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Pergamon: A Theoretical Study of The Effect of Weld Geometry Parameters On Fatigue Crack Propagation Life
Pergamon: A Theoretical Study of The Effect of Weld Geometry Parameters On Fatigue Crack Propagation Life
Pergamon: A Theoretical Study of The Effect of Weld Geometry Parameters On Fatigue Crack Propagation Life
1-18, 1995
~ Pergamon 0013-7944(94)00241-X
Copyright © 1995 ElsevierScienceLtd
Printed in Great Britain. All rights reserved
0013-7944/95 $9.50+ 0.00
A T H E O R E T I C A L S T U D Y OF THE E F F E C T OF W E L D
GEOMETRY PARAMETERS ON FATIGUE CRACK
P R O P A G A T I O N LIFE
T. NINH NGUYEN and M. A. WAHAB
Department of Mechanical Engineering, The University of Adelaide, SA 5005, Australia
Abstract--In the present work, the effect of important butt weld geometry parameters e.g. tip radius of
undercut at weld toe, weld toe radius, flank angle, plate thickness and edge preparation angle, and the
effect of initial crack geometry on the fatigue crack propagation life have been studied by using Linear
Elastic Fracture Mechanics (LEFM), Finite Element Analysis (FEA) and superposition approaches. A
simple mathematical model has been developed to predict the co-influence effect of the above-mentioned
weld geometry parameters on the fatigue stress range vs life (S-N) curve. This model gives an explanation
for the overall effect of weld geometry parameters as the main reason of scatter phenomenon in fatigue
testing practice. The predicted scatter band of S-N curves subject to the variation of all the weld geometry
parameters is in good agreement with S-N curves covered by design classes from D to W (BS 5400). The
design class F which is commonly used for design of butt welded joints has fallen in the middle of the
predicted scatter band of S-N curves. It suggests that for the sake of safe design practice class W should
be used for fatigue design of butt welded joints instead of class F.
NOTATION
r ~ tip radius of undercut at weld toe
t" weld toe radius of butt welded joint
d depth of weld toe undercut
! plate thickness
tO weld bead flank angle
plate edge preparation angle
parametric angle of the ellipse
a crack length (edge crack); also half-length of minor elliptical surface crack
half-length of major elliptical surface crack; also half-length of central through-thickness crack
a/c crack aspect ratio
(a/c)o initial crack aspect ratio
b half-width of cracked plate
h half-length of cracked plate
ai crack initiation length
of final crack length
Np fatigue crack propagation life
C,m material constants in Paris' equation
A,m constants in the model equation representing S N curve in the case of butt welded plate
A 0 ' Dlf) constants in the model equation representing S N curve in the case of un-welded plate (based
plate)
CA, C~ material constants in Paris' equation at points A and B of crack front, respectively
K~o stress intensity factor for edge crack in finite plate
K~n stress intensity factor for central through-thickness crack in finite plate
Ksc stress intensity factor surface crack in finite plate
Ksc,A stress intensity factor at point A for semi-elliptical surface crack in flat plate
Ksc,B stress intensity factor at front surface point B for semi-elliptical surface crack in flat plate
AKA range of stress intensity factor at A
AKB range of stress intensity factor at B
stress intensity factor of welded plate for edge crack
stress intensity factor of welded plate for central through-thickness crack
KL.A stress intensity factor at point A for semi-elliptical surface crack in welded plate
K~.B stress intensity factor at front surface point B for semi-elliptical surface crack in welded plate
Y geometry-configuration correction factor which depends upon the geometry of the crack and
loading condition
Yo geometry-configuration correction factor due to cracked flat plate
Mk stress intensity magnification factor produced by weld profile geometry (M k = Y~ Y~)
M~ stress intensity magnification factor produced by weld profile geometry in through-thickness
direction
M~" stress intensity magnification factor produced by weld profile geometry in through-plate width
direction
Q shape factor due to elliptical surface crack
2 T . N . N G U Y E N and M. A. WAHAB
S S
B~Zc-.4 ~ t
tttttll f
y
)}))))) ) ) ) ) )l)))ll
_~2c
25 r I
= 2b -
I
S S
SURFACE CRACK IN BUTT WELDED JOINT (MODE I)
INTRODUCTION
FATIGUE behaviour of welded structures is complicated by many factors intrinsic to the nature of
welded joints. Normally crack-like defects e.g. slag inclusions, gas pores, lack of penetration at weld
root or undercut at weld toes may be introduced in welded joints. Fatigue behaviour of welded
joints and welded structures is also greatly affected by the geometry of welded joints[I-7].
However, in design practice, the effect of weld geometry parameters is simply ignored or considered
to be non-significant to fatigue behaviour of welded joints. This conservative attitude is no longer
acceptable due to recent research progress concerning the effect of weld geometry on the fatigue
of welded joints [2-7]. A recent proposal for revision of fatigue clauses in BS PD 6493 [2] has
emphasised the importance of the "size effect" of weld geometry e.g. plate thickness and attachment
length on the fatigue strength of welded joints. However, no further research has been attempted
to study other important weld geometry parameters (e.g. weld toe undercut) or the co-influence
effect of all the weld geometry parameters e.g. tip radius of undercut at weld toe, weld toe radius,
flank angle, plate thickness and edge preparation angle, and the effect of initial crack geometry.
The existence of crack-like flaws in the welded steel joints as a result of weld defects is
unavoidable. Under cyclic loading, fatigue cracks are initiated from these defects and will propagate
through the plastic thickness during the fatigue life. A study by Mattos and Lawrence [7] has
revealed the important effect of weld geometry on fatigue crack initiation life. The effect of
individual weld geometry parameters on fatigue of welded joints has been studied by many other
researchers [8-14]. However, so far no complete theoretical analysis of the effect of weld geometry
parameters on fatigue crack propagation has been carried out. Therefore, this study aims to develop
a model to predict the effect of all the important butt weld geometry parameters on fatigue crack
propagation life, as well as their overall effect on S-N curve.
In this study, a semi-elliptical surface crack model was constructed to evaluate the contribution
of the weld geometry to the stress intensity factor based on Linear Elastic Fracture Mechanics
(LEFM), superposition and finite elements approaches. Then the co-influence effect of the
above-mentioned weld geometry parameters on the fatigue behaviour of welded joints can also be
evaluated by using dimensional analysis technique.
A theoretical study o f the effect of weld geometry parameters on fatigue crack propagation life 3
ANSYS 5.0 31
OCT 27 1993
12:21:38
PLOT NO. l
ELEMENTS
TYPE NUM
U
PRIES
ZV =1
DIST = 55
XF = 50
YF = 6.928
CENTROID HIDDEN
ANSYS 5.0 31
OCT 27 1993
11:48:14
PLOT NO. 1
ELEMENTS
TYPE NUM
PRES
ZV =1
* DIST = 15,243
* XF = 6.486
~,* YF = 9 . 7 8 8
t CENTROID HIDDEN
Fig. 2. A 2-D finite element mesh used for the calculation of stress distribution along potential crack line
in butt welded joints.
THEORETICAL APPROACH
I t is k n o w n from Fracture Mechanics that the stress intensity factor (K) for crack opening
mode (mode I) c a n b e e x p r e s s e d in the following form:
r = r. s. (1)
4 T . N . N G U Y E N and M. A. W A H A B
For the cracks which propagate in the region of stress concentrations produced by the
geometry of welded joints, i.e. cracks at weld toes, a further correction factor (Mk) is introduced
and known as geometry magnification factor [2, 3]. Then eq. (1) can be rewritten as follows:
Solutions for the stress intensity factor due to various crack geometries are available from
literature in Fracture Mechanics and can be used for the fatigue assessment of welded structures.
In this study a semi-elliptical surface crack with various initial crack shape aspect ratios (a/c)o (from
0.1 to 1.0) [Fig. 1] is assumed to be located at weld toe as a result of weld defect of the order of
0.1 mm (ai=0.1 mm). This conservative assumption was also supported by other re-
searchers [1, 3, 12]. Then the total fatigue life of the welded plate can be considered as the number
of cycles needed for this initiated semi-elliptical surface crack propagating through the thickness
of welded plate.
An empirical solution for the stress intensity factor due to a semi-elliptical surface crack in
the centre of a finite plate in mode I loading is given by Newman and Raju [15] as follows:
However, by using this solution the effect of weld geometry of the welded joint can not be
included. In order to overcome this obstacle, the weight function method was applied to calculate
the stress intensity factor and it is necessary to assume the "similarity effect" between the stress
intensity values of a notched and unnotched body due to various crack shapes. It means that the
ratios of stress intensity values between a notched and unnotched body are the same for surface
25
20 • ~ r=O.3mm
r =0.5 mm
"; 15
-~-- r = 0.8 m m
r = 1,2mm
,~-10
r = 2.0turn
r = 2.5ram
5
! I ' I I
0.2 0.4 0.6 0.8
a/t
0.9
0.8 --=-- r = 0.3 m m
0.7 r =0.5 mm
0.6 --°~r=O.Smm
E
0.5 ----o---- r= 1.0ram
0.3 r = 1.6ram
0.1 r = 2.5 m m
0
0 0.2 0.4 0.6 0.8 1
0.9 • r =0.3mm
0.8
0.7
¢ / ----c---- r = 0.5 mm
f T
.~= 0.6
f
7 ;Iiiii t
- - - - - r = 0.8 mm
r = 1.0mm
.~ 0 . 4
f ililil - - ~ r = 1.2 m m
r = 1.6mm
,-3 0.3
--*-- r = 2.0 m m
0.2
r = 2.5mm
0.1
0 I I I I I I I
1 2 3 4 5 6 7 8
Number of cycles, N x 10 o
1000
- - - - a - - r =0.3 mm
r=0.5mm
--'-- r = 0.8 mm
B, 100
r=l.2mm
r =2.0mm
r = 2.5ram
10
10 s 10 ' 10"
Number of cycles N
crack, edge crack or central through-thickness crack. This assumption is already supported by other
researchers [16, 17]. When a welded joint is considered as a notched body then the following
equations can be written:
K wsc,A/Ksc,A:KeWd/Ked= M A (4)
K~,,/K~c., - Kc~,/K¢~, = M~.
- - w
(5)
Using eqs (4) and (5) the stress intensity factors due to the semi-elliptical surface crack at the
weld toe for point A and surface crack front point B (Fig. 1) can be calculated if the stress intensity
solutions for edge crack and central through-thickness crack of welded plate and flat plate are
known. Using Bueckner's weight functions for edge crack in a finite plate [18] and Kanazawa's
weight function for central through-thickness crack [19], stress intensity factors can be calculated
as follows:
Kcd = f"
jo
S ( x ) " re(a, x)" dx (6)
When S ( x ) and S(y) are the local stress distributions along potential crack direction x and
y, respectively, then each of them should be a resulting stress due to local stress subjected to weld
geometry and external loading in the proper direction.
6 T.N. NGUYEN and M. A. WAHAB
Eqs (4)-(7) enable us to study the effect of various weld geometry parameters on the stress
intensity factor, as well as fatigue behaviour of welded joints, quite simply and satisfactorily once
stress distribution along potential crack line in weldment is evaluated. By using 2D-Finite
Elements [20] the local stress distributions subjected to weld geometry can be calculated (Fig. 2)
and fitted into the polynomial form and used for the calculation of the stress intensity factor. With
the above assumptions the stress intensity magnification factors, M A and M~, due to the
co-influence effect of weld geometry parameters can be obtained, and also AKA and AKB can be
obtained.
The crack-growth rates were calculated by assuming that Paris' equation [21] is obeyed
independently at points A and B at the crack front, and it can be rewritten as:
16
14
12 --m-- 0=0¢
0=5 °
,,g --*-- 8= IO °
~ 8
- - - ~ 8= 20 ©
6 0=400
4 9=60 a
2
S = 80 MPa
0 I I I I
0.2 0.4 0.6 0.8
a/t
1.2
• ' 0=~
1
o 0=5*
g 0.6
----0----
~.
0=15.!
0=20*
I
0.4 e=3¢
~ - - 0=40 ~
0.2
------o-----0=50'
0 I I I I --×-- 0=60 •
0.2 0.4 0.6 0.8
Relstlve crack length (s / t)
o., i ! • O=0*
0.8 i 0=5"
-~0.4 8=30 °
(c) E f f e c t o f ( O ) o n c r a c k p r o p a g a t i o n life.
1000
• 0=0'
.------0-----0=5*
____¢1_ 0=20*
100 u
e 0=30"
to
" - " ~ - - - - O= 40"
""~-- 0=50'
-----0---0=60'
10
10' 10' 10
Number o! cycles N
(d) E f f e c t o f ( O ) o n S N c u r v e .
Fig. 4. The effect of flank angle on the fatigue behaviour of butt welded joints.
In order to quantify the co-influence effect of all the weld geometry parameters on fatigue
behaviour of a butt weld joint, a mathematical model for the S - N curve subjected to the variation
of weld geometry parameters is proposed on the basis of the fatigue design rule BS 5400 [2] as
follows:
where
m / m o = f m ( r ' / r , r/t, (9, dp, t / b )
R E S U L T S AND DISCUSSION
Effect of weld toe radius
Figure 3(a) shows the effect of the weld toe radius on the stress intensity factor KWA calculated
for the constant stress range S = 80 MPa (other weld geometry parameters are kept constant:
r' 0, 6) = 30 °, q5 = 600 and t = 12 mm). It shows that the value of K sc,A
w is decreased as the weld
toe radius (r) increases. The significant difference between the values of K sc,A~ is observed due to
the increase of the weld toe radius (r) from 0.3 to 2.0 mm. However, only little difference between
the values of K sc,A
w is observed due to the increase of (r) from 2.0 to 2.5 mm.
Figure 3(b) shows the effect of the weld toe radius on the crack aspect ratio (a/c). It shows
that a semi-elliptical surface crack, with a certain initial crack shape [(a/c)o = const] propagating
a butt welded joint with a higher value of weld toe radius, tends to develop at the crack shape
with a higher value of (a/c) during crack propagation life. At the early stage of crack growth
(a/t < 0.1) the surface crack tends to reach the shape with a higher value of (a/c), i.e. close to the
shape of a semi-circular crack. However, the value of ratio (a/c) decreases as the crack propagates
further.
Figure 3(c) shows the effect of the weld toe radius on the fatigue crack propagation life. It
is obvious that the fatigue crack propagation life is increased as the value of (r) increases. It means
that the fatigue life of the butt welded joint can be improved by increasing the value of the weld
toe radius (e.g. by grinding or other post-weld finishing techniques). This conclusion is consistent
with the results claimed by several other researchers [1, 3, 8, 9]. This figure also shows that the
improvement of the fatigue crack propagation life due to an increase of (r) from 0.3 to 2.5 mm
is of the order of 4.5 × 1 0 6 cycles for a constant nominal applied stress range (S = 80 MPa).
60
5O
/"
/ ---'-- t = 9 mm
4O - ~ : ~ - - - t = 12 rnm
~30
,/ ..-/ --'-- t = 16 mm
t=2Omm
20 ---'--- t = 25 mm
10
~ g.;.~ ...... t = 32 mm
0 I I I I
1.6 1 ~
• t=9mm
~1"4 t
o t= 12mm
• t= 16ram
o io o t = 20mm
~0.8
o QD~
• t = 25ram
~o6~ "°OOo,:
"'~. ~. . . . . ~ e ~ t =32ram
OJ I I I I
0 0.2 0.4 0.6 0.8 1
Relative c r a c k length (a / t)
.,P-,,,Q •
1
• D •
0.9
e.'2:
0.8 o * o •
o • o • • t=9mm
v 0.7 o D •
<> • o • o l= 12mm
0.6 / ¢ • O •
• ¢ • o • " t= 16mm
0.5 • o • ~ •
• <> • o • o t= 20mm
0.4 • ¢ * o •
A • o • o • • t = 25 m m
.e.
0.3 • o * O •
/~ • o * [] • t~ t = ~ g m m
0.2 A~ • 0 * 0 •
• ¢DI • DI
0.1 " <> " S : 80 M P a
. . . . : . . . . : . . . . .: . . . . : . . . . : . . . .
0
1 2 3 4 5
Number of cycles, N x 10 s
1000
• t=9mm
----D--- t = 12 m m
--*-- t = 16 m m
100
---'¢-~ t = 20 m m
----*-- t = 25 m m
-~---- t = 32 m m
10 . . . . . . . . . . . . . . . . . . .
10 s 10 e 10 r
Number of cycles N
Fig. 5. The effect of plate thickness on the fatigue behaviour of butt welded joints.
Figure 3(d) shows the effect of weld toe radius on the S - N curve. It shows that the S - N curve
tends to move from left to right as the value of the weld toe radius increases. As a result, the fatigue
strength and fatigue life of butt welded joints can be improved correspondingly. This figure also
shows that the fatigue strength of a butt joint at 2 × 106 cycles is increased by 34% as the weld
toe radius increases from 0.3 to 2.5 ram.
Figure 4(b) shows the effect of the flank angle on the crack aspect ratio (a/c). It shows that
a semi-elliptical surface crack with certain initial crack shape [(a/c)o = const] propagating in a butt
welded joint with a lower value of flank angle tends to develop the crack shape with a higher value
of (a/c) during crack propagation life. At the early stage of crack growth (a/t < 0.1) the surface
crack tends to reach the shape with a higher value of (a/c), i.e. close to the shape of a semi-circular
crack. For a base plate or flush-ground welded plate (with O = 0) the initial semi-elliptical crack
becomes semi-circular after a few cycles. However, the value of ratio (a/c) decreases as the crack
propagates further. It is also observed from this figure that there is no significant difference between
10 T.N. NGUYEN and M. A. WAHAB
crack shapes that developed during crack propagation life corresponding to various values of flank
angles from 20 ° to 60 ° .
Figure 4(c) shows the effect of flank angle on the fatigue crack propagation life. It is obvious
that the fatigue crack propagation life is increased as the value of (O) decreases. It means that the
fatigue life of the butt welded joint can be improved by decreasing the value of flank angle (e.g.
by grinding or other post-weld finishing techniques). This conclusion is consistent with the results
claimed by several other researchers [1, 3, 8, 9]. The improvement of fatigue crack propagation life
due to the decrease of (6)) from 60 ° to 0 ° is of the order of 14 x 106 cycles for a constant nominal
applied stress range (S = 80 MPa), while the improvement of the fatigue life due to the variation
of (r) is of 4.5 × l06 [Fig. 3(c)]. It means that the degree of influence of the flank angle on the fatigue
crack propagation life is more significant than that of the weld toe radius.
Figure 4(d) shows the effect of the flank angle on the S-N curve. It shows that the S-N curve
tends to move from left to right as the value of the flank angle decreases. As a result, the fatigue
strength and fatigue life of butt welded joints can be improved with respect to a smaller flank angle,
i.e. to smoother weld bead. The flush ground welded plate will have the highest fatigue strength
and this is equal to the fatigue strength of the parent plate [3]. This figure also shows that the fatigue
strength of butt welded joints at 2 x 106 cycles is increased by 21% as the flank angle decreases
from 60 ° to 5° . However, the fatigue strength of the butt joint would be increased up to 54% as
the flank angle decreases further to the level of the base plate (O = 0°).
16
14
-----a-- ~b: 45'
12
-----0---- ~ = 50'
<10
--*-- ~ = 60'
8
~,=70'
6
- ' - - ' - " - - ~ = 80'
4
----6--- ~=90 ~
2 S = 80 MPa
0 I I I I
0 0.2 0.4 0.6 0.8 1
a/t
( a ) E f f e c t o f (~b) o n K ~ , A.
0.8
~ 0.7
--m-- t~=45 o
"~= 0.6
._ ----o--- t~=50 °
~ o.s
--°-- ~=60 °
~o . 4
----o---- ~=70 •
0.3
¢=SO °
.~ 0.2
0.1
I I I I
0.2 0.4 0.6 0.8
Relative crack length (a I t)
0.9
0.8 I -"-"~-- ¢=45*
0.7 + ¢~=50*
0.6 - - . - - ~,=60o
0.5,
,~ 0.4
I/i/i ~-- m=80*
0.3 251 ~.,"
----~---, =9o*
0,2
0.1
.... : .... , .... : .... : .... : .... ; ....
1 2 3 4 5 6
Number of cycles, N x 10 o
1000
~-- 0=45.
=2 0=50*
- - ' - - ¢=60'
100
---o-----0=70*
~-- 0=80*
~ 0=90"
I
r = 1 mm, r ' = 0, O = 30 ° and ~b = 60°). It shows that the value of KwA is increased as the value
of plate thickness increases. This can explain the well-known effect of plate thickness [1] in reducing
the fatigue life of a weld joint [Fig. 5(d)].
Figure 5(b) shows the effect of plate thickness on the crack aspect ratio (a/c). It shows that a
semi-elliptical surface crack with certain initial crack shape [(a/c)o = const] propagating in a butt
welded joint of thinner plate tends to develop the crack shape with a higher value of (a/c) during
the crack propagation life. At the early stage of crack growth (a/t < 0.1) the surface crack tends
to reach the shape with a higher value of (a/c), i.e. close to the shape of a semi-circular crack.
However, the value of the ratio (a/c) decreases as the crack propagates further.
Figure 5(c) shows the effect of plate thickness on the fatigue crack propagation life. It is
obvious that the fatigue crack propagation life is decreased as the value of (t) increases. This
conclusion is consistent with the experimental results obtained by several other re-
searchers [I, 3, 12-19]. The improvement of the fatigue crack propagation life due to the decrease
o f ( t ) from 32 to 9 m m is of the order of 3 x 106 cycles for a constant nominal applied stress range
(S = 80 MPa), while the improvements of the fatigue life due to the variations of (r) and (O) are
of the order of 4.5 × 106 and 14 x 106, respectively. It means that the degree of influence of plate
thickness is less significant than that of both the weld toe radius and flank angle.
Figure 5(d) shows that the fatigue life is significantly increased as the plate thickness decreases
from 32 to 9 mm. However, the improvement of the fatigue life due to the decrease of plate
thickness from 20 to 9 m m is non-significant. It means that for the lower range of plate thicknesses
(less than 20 mm), the effect of plate thickness is ignorable. It is also clear from this figure that
12 T . N . N G U Y E N and M. A. W A H A B
the thicker plate tends to move the S-N curve from right to left. It means that the fatigue life and
fatigue strength of welded plates are decreased with increasing value of plate thickness. Fatigue
strength of butt joints at 2 × 106 cycles is decreased up to 21% as plate thickness increases from
9 to 32 mm.
35
r'= 0.10mm
r ' = 0.25 m m
15
r ' = 0.35 m m
10
r ' -. 0.50 rnm
I I ' I I
0.2 0.4 0.6 0.8
0.8
0.7
--m-- r ' = 0.05 m m
0.6
I
.~
.o r ' = 0.10 rnm
~ 0.1
0
0.2 0.4 0.6 0.8
0.9
0.8 --'-- r'= 0.05 mm
I
v~0.7 r' = 0.10 rnm
~0.6
o
0.5 / I /'7I --°-- r" = 0.15 mm
r'= 0.25mm
,~
>~
0.4
?/
!g J
/Y d --'-- r ' = 0.35 mm
0.3
r ' = 0.50 mm
0.2
0.1
! ! !
0.5 1 1.5
Number of cycles, N x 10 e
1000
• r'= 0.05 mm
r'= 0.10mm
~ - - r' = 0.35 mm
v)
r' = 0.50 rnm
10104 10 s 10 e 1{) 7
Number of cycles, N
the order o f 4.5 × 106, 14 x 106 and 2 × 106, respectively. It means that the degree of influence o f
the edge preparation angle is less significant than that o f other weld geometry parameters, i.e. the
weld toe radius, flank angle and plate thickness.
Figure 6(d) shows the effect of the edge preparation angle on the S - N curve. It shows the S - N
curve is slightly m o v e d from left to right as the value o f angle (~b) decreases. However, the small
improvement o f the fatigue and fatigue life o f butt welded joints can be considered to be
non-significant as S - N curves corresponding to various values o f angle (4)) almost overlap each
other. This figure also shows that the fatigue strength o f butt joints at 2 × l06 cycles is increased
by 7% as angle (~b) decreases from 90 ° to 45 °. This increment is ignorable due to the large scatter
o f fatigue data often met in fatigue testing.
Figure 7(b) shows the effect of the tip radius of undercut at the weld toe (r') on the crack aspect
ratio (a/c). It shows that a semi-elliptical surface crack with certain initial crack shape
[(a/c)o = const] propagating in a butt welded joint with a higher value of tip radius of undercut
(r') tends to develop the crack shape with a higher value of (a/c) during crack propagation life.
At the early stage of crack growth (a/c < 0.1) the surface crack tends to reach the shape with a
higher value of (a/c), i.e. close to the shape of a semi-circular crack. However, the value of the
ratio (a/c) decreases as the crack propagates further.
Figure 7(c) shows the effect of the tip radius of undercut at the weld toe (r') on the fatigue
crack propagation life. It is obvious that the fatigue crack propagation life is increased as the value
of (r') decreases. It means that the fatigue life of the butt welded joint can be improved by
decreasing the value of (r') or by eliminating the undercut at the weld toe by grinding or other
post-weld finishing techniques. The improvement of the fatigue crack propagation life due to the
decrease of the tip radius of undercut from 0.5 to 0.05 mm is of the order of 1.7 x 10 6 cycles
(S = 80 MPa), while that due to variation of (r), (O), (t) and (q~) is 4.5 x 10 6, 14 x l 0 6, 3 × l06
and I × 10 6 cycles, respectively. It means that the degree of influence of the tip radius of undercut
on the fatigue behaviour of butt welded joints is less than that of (r), (O) and (t), but stronger
than that of (tk).
Figure 7(d) shows the effect of the tip radius of undercut at weld toe (r') on the S-N curve.
It shows that the S-N curve tends to move from left to right as the value of (r') decreases. It means
that the fatigue strength and fatigue life of butt welded joints can be improved by either partly
or totally removing the weld toe undercut. This figure also shows that the fatigue strength of butt
joints at 2 x 10 6 cycles is increased by 12% as the tip radius of undercut decreases from 0.5 to
0.05 mm.
20
18
• a/c :0.1
16
---o---- ale : 0.2
14
--°-- a/c:0.3
,<12
---'0--- a / c : 0.5
~: 10
8 • ..... a l e : 0 . 8
6 ~ a/c=1.0
4
2
0 : : : :
0 0.1 0.2 0.3 0.4 0.5
Relative crack length (a / t)
1
0.9
-.~ 0.8 • (alc), =0.1
c:
v 0.7
o o (a/c), =0.2
0.6
c.: • (a/c), =0.3
~ 0.5
o ( a / c ) , =O.S
~. 0.4
• ( a / c ) , :0.8
0.3
~ 0.2 5, ~ e O n n n o n n n n n o n o n e o n o ooooooo
( a / c ) , =1.0
0.1
I I l
j//U
0.8
0.7
0.1
0 I I I I I I I
6 8 10 12 14 16 18 20
N u m b e r of c y c l e s , N x 10 s
1000
--m-- a / c =0.1
o
"s:
v ~ a/c=0.2
cJ~
--'-- ale=0.3
100
o -~o--- a / c = O.5
~ - - a l e =0.8
P
- ~ - a - - - - a i c = 1.0
1010a 10 s 10 e 107
N u m b e r of c y c l e s , N
EFM ~ l : l - B
16 T, N. N G U Y E N a n d M. A. W A H A B
Figure 8(d) shows the effect of the initial crack shape aspect ratio (a/c)o on the S-N curve.
It shows that the S-N curve tends to move from left to right as the value of (a/c)o increases from
0.1 to 1. This figure also shows that there is no significant difference between the effect of (a/c)o
on the S-N curve for a large range of the initial crack shape aspect ratio from 0.2 to 1.0 mm.
Therefore, it suggests that when using a semi-elliptical crack propagation model to evaluate fatigue
behaviour of butt welded joints an initial crack with aspect ratio of 0.2 can be adopted.
1000
S max, pred
u~. 100
• Exper. Data [NRIM]
10
10 4 10 s 10 6 10 7 10 s
Number of cycles, N
D to W (BS 5400). The design class F which is commonly used for design of butt welded joints
has fallen in the middle of the predicted scatter band of S - N curves. It is suggested that for the
sake of a safe design concept, class W should be used for fatigue design of butt welded joints instead
of class F.
CONCLUSIONS
The analysis of the effect of weld geometry of butt welded joints on the fatigue crack
propagation life gives the following important conclusions:
(1) The fatigue life and fatigue strength of butt welded joints can be improved by modifying
one of its weld geometry parameters as follows:
• Increasing the radius of weld toes
• Decreasing the value of flank angle. The significant improvement is obtained when the flank
angle is decreased beyond the value of 20 ° . The best case is to flush-grind the weld bead
to the level of the base plate
• Decreasing plate thickness
• Decreasing the edge preparation angle
• Decreasing the tip radius of undercut at weld toes or eliminating the weld toe undercut
completely.
(2) The degree of influence of various weld geometry parameters on fatigue behaviour of butt
joints is in the following order: flank angle, weld toe radius, plate thickness, tip radius of undercut
and edge preparation angle.
(3) The effect of butt weld geometry parameters on fatigue crack propagation life is due to
the early stage of crack growth only. Beyond that crack length the weld geometry no longer has
a significant effect on fatigue crack propagation life.
(4) A theoretical explanation for the well-known side effect of plate thickness in decreasing
the fatigue life and fatigue strength of welded joints is revealed. However, for the lower range of
plate thicknesses (less than 20 mm) this effect is found to be non-significant.
(5) The initial crack shape aspect ratios play important roles in fatigue crack propagation life.
The initial semi-circular surface crack is less harmful than the semi-elliptical or edge one. However,
there is no significant effect between the large range of initial crack shape aspect ratio from 0.2
to 1.0. It suggests that for the fatigue assessment of butt welded joints using LEFM, an initial crack
aspect ratio of 0.2 can be adopted.
(6) A mathematical model that developed in this study to predict the co-influence effect of butt
weld geometry parameters satisfactorily gives a new insight into fatigue design.
This analysis shows the basic understanding of the effect of weld geometry on the fatigue crack
propagation life of butt welded joints in structural steel. It gives a good explanation for post-weld
treatments (e.g. grinding of the weld toe) commonly used in practice to improve fatigue
performance of welded structures. It also introduces the recommendation for more efficient use of
post-weld treatments subject to particular cases.
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