Fatigue Assessment of **

Weld Joints Using ANSYS,

Verity & FE-Safe
Zhichao Wang
Aditya Sakhalkar
5/8/2007

Part I: Key Points on Equivalent SS Method

Part II: Example Application

** Verity is a weld fatigue assessment software

developed by Battelle based on Structural
Stress & Fracture Mechanics theory proposed
by Dr. Dong et al, Battelle
Part I: Key Points on SS & Weld Assessments

Zhichao Wang
Sr. Lead Engineer
Emerson Climate Technology Inc.

Background
Why The Battelles Structure Stress Is Not Sensitive To FE Mesh
Size?
How Could Multiple Joint S~N Curves Be Reduced to A Single S~N
Curve, the Master S~N Curve?
Example Application (Part ii, Aditya)

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 Background

Fatigue Assessment Unwelded Structures

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Fatigue Assessment Welded Structures

Its been commonly recognized that the fatigue life of the polished
specimen is dominated by fatigue crack initiation, whereas that of
welded structures is dominated by small crack propagation from some
pre-existing discontinuity.

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Fatigue Assessment Welded Structures

(i). Nominal Stress Method (BS,IIW)

The nominal stress range is used to develop the S~N curves using
samples with actual weld joint geometry. The life curves refer to
particular weld details, there is no need for the user to attempt to quantify
the local stress concentration effect of the weld detail itself.
(ii). Hotspot Stress Approach (structural stress, geometric stress,
BS, IIW, CEN,DNV)
This procedure uses hot-spot stress range as a parameter. The SN
curves are obtained from tests of actual welded joints based on the hot-
spot stress range rather than the nominal stress range.
(iii). Local Notch Stress Method (ASME, BS, IIW).
The notch stress approach attempts to include all sources of stress
concentration in the stress used with the design SN curve. Thus a single
SN curve may be sufficient for a given type of material. The problem is
that the local geometry of the toe or root of a weld is highly variable. It
may be hard to achieve consistent results.

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Fatigue Assessment Welded Structures

(iv). The Fracture Mechanics Approach (For crack propagation life)

The parameter widely used is SIF, K. The fatigue resistance is represented by
fatigue crack growth rate da/dN. Many crack propagation laws are available. The
simplest one is Paris Law in which the crack growth law approximates to a linear
relationship:
da
C (K)n (1)
dN
For a flaw size starts from a0 to a critical fatigue crack size af, the remaining
fatigue life N under stress range S is obtained by integrating Eq (1):

af da
a0 (K) n
C N (2)

(v) Verity Equivalent Structural Stress Method (Battelle)

Equivalent Structural Stress + Single Master S~N Curve

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 Structural Stress & Mesh Sensitivity

x ps
A
Y t (Structural Stress)
0.4 t
A
X

A
P
t
(b) Comparison of SCF predicted by various modeling
0 FE procedures and extrapolation based HSS at the weld toe [12].

Hot Spot ~ No min al

x
No min al (Human Factor )

FE
Hot Spot
No min al

X
~0.4 t

(a) Normal Stress at the sharp corner (c) Structural Stress Using Verity Method

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 Why Structure Stress
Is Not Sensitive To FE Mesh?
Y
P1
P2 Calculation of Structure Stress
X
(a) 3-D Solid Element:
Fy t P1 i. Calculate nodal force
Fx P2 ii. Transformation of nodal force to neutral
Neutral axis axis to obtain resultant forces (N, m).
t tm tb iii.Calculation of structural stress
m P1 N m
N P2 (tm )= (tb )=
A W
Q
Shell Element:
P1
P2 i. Calculate nodal force ( N/, m/, Q/ )
(b) (t ) (tm ) (tb )
ii. Calculation of structural stress
m/ P1 Because equilibrium has to be satisfied
N/ P2 Thus: m/=m

Q/=Q And t / t /
Q/ /
N =N
m = t
m , b = t
b

The equations in the calculation of

structural stress are the same. Hence, the
structural stress is mesh independent
(c) Structural Stress Using Verity Method

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 Master S~N Curve
Weld Joint Categorization

Categorization of Weld Joints (BS 7608) Weld Joints (IIW)

Most codes divide weld joints into different types

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Multiple S~N Curves Due to Weld Joint Categorization

Example Design S~N curves for

welded joints: (a) Steel weld joint S~N
curves (BS 7608); (b) Weld joint type
and S~N curves (IIW
recommendations); (c) Aluminum weld
joint S~N curves (IIW
recommendations)
(a)

(b)

Multiple S~N curves provide flexibility

for the selection of life curves and
increase difficulty to select the proper (c)
one due to the variation of actual
joints

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 How Could multiple joint S~N curves be
merged into one - Master S~N curve?

Nominal Stress Method (BS) Hot Spot Stress Method (IIW)

Weld Joints (IIW) Equivalent SS Method

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Small Crack Propagation Behavior

Specimens for notch induced short crack growth test. (a)

Compact tension (CT) with keyhole by Ramulu; (b) single edged (g) K-correlated small
notched (SEN) by Shin and Smith; (c) double edged notched crack vs. large crack
(DEN) by Shin and Smith; (d) center notched (CB) by Tanaka and growth, 7075-T6 AI [13]
da da
Nakai; (e) dN K for CT specimen; (f) dN K for three different The curves show that
specimens small crack growth faster
The data does not fall into one curve for the same specimen; than corresponding large
Multiple da/dN curves obtained for the same or different cracks at the same value
specimens, which tells that the Paris Law does not hold for of the driving force K.
small crack growth. This is called anomalous crack growth
behavior.
Different factors may attribute to short crack anomalous growth such as the effect of crack
closure, micro structure interaction and that of notch details.
A unified SIF formulation for both short and long crack and a two stage crack propagation model
were proposed by Dr. Dong & his coworkers, Battelle, to use Equivalent Structural Stress as a
parameter for weldments fatigue life assessment.

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A Unified Stress Intensity Factor (SIF) Formulation

A A R1
1 A 1
l l 0 t1
x 2
t t t 2 x

3
A 3
(a) (b) A (c) A R2
t1/t=0.1
A
1 A A
1
t1
t1 2
t
t 2
t
t
3 3

A A
(d) A
(e) (f)

=
/
x
t
= /x - t
(a) Weld geometry with a hypothetical crack l ; (b) Actual normal stress distribution; (c)
Simplification; (d) Decomposition; (e) Equilibrium-equivalent structural stress or far-field
stress; (f) Self-equilibrating stress (notch stress) with respect to a reference depth t1.

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A Unified Stress Intensity Factor

A A
1
l t1 2
t t
t
3

A A
(a) (b)

K = K n (t ) K s () (0 l t)
(c)

Notch Stress
Structural Stress, Far field stress
The drive force for crack to start and grow is the crack tip stress, introduce crack
surface traction ps called self equilibrating surface traction due to (notch effect)

ps (e) ps = f( )
= f( , t x/ )
(d)
A
l l
t t1
t x
3

K s () K s (ps ) K s ( , )
t /
x (0 l t )

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A Unified Stress Intensity Factor

ps
A
l l
t t
t

(d) A
(e) (f)

K = K n (t ) K s (ps ) (0 l t )
Notch Effect
Structural Stress, Far field stress

Notch Effect Notch Effect

Far Field SIF Stress intensity solutions

using published weight
Far Field SIF function results: (a) remote
tension; (b) remote
bending.

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SIF Magnification Factor Mkn

K = K n (t ) K s (ps ) (0 l t )
Introduction of notch induced SIF magnification factor Mkn :
K n (t ) K s (ps )
Mkn = 1.0 (0 l t)
K n ( t )
K = Mkn K n (t ) (0 l t)

a/t a/t
Comparisons of stress intensity magnification factor Mkn at 135 sharp V notch for various
specimen geometries and loading conditions: (a) Edge crack solutions; (b) Elliptical crack
solutions for a/c = 0.4

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Mkn for 1350 V Notch Specimen

a/t a/t

Conclusions:
Mkn approaches unity as crack size a/t approaches 0.1 i.e., a/t=0.1 (short
crack correction factor) Thus a/t=0.1 can be taken as a characteristic
parameter beyond which the notch effect is negligible
The difference between edge crack and elliptical crack solutions are not
significant.

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Modified Paris Law

Paris Law :
da
CK mn (a)
dN
Introduce theUnified SIF :
da
CMnkn K nm (b)
dN

Figures showed the

significant improvement
for the application of
Paris Law and its
application
More important the
crack starts from zero
that covers crack
initiation life

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Master S~N Curve

Using the Unified Paris Law,

da
CMnkn K mn S ~ N curve can be obtained (a)
dN
a af da
N (b)
a 0 CMn K m
kn n
Introduction of generallized SIF range, leads to,
1 1 m2
N t -m s I(r) (c)
C
a / t 1 d(a / t)
Where, I(r) (d)
a / t 0 Mn {f (a / t) r [f (a / t) f (a / t)]} m
kn m m b

Then
1 2 m 1 1
s C tm 2m m
I(r) N m
(e)

Introduce Equivalent Structrual Stress Range,

s
1 1
S s 2m 1 Ss C N m m
(f )
t 2m I(r)m

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Master S~N Curve

Nominal Stress Method Hot Spot Stress Method

Weld Joints (IIW) Equivalent SS Method

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Summary

The Structural Stress Method developed at Battelle is

mesh insensitive that removes the uncertainty in the
calculation of structural stress for weld joint fatigue
assessment
The nature of weld joint fatigue is considered through the
introduction of Equivalent Structural Stress based on
fracture mechanics, which enable most fatigue curves of
weld joints merged into a narrow band, the Master S~N
curve. Thus one S~N curve can be used for majority of
weld joints

Note: I believe that the weld joints have to be stress

concentration dominant to achieve consistent
results with test data.

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 References

[1]. BS PD 5500: , BSI Standards, London, 2000.

[2]. European Standard for Unfired Pressure Vessels, EN 13445: 2002, BS EN 13445:2002, BSI, London, 2002
[3]. ASME Boiler and Pressure Vessel Code, Section VIII, Rules for construction of pressure vessels, Division 2-
Alternative rules, ASME, 2003.
[4]. Carl E. Jaske, FSRF for WPVP, Journal of Pressure Vessel Technology, AUGUST 2000, Vol. 122, 297-304
[5]. S.J.Maddox, Review of fatigue assessment procedures, Int. J. of Fatigue, Vol. 25, 12, 2003, 1359-1378.
[6]. Maddox S J: 'Fatigue aspects of pressure vessel design, Spence J and Tooth A S, E & F N Spon, London, 1994.
[7]. Harrison J D and Maddox S J: 'A critical examination of rules for the design of pressure vessels subject to fatigue
loading' in Proc. 4th Int. Conf. on 'Pressure Vessel Technology', Mech E, London, 1980.
[8]. Taylor N (Ed): 'Current practices for design against fatigue in pressure equipment', EPERC Bulletin No.6, European
Commission, NL-1755ZG, Petten, The Netherlands, 2001.
[9]. Dong, P., 2005, A Robust Structural Stress Method for Fatigue Analysis of Offshore/Marine Structures, Journal of
Offshore Mechanics and Arctic Engineering , Vol. 127, pp. 68-74.
[10]. Dong, P., 2001, A Structural Stress Definition and Numerical Implementation for Fatigue Evaluation of Welded
Joints, Int. J. Fatigue, 23/10, pp. 865876.
[11]. Dong, P., Hong, J. K, Osage, D., and Prager, M., Assessment of ASMEs FSRF Rules for Pipe and Vessel Welds
Using A New Structural Stress Method, Welding In the World, Vol. 47, No. 1/2, 2003, pp. 3143.
[12] Dong, P., Hong, J. K., Osage, D., Prager, M., 2002, Master S-N Curve Method for Fatigue Evaluation of Welded
Components, WRC Bulletin, No. 474, August.
[13]. Lankford, J. , Fatigue of Eng Mater and Structures 5 (1982), pp233-248
[14]. R. Craig McClung, et al, Behavior of Small Fatigue Cracks, ASME, Vol. 19, Fatigue & Fracture, P153
[15]. Fricke W., 2001, Recommended Hot-Spot Analysis Procedure for Structural Details of FPSOs and Ships Based on
Round-Robin FE Analysis, ISOPE Proceedings, Stavanger, Norway, June.

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Part II: Example Application

Aditya Sakhalkar
Sr. Applied Mechanics Engineer
Emerson Climate Technology Inc.

Background
ANSYS, Verity, Fe-Safe Weld Assessment Procedure
ANSYS Preprocessing
Verity Analysis
Fe-Safe Analysis
ANSYS Results
Comparison of Analysis Results with the Test Results
Conclusions

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 Background

Resistance welded suction fitting

Three failures in the suction fitting weld
during reliability testing
Crack initiated at the weld toe (9 o clock)
and propagated through the shell.
Failure due to reverse bending fatigue.

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ANSYS, Verity, Fe-Safe Weld Analysis Procedure

Ansys Preprocessing Calibration

- Meshing per Verity requirements Quantify loading
- Linear material properties relative to the test
for FEA
- Apply load
- Solution

Verity, Fe-Safe Weld analysis

Verity Analysis (Eq. Structural Stress
calculations along the weld line)
- Fe-Safe analysis (Weld life calculations
using Master S-N curve)

Reliability Testing

Ansys Post processing

- Import .rst file Verity result validation
and comparison
- Post processing

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 Ansys Preprocessing- FE Model

Mesh Requirements
Shell Elements: Suction Fitting
Shell
3D mid-surface element with no through-
thickness dimension
Solid Element:
Rectangular faces required along the through- Weld Line

thickness cut from the weld line

Regular mesh along the through thickness cut
from weld line Element Type: Solid 186
Recommended elements: Hexahedral (brick) and
Pentahedral (wedge)
Tetrahedral elements can be used. Requires
Top & Bottom
special handling. fixed

Symmetry BC
On sides

Linear material properties

Hex elements along weld line (E = 29,000 Ksi, = 0.29)

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ANSYS Results

Maximum Stress Equivalent Stress

1 eq

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 Verity Procedures

Structural Stresses calculated along the

weld line at each node
Fe-Safe builds a connectivity table and
maps the stresses to elemental stresses.
These stresses are inserted into the
stress matrix to be used for fatigue
evaluation

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 Fe-Safe Analysis Weld life predictions
using Master SN Curve

Fully reverse loading defined

Fe-Safe calculates weld fatigue life
based on the Battelles Master SN
curve
The weld life (log N) data at each
node is written in the ANSYS .rst
format

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ANSYS Post processing Weld Life Results

Minimum life at element # 4436, node # 4212

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 Comparison of Verity Predictions
with Reliability Test Results

Conservative life estimate!

Predicted Failure Location correlated well with the test failures!!

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 Conclusions

ANSYS could be used for the fatigue assessment of welded

joints in conjunction with Verity & Fe-Safe
Verity provides conservative estimate of the weld life
Good correlation with the predicted and test failure locations
Verity & Fe-Safe provides a excellent weld design tool in
conjunction with ANSYS

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