Int J Adv Manuf Technol (2009) 40:74–83
DOI 10.1007/s00170-007-1312-5
ORIGINAL ARTICLE
Investigation of the fatigue behaviour of butt-welded joints
treated by ultrasonic peening process and compared
with fatigue life assessment standards
G. R. Jinu & P. Sathiya & G. Ravichandran & A. Rathinam
Received: 10 August 2007 / Accepted: 7 November 2007 / Published online: 18 December 2007
# Springer-Verlag London Limited 2007
Abstract Ultrasonic peening is a technique to be used for
improving the fatigue life of welded structures. The
technique makes use of an ultrasonically vibrated pin
which is pressed against the toe regions of the weld. The
beneficial effect is mainly due to the introduction of
favourable compressive stresses on weld toe regions,
causing local plastic deformation and reducing stress
concentration effect. This paper deals with the influence
of ultrasonic peening treatment on fatigue life improvement
in butt-welded plates. Fatigue life is predicted for the
welded plate as per BS 7608 standard, AWS D 1.1
structural welding code and IIW-XIII-1539-96 standard,
and they are compared with the experimental results. The
ultrasonic peening technique is applied on a plain carbon
steel plate weldment, and specimens conforming to ASTM
E 466 standard are prepared and tested in a servohydraulic
static dynamic testing machine at three different stress
levels. Afterwards their fatigue lives are obtained. The
comparison of the fatigue life in unpeened and peened
specimens brings out the beneficial influence of the treatment.
It is found that the improvement in fatigue life is up to 35% at
250 MPa of applied stress. But at higher stress levels, the
benefit is less. At 350 MPa of applied stress, peening results in
lower fatigue life. A comparison of the predicted fatigue lives
from various standards with the experimental results shows
that it is very close to the life at 50% probability of survival as
G. R. Jinu : P. Sathiya (*)
Department of Production Engineering,
National Institute of Technology,
Tiruchirappalli 620 015 Tamil Nadu, India
e-mail: psathiya@nitt.edu
G. Ravichandran : A. Rathinam
Welding Research Institute, Bharat Heavy Electricals Limited,
Tiruchirappalli 620 014 Tamil Nadu, India
predicted by the BS 7608 standard. The details of the
experiments conducted and the results obtained are furnished
in this paper.
Keywords Local plastic deformation . Ultrasonic peening .
Fatigue performance . Welded joints . Standards . S-N curve
1 Introduction
Fatigue is a form of failure that occurs in structures
subjected to dynamic and fluctuating stress. Under these
circumstances it is possible for failure to occur at a stress
level considerably lower than the tensile or yield strength
for a static load [1]. The presence of high tensile weld
residual stress during welding process is an important factor
contributing to fatigue failure. This may cause fatigue
failure earlier than non-prestressed materials. A compres-
sive stress induced by post weld treatment may be
beneficial by eliminating the tensile residual stresses and
introducing compression residual stresses which improve
fatigue strength of welded structures. Stresses in a welded
structure are a combination of applied stress due to load and
the locked- in weld residual stresses which are independent
of the load. When the applied stress is superimposed on the
residual stress at a point in the material the tensile
component of the internal stress (internal stress: (s′=
sapplied +sresidual) will contribute to fatigue crack develop-
ment and is defined as effective stress range. The fatigue
strength will strongly influenced by the joint classification
[2–4]. Severity of joint geometry is the most critical factor,
the more severe the geometry, the lower the fatigue strength
of the weldment.
Some literature [5–8] classifies the methods of improv-
ing fatigue life into two methods: "modifying the weld
Int J Adv Manuf Technol (2009) 40:74–83
geometry” and “introduction of favourable residual stresses
in the weldment”. In the first method, the fatigue life is
improved by reducing the stress at the critical section by
avoiding sharp corner or edges in the joints. In general the
improvement in butt and fillet welded T-joints can be
achieved by forming correct contours at the toes of the
joints. In the second method, favourable compressive
residual stresses are imposed in critical regions through
suitable methods.
Conventional post-weld treatment techniques include
grinding, air hammer peening, shot peening, needle peening
and TIG (tungsten inert gas) remelting. Grinding and TIG
dressing can well improve the weld toe profile and reduce
stress concentration effects. However, tensile residual stresses
remain due to the heat produced in the treatment operation.
Peening techniques can both improve the weld toe profile and
induce beneficial compressive stresses at weld toes [9].
Failures are reported in welded structures subjected to
fatigue load applied in bridges, ships and pressure vessels.
The post-weld treatment can provide enhanced fatigue
strength for structures. A modern treatment technique,
ultrasonic peening (UP), is a possible way to effectively
improve the residual stress conditions near weld toe. This
technique utilizes ultrasonic impulse at frequency of
22 kHz to provide treatment on weld toe surfaces [10].
Statnikov [11] developed the UIT technique in the late
1950s. The developer noted that the residual stress
improvement is due to ultrasonic wave fluctuation trans-
ferred through the tool to the applied material. The weld toe
profile improvement is carried out by 3 mm diameter pins.
The operation is similar to air hammer and needle peening,
but the tool is smaller, lighter and much easier to handle
with less noise.
Statnikov et al. [12] described the theory and the results
of the experimental investigations in harmony the physics
of the ultrasonic impact. Also, the mechanism of the
ultrasonic impact based on high-power ultrasonic trans-
ducers is exercised.
Cheng et al. [13] used UIT and shot peening process for
postweld treatment. From the experimental conditions and
results of the stress measurements they revealed that the
peak compressive residual stress induced by both treat-
ments exceeded the yield stress of the base material near the
sample surface. The depth of compressive stress layer in
base metal was 1.5–1.7 mm for UIT and 0.8 mm for shot
peening. The induced compressive residual stresses benefit
to increase the stress intensity factor range, _Kth, for
fatigue crack initiation and early propagation. The effect of
residual stresses modification on fatigue strength is dis-
cussed, based on fracture mechanics model and verified by
fatigue test results of large-scale welded beams.
Abramov et al. [14] demonstrate the influence of the
technological parameters on the surface hardening of metals
75
by ultrasonically accelerated small balls. They demonstrated
that the impact force grows with the increase of the
amplitude and frequency of ultrasonic vibrations, density of
material and size of balls and decreases with the increase of
the distance between irradiator and sample. The experimental
results showed that the ultrasonic impact treatment of steel
might be used in industries. The general advantages of
ultrasonic treatment are very short treatment time and the
ability to treat all shapes with a simple apparatus.
Pinho-da-Cruz et al. [15] report the fatigue behaviour of
thin AlMgSi1 aluminium alloy weldments and the im-
provement in fatigue strength due to post-weld treatments.
Several fatigue tests were performed using two distinct
types of thin welded joints, T and single lap, manufactured
using a 6xxx series aluminium alloy, and the efficiency of
fatigue life improvement techniques, such as post-weld heat
treatment and weld toe’s burr dressing, were studied. Both
the post-weld heat treatment and the burr dressing produced
a fatigue strength improvement for both geometries.
Finally, several fatigue tests were performed under variable
amplitude block loading using T6 post-weld heat-treated
single lap joints, and the corresponding fatigue lives were
compared with the predictions of Miner’s rule.
Kudryavtsev et al. [16] discussed the basic principles,
technology and equipment for UP as well as the efficiency
of UP application for fatigue life improvement of tubular
welded joints. They applied ultrasonic peening for rehabil-
itation and repair of welded elements and structures. The
experiments are conducted by applying UP treatment to
large-scale welded specimens in as-welded condition, after
50% of expected fatigue life and after repair of fatigue
cracks. Also, different techniques for restraining and repair
of fatigue cracks were analyzed and compared(overloading;
drilling of the crack tips; drilling of the crack tips with
installation of high strength bolts; local explosive treatment;
local heat treatment; welding with and without UP of weld
toe zones).The practical application of UP for rehabilitation
and repair of welded elements of highway and railway
bridges were also discussed and the results showed that
ultrasonic peening treated after 50% of expected fatigue life
gives better life.
Kudryavtsev et al. [17] discussed the efficiency of
ultrasonic peening (UP) application for fatigue life im-
provement of automotive welded wheels. The improvement
treatment of welded wheels was performed using the
computerized complex for UP. Based on the results of
fatigue testing of real wheels in as-welded conditions and
after, application of the UP showed that the UP-treated
welded wheels demonstrated longer fatigue life that the
same automotive wheel in as-welded condition.
Toyosada et al. [18] developed a model which is capable
of evaluating effects of the stress ratio, overload, and
residual stress, grain size of steel, variable amplitude
76
Table 1 Chemical composition of IS 2062 material
S. No. Element (wt %)
C Si Mn P S
1 0.180 0.180 0.980 0.016
loading and sequence of load on fatigue initiation and
growth curve.
Meo et al. [19] employed predictive simulation tools for
describing the effects of shot peening on the residual stress
of welded aircraft plates. The author described a detailed
modeling and simulation of the residual stress field and also
discussed with shot peening process. They concluded that
the use of shot peening process would improve significantly
the structural performance of welded joints.
Tenga et al. [20] investigated thermal elasto-plastic
analysis using finite element techniques to analyze thermo-
mechanical behavior and evaluate residual stresses in
weldments. They developed an effective procedure by
combining finite elements and multiaxial fatigue theory
while considering the welding residual stress as the initial
conditions in accurately predicting the fatigue life of
welded joints, the fatigue lives of butt-welded joints are
forecast using the proposed procedure. The proposed
procedure that followed the conventional strain-based
method (maximum principal strain and von Mises effective
strain) to predict the fatigue life of the butt-welded joints was
fairly sensitive to welding residual stress. They show best
agreement with the experimental data of butt-welded joints.
Nguyen et al. [21] developed a numerical model to
predict the combined effect of a weld toe undercut, residual
stresses and mi-alignment on the fatigue strength and
fatigue life of butt-welded joints subjected to pulsating
tensile loading. Linear elastic fracture mechanics (LEFM),
finite element analysis (FEA) and superposition approaches
have been used for the modelling. It has been found that the
effect of undercut is the most significant geometrical effect
affecting the fatigue behaviour of butt-welded joints and is
governed by the effect of other weld geometry parameters.
The effect of misalignment may be beneficial for high cycle
fatigue life of the order of greater than 2×105 cycles,
especially when compressive residual stresses are intro-
duced into the weld toe surface by using surface treatment
(i.e., shot peening, hammering).
From the above literature, it is clear that fatigue lives
are improved in weldments by post weld treatments,
among them ultrasonic peening is found to be more
efficient. Much work has already done using UPT for
fatigue life improvement in bridges, automobile wheels,
etc. Mathematical models were developed to predict
fatigue life in welded joints and the effects of weld
defects on fatigue life were also studied. Little work has
Int J Adv Manuf Technol (2009) 40:74–83
Cr Mo Ni N2 Cu
0.016 – – – – –
been done in evaluating the influence of post weld
treatment on fatigue life of the welded structures subjected
to high stress levels.
The objective of this paper is to compare fatigue life
enhancement due to the application of ultrasonic peening
technique at different stress levels on plain carbon steel
plate. The study is carried between butt-welded peened
and unpeened specimens. The specimens are subjected to
fatigue loading at different stress levels. Based on the
experimental results, the S-N curves are plotted. The
fatigue life predicted as per BS 7608, AWS D 1.1 and
IIW-XIII-1539-96 standards based on different probabil-
ities of survival are also compared with the experimental
results.
2 Experimental work
2.1 Specimen preparation
In this work, a plain carbon steel plate (conforming to IS
2062 grade B specification) of thickness 16 mm is used.
The chemical composition and the mechanical properties of
this carbon steel material are shown in Tables 1 and 2,
respectively.
Two plates of size 150×300 mm is taken for welding
and single V-joint with bevel angle 30 degrees; root face
of 2 mm and the root opening of 2–3 mm are prepared.
The plate is butt-welded by shielded metal arc welding
process with E-7018 electrode in 1 G /flat position. The
root pass is welded with 2.5 mm diameter electrode with
90–115 amperes. The intermediate passes are welded
using 3.15 mm diameter electrode with 125–135 amperes.
The final layer is welded with 4 mm diameter electrode
with 135–150 amperes. Figure 1 illustrates the dimensions
of the butt-welded plate which is used for specimen
preparation.
As illustrated in Fig. 2 one butt-welded plate is treated
with ultrasonic peening on the weld toe region where
Table 2 Mechanical properties of IS 2062 grade B
Property
Ultimate tensile strength, UTS [MPa] 562
Monotonic yield strength, YS [MPa] 250
Int J Adv Manuf Technol (2009) 40:74–83
Fig. 1 Dimensions of the butt-
welded plate used for specimen
preparation
residual stress is more. The ultrasonic impulse is at 22 kHz,
and the pin diameter of the head is 3 mm. The UP treatment
is applied to one plate which produces a circularly -
contoured groove, 2–5 mm width and 0.2–0.5 mm depth as
shown in Fig. 3.
Fatigue specimens conforming to ASTM E 466 standard
are prepared from both the peened and unpeened plates as
shown in Fig. 4 (a) and (b). The test section is prepared
with size of 20×16 mm. and the parallel length is kept as
50 mm. Figure 5 shows the schematic representation of the
fatigue testing specimen.
Fig. 2 Close-up view of the
peening system employed for
the study
77
2.2 Experimental procedure
All experiments are performed in load control mode using a
closed loop servo-hydraulic testing system, having 250 kN
capacity. All tests are conducted in air, at room temperature
of 25°C and with a frequency of 3 Hz with an R ratio of
0.1. The details of the specimen and the test parameters are
given in Table 3. Fatigue tests are performed with the
maximum stress levels of 250, 300 and 350 MPa. The loads
corresponding to the stress levels are presented in Table 4.
A set of specimens is taken for conducting the fatigue
78 Int J Adv Manuf Technol (2009) 40:74–83

Fig. 3 Butt-welded plate

treated with UP on the weld toe
region

testing at each stress level to confirm the repeatability. The

tests were conducted till complete failure of the specimens.

3 Fatigue life assessments using various methods

The fatigue life of the weldments can be assessed by various

standards. In this paper fatigue life is assessed as per BS
7608 standard, AWS D 1.1 structural welding code and IIW-
XIII-1539-96 standard. The fatigue life is assessed below.

3.1 Fatigue life analysis using Bs 7608

According to BS 7608 standard, the butt weld which is

made in the shop, either manually or by an automatic

Fig. 4 (a) Specimen used for the fatigue testing (peened) (b) Specimen
used for the fatigue testing (unpeened) Fig. 5 Sketch indicating the dimensions of the fatigue testing specimen
Int J Adv Manuf Technol (2009) 40:74–83 79

Table 3 Specimen and testing specifications

Sl. No. Particulars Specifications

1 Material used IS 2062

2 Thickness of plate 16 mm
3 Welding process Shielded metal arc welding
4 Filler material used E 7018
5 Electrode diameter 2.5, 3.15, and 4 mm
6 Joint type Butt joint
7 Edge preparation Single-V
8 Welding position 1G/Flat
9 Testingtype Constant amplitude axial high cycle fatigue test
10 Testing standard used ASTM E 466
11 Specimen type Tangentially blended fillet between the uniform test section and ends.
12 Size of specimen 20×16 mm
13 Parallel length 50 mm
14 Testing equipment INSTRON 8502
16 Testing stress ranges 250, 300, 350 MPa

process other than submerged arc, provided all runs are
made in flat position is classified as class D. The equation
containing the stress, slope of S-N curve, standard
deviation, and distribution of the standard deviation, a
constant, and the fatigue life is presented in the standard
which is given below.
log N ¼ log a
dσ þ m log s
where N is the number of cycles for failure, a is a constant,
d is the distribution, σ is the standard deviation, m is the
slope of S-N curve, S is the stress in MPa.
The standard also gives the values for all the terms in the
equation for various classes of welds. For class D, the
values are given below.
Log10 a=12.6007
m=−3.0
log10 σ=0.2095
The value d corresponds to probability of survival of
the weldment. When a value of distribution (d) is
assumed as −2, −1, 0, +1 and +2, then the weld has a
probability of survival of 5%, 15%, 50%, 85% and 95%,
respectively. So for class D joint and for the various
stress levels, the fatigue life can be evaluated as given in
Table 5.
3.2 Fatigue life analysis using AWS D 1.1
According to the AWS D 1.1 structural steel welding code,
the weld with base metal and filler metal in or adjacent to
the toe of complete joint penetration, T- or corner joints
with backing removed or splices, with or with out
transitions in thickness having slopes value greater than 1
to 2-1/2 and when weld reinforcement is not removed are
considered as stress category ‘C’ as shown in Fig. 6.

Table 4 Loads applied on the specimen for different stress levels

Sl no Type Condition Stress in MPa Pmax in kN Pmin in kN Pmean in kN Pamp in kN

1 Butt weld as-welded 250 82.5 8.25 45.38 37.13

2 Butt weld as-welded 250 82.5 8.25 45.38 37.13
3 Butt weld peened 250 82.5 8.25 45.38 37.13
4 Butt weld peened 250 82.5 8.25 45.38 37.13
5 Butt weld as-welded 300 99 9.9 54.45 44.55
6 Butt weld as-welded 300 99 9.9 54.45 44.55
7 Butt weld peened 300 99 9.9 54.45 44.55
8 Butt weld peened 300 99 9.9 54.45 44.55
9 Butt weld as-welded 350 115.5 11.55 63.53 51.98
10 Butt weld as-welded 350 115.5 11.55 63.53 51.98
11 Butt weld peened 350 115.5 11.55 63.53 51.98
12 Butt weld peened 350 115.5 11.55 63.53 51.98
80 Int J Adv Manuf Technol (2009) 40:74–83

Table 5 Fatigue life calculations for different stress levels as per BS Table 6 AWS D 1.1 — predicted life
7608 code
Stress in MPa Life in cycles
Stress level Distribution Probability of Fatigue life in
in MPa ‘d’ survival (%) cycles 250 92,646
300 53,614
250 −2 5 669,699 350 33,763
−1 15 413,409
0 50 255,200
1 85 157,536 for other stresses are found by using the equation given
2 95 97,248 below
300 −2 5 387,558
−1 15 239,241 σ3  N ¼ constant
0 50 147,685
where
1 85 91,167
2 95 56,278 σ is the stress in MPa and N is the number of cycles for
350 −2 5 244,060 failure. By using this equation, the life is evaluated and the
−1 15 150,659 values are presented in Table 7.
0 50 93,003 The fatigue life assessed using various standards and
1 85 57,411 codes are compared with the experimental results.
2 95 35,440

4 Results & discussion

The experimentally obtained fatigue lives of the butt-

For stress category C, AWS D 1.1 presents the equation
containing the stress and the fatigue life.
σ3  N ¼ 44  108  329
where
σ-stress in MPa, N-number of cycles to failure.
In this equation the fatigue life is specified for 95%
probability of survival. Using the above equation fatigue
life of the specimen can be evaluated as given in
Table 6.
welded specimens at various stress levels for both the
peened and unpeened conditions are presented in the
Table 8.
The fatigue tested samples are shown in Fig. 7, the
failure occurs in all the specimens at the weld toe. This
shows that weld toe is the weakest point in the welded
joints.
4.1 Comparison of fatigue life of as-welded and ultrasonic
peened joints at various stress levels

3.3 Fatigue life analysis using iiw-xiii-1539-96 standard
This IIW-XIII-1539-96 is a document of IIW recommen-
dations on fatigue life evaluation of welded structures.
According to this document, the butt-welded joint is
specified as FAT 100. The fatigue life of FAT 100 class
weld is 2 million cycles at a stress level of 100 MPa with
95% probability of survival. By using this value, the life
From the experimental results it is found that peening
improves the fatigue life especially in the low stress regime.
However when the stress levels are higher, the effectiveness
of peening is less. The experimental results show that the
improvement in fatigue life due to peening is found to be
35% at the stress of 250 MPa. But at 300 MPa stress, the
peening results in a reduction of fatigue life by 24% as
compared to unpeened specimens and at 350 MPa stress

Fig. 6 Some examples of

welded joints under stress cate-
gory ‘C’ as per AWS D 1.1 [5]
Int J Adv Manuf Technol (2009) 40:74–83 81

Table 7 IIW-XIII-1539-96-Predicted Life

Stress in MPa Life in cycles

250 128,000
300 74,074
350 46,647

level, the reduction is nearly 110% for peened specimens

when it is compared to unpeened specimens.
From the observed values it is found that, peening gives
good improvement in life at lower stresses. At higher
stresses especially at stress levels close to the yield stress,
the peening treatment is not effective.
The ineffectiveness of peening treatment at high stress
levels can be explained as follows. As at higher stresses, the
induced compressive stress is nullified by the applied
tensile stress at initial cycles itself, hence the peening
treatment loses its effectiveness.
4.2 Comparison of various standards with experimental results
Table 9 presents the experimentally determined fatigue
lives and predicted lives as per BS 7608, AWS D 1.1 and
IIW-XIII-1539-96 for different probabilities of survival.
From the above Table 9, S-N curves are plotted for
peened and unpeened specimens based on the experimental
results and the predicted results as per BS 7608 code, AWS
D 1.1 and IIW-XIII-1539-96 for different probabilities of
survival and is shown in Figs. 8, 9 and 10.
From the above Figs. 8, 9 and 10 the equations relating
the fatigue life and applied stress which is obtained from
the relations given in various standards and experimental
results are presented below.
– As per BS 7608:
– At 95% of probability y=11496 x−0.3333
– At 50% of probability y=15858 x−0.3333
– At 5% of probability y=21873 x−0.3333
– As per AWS D 1.1:
– y=11312 x−0.3333
– As per IIW: y=12599 x−0.3333
Table 8 Results of fatigue lives of butt-welded joints in unpeened and
peened condition
Stress in MPa Fatigue life in cycles
As-welded
250 1525,47
250 188,803
300 116,778
300 141,086
350 74,568
350 73,625
Fig. 7 Specimen after fatigue testing
– Experimental result for:
– Unpeened specimens y=24049 x−0.3762
– Peened: y=2406.3 x−0.1823
where x is the fatigue life in cycles and y is the applied
stress in MPa.
From Figs. 8, 9 and 10, it is seen that the slopes of all the
theoretical curves are −3.0 as given by the above codes and
standards. From the equations of the curves, the slope of
unpeened curve is found to be −2.7, which is close to the
slope given in the code. In the case of peened curve the
slope is found to be −5.4. Thus it can be seen that peening
gives improvement to fatigue life by modifying the slope of
the S-N curve from −2.7 to −5.4.
On evaluating the results of the fatigue life from the
applied stress values, it is found that the life predicted from
AWS D 1.1 , IIW-XIII-1539-96(95% of survival) and BS
7608 code (95% probability of survival ) are much less than
the experimental value. But it is also found that the
experimental results are very close to the life at 50%
probability of survival as predicted by BS 7608 standard.
5 Conclusion
The effect of ultrasonic peening on the fatigue life
improvement in a butt-welded plate is studied effectively.
The ultrasonic peening treatment is found to provide good
improvement in fatigue life, especially in the low stress
regimes. The improvement is on the order of 35% at a
stress level of 250 MPa. The slope of the peened specimen
improves to −5.4 from a value of −2.7 for unpeened
specimens. The improvement caused by the treatment is
Peened
better at operating stresses lower than 250 MPa. The reason
250,880 for the poor results can be due to the loss of beneficial
208,164 effects of compressive stress due to peening treatment.
107,786 The experimental results are compared with the results
100,538 predicted as per BS 7608, AWS D 1.1 and IIW-XIII-1539-
35,407
96 for different probabilities of survival. The experimental
30,568
results are found to be in close agreement with those
82 Int J Adv Manuf Technol (2009) 40:74–83

Table 9 Fatigue life of the specimens for different stress levels

Stress, MPa Predicted fatigue life in cycles Experimental value in cycles

BS 7608 BS 7608 BS 7608 AWS D1.1 IIW XIII-1539 Peened Unpeened

(95% pos) (50% pos) (5% pos)
Set I Set II Set I Set II

250 97248 255200 669699 92646 128000 250880 208164 152547 188803
300 56278 147685 387558 53614 74074 107786 100538 116778 141086
350 35440 93003 244060 33763 46647 35407 30568 74568 73625

Note: pos – probability of survival

Fig. 8 S-N curve of BS 7608

and experimental results

Fig. 9 S-N curves of AWS

D1.1 and experimental results

Fig. 10 S-N curves of IIW and

experimental results
Int J Adv Manuf Technol (2009) 40:74–83
predicted by BS 7608 standard corresponding to 50%
probability of survival.
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