of Welds

Material
Data
Component
Geometry
Service
Loading
Uncertain, but unimportant
Uncertain, but very important
Uncertain, but important
How do we deal with these uncertainties?

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Analyzing Welds
Nominal Stress
Structural or Hot Spot Stress
Local Stress Strain
Crack Growth
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Nominal Stress Weld Classifications

D
F2
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BS 7608 - Steel
400
B
300
C
D
200
100
Fatigue of Welds
105
F2
106
107
Fatigue Life, Cycles
108
34 of 65
IIW Classification
m N = C
C (FAT) m 2 106
=
m=3
1 ) ( 1 )
(
= C m N m
2 10
= FAT
Fatigue of Welds
( 1m)
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Japan Society of Steel Construction
Fatigue of Welds
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Crack Growth Data

yield
Crack Growth Rate, m/cycle
Ferritic-Pearlitic Steel:
252
273
392
415
10-6
da
= 6.9 10 12 K MPa m
dN
3 .0
Martensitic Steel:
da
= 1.4 10 10 K MPa m
dN
10-7
2.25
Austenitic Stainless Steel:
10-8
5
10
K, MPam
100
da
= 5.6 10 12 K MPa m
dN
3.25
Barsom, Fatigue Crack Propagation in Steels of Various Yield Strengths

Journal of Engineering for Industry, Trans. ASME, Series B, Vol. 93, No. 4, 1971, 1190-1196
Fatigue of Welds
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Nominal Stress - Aluminum

125
100
75
50
D
25
E
F
105
106
107
108
Sharp, Behavior and Design of Aluminum Structures,McGraw-Hill, 1992

Fatigue of Welds
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Crack Growth Rate m/cycle
Crack Growth Data

10-2
10-4
Steel welds are 3 times

stronger than aluminum
2024-T3 m/cycle
10-6
10-8
3
3X
A533B m/cycle
10-10
10-12
1
10
100
Cyclic Stress Intensity, MPam

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Residual Stress from Welding
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Weld Distortion
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Weld Toe Residual Stress
Yield
stress
Maximum stress at the weld toe

is nearly the same for any cycle
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Mean Stress Effects

As welded structures usually have the
maximum possible mean stress
Stress relief, peening, etc. will have a
substantial effect on the fatigue life
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Butt and Fillet Weld Test Data

The good welds
Stress Range, MPa
1000
100
99% survival with 95% confidence
10
Failures
103
104
105
106
Run outs
107

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Weld Terminations
Stress Range, MPa
1000
The bad welds
100
10
99% survival with 95% confidence
Failures
103
104
105
106
Run outs
107
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Sources of Inherent Scatter
Weld quality
Mean, fabrication and residual stresses
Stress concentrations (geometry)
Weldment size
Material properties
Opportunities for Improvement !
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The Good and Bad

Good weld design
Local stress concentration from weld toe

Poor weld design
Macroscopic stress concentration from a geometry change

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Nominal Stress ?
Solution: use structural stress approach
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Typical Butt Weld
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Weld Toe
Microcracks form during welding process

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Cold Lap
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All Welds Contain Microcracks
K, MPam
100
da
= C K m
dN
400
B
300
m~3
m~3
10
D
200
100
0
1
10-6
10-7
10-8
10-9
10-10
10-11
F
105
10-12
F2
106
107
108
Crack Growth Rate, m/cycle
Same slope means same mechanism, crack growth
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Fracture Mechanics Modeling
Driving force is crack depth, a, not length, c
Fatigue of Welds
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Stress Intensity Solution

N=
af
da
C ( K )
ao
K
= K max K min
K max K applied + K residual
=
Fatigue of Welds
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Size Effects
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Weld Improvement
Reduce stresses
Residual
Distorsion
fabrication
Reduce KT
Weld toe
Macroscopic Shape
Weld starts and stops
Fatigue of Welds
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Gradual Change in Stiffness
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Weld Terminations
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Stress Diffuser
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Stress Diffuser Improvement
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Shape
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Improvement Strategies
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TWI Suggestions
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Experimental Results
Fatigue of Welds
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Things Worth Remembering

Local weld toe stresses, geometry and flaws
control the life of weldments
There are many ways to improve the fatigue
strength of welded structures.
Fatigue of Welds
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Fatigue of Welds

Welds Simple Methods

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Fatigue of Welds

Professor Darrell F. Socie

Weld Fatigue Problems

2010-2014 Darrell Socie, All Rights Reserved

2010-2014 Darrell Socie, All Rights Reserved

Two Similar Shapes

2010-2014 Darrell Socie, All Rights Reserved

This one is difficult

This one is easy

2010-2014 Darrell Socie, All Rights Reserved

2010-2014 Darrell Socie, All Rights Reserved

2010-2014 Darrell Socie, All Rights Reserved

2010-2014 Darrell Socie, All Rights Reserved

Local Stress Strain

2010-2014 Darrell Socie, All Rights Reserved

2010-2014 Darrell Socie, All Rights Reserved

Local stresses and strains

2010-2014 Darrell Socie, All Rights Reserved

Nominal stresses and crack

2010-2014 Darrell Socie, All Rights Reserved

Vehicles Are Frequently Overloaded

Occasional plastic deformation strain life analysis

2010-2014 Darrell Socie, All Rights Reserved

Strain-Life Fatigue Analysis

2010-2014 Darrell Socie, All Rights Reserved

Strain-Life Fatigue Analysis

2010-2014 Darrell Socie, All Rights Reserved

Strain-Life Fatigue Analysis

2010-2014 Darrell Socie, All Rights Reserved

Crack Growth Fatigue Analysis

2010-2014 Darrell Socie, All Rights Reserved

Crack Growth Fatigue Analysis

Stress distribution along crack path

2010-2014 Darrell Socie, All Rights Reserved

Crack Growth Fatigue Analysis

2010-2014 Darrell Socie, All Rights Reserved

Why Are Welds Difficult to Analyze?

This one is difficult

This one is easy

2010-2014 Darrell Socie, All Rights Reserved

Welds Have Distortions

What is the real stress at a weld toe?

2010-2014 Darrell Socie, All Rights Reserved

How is the weld loaded ?

2010-2014 Darrell Socie, All Rights Reserved

Many Possible Failure Locations

2010-2014 Darrell Socie, All Rights Reserved

2010-2014 Darrell Socie, All Rights Reserved

2010-2014 Darrell Socie, All Rights Reserved

What Is The Weld Shape ?

2010-2014 Darrell Socie, All Rights Reserved

2010-2014 Darrell Socie, All Rights Reserved

2010-2014 Darrell Socie, All Rights Reserved

2010-2014 Darrell Socie, All Rights Reserved

2010-2014 Darrell Socie, All Rights Reserved

2010-2014 Darrell Socie, All Rights Reserved

Fatigue Analysis of Welds

Uncertain, but unimportant

Uncertain, but very important

Uncertain, but important

How do we deal with these uncertainties?

2010-2014 Darrell Socie, All Rights Reserved

2010-2014 Darrell Socie, All Rights Reserved

Nominal Stress Weld Classifications