Institut of Materials Engineering PHD Programme

Fatigue life calculation of welded joints based on fracture mechanics

Ahmed M. Al-Mukhtar* MSc. Materials and Manufacturing Engineering BSc. Aeronatical Engineering

Supervisors:

Prof. Dr.- Ing. habil. H. Biermann* Prof. Dr.- Ing. P. Hbner**

*Institute of Materials Engineering, Technische Universitt Bergakademie Freiberg, Germany **Fachhochschule Mittweida, Mittweida, Germany

Outlines
1) 2) 3) Aim of reaserch (Objectives) - Procedure Introduction (Why fracture mechanics?) Finite Element Analysis (FEA)
- Modelling - Crack path direction

4) 5)

Standard and fatigue design recommendations Results (benchmarking)

- SIF calculation and comparison for some welded joints - Fatigue life calculation and comparison for some welded joints - Case study not presented in the recommendation

6)

Conclusions

1.1. Aim and Ziel Proecdures und Aufgabenstellung

Aim
- Accurate SIF calculation - Moreover, calculate the fatigue life, and the fatigue strength (FAT) of the welded joints with different geometries that not presented in recommendations

Procedures
1) FE modeling which give accurate stress intensity factor. 2) With knowledge of the stress intensity factors KI at different crack depths (a), it was possible to make curve fits for KI(a) for the different loading and use Paris law to integrate numerically and calculate the expected fatigue life for the specimens. 3) Case studies can be consulted, and the need for well thought out benchmarking of analytical results against experimental databases-IIW 3

2.1. Introdcution - Why Fracure Mechanics? Ziel und Aufgabenstellung

- One of the most important deterioration mechanisms of

Aloha Airlines.1988

Aircrafts, ships and steel bridge structures which occur in service condition is Fatigue.
- Fatigue Failure, accounts for at least 75% of all machines

and structures failures

- Crack normally existed! But may be accelerated due to

environment and loading condition-A.A. Griffith (18931963)

De Havilland First commercial jet aircraft fatigue cracks initiated at square windows, 1954

Goal: Calculate ai, which already existed and

crack growth parameters Fatigue life calculation and FAT Safe life and lower cost consuming for experiments tests

2. Introdcution - Why Fracure Mechanics?

Seven of the Liberty ships built during the world war II has broken completely in two as a result of brittle fractures. (1943) However, larger safety factor !! Crack normally existed !! How long?

2. Introdcution - Why Fracure Mechanics?

Fontana Dam, North Carolina, USA

Ref.Ingraffea A R. Case Studies of Simulation of Fracture in Concrete Dams. Eng. Fracture Mech., 35, 1/2/3, 1990, 553-564.

3. FRacture ANalysis Code (Finite Element Analysis FEA) Two Dimension FRANC2D & CASCA (*)

FRANC2D is a FE based simulator for curvilinear crack propagtion planar structures. CASCA which used for the creating the meshes, is a preprocessor for genrating initial input file for FRANC2D.

Applicatons
Civil Engineering (Dams) Mechanical Engineering (Welded joints)

Output
Stress intensity fcator,SIF(KIC)

Compare with other FEM sofware

The results have been shown that FRANC2D has advantages over other simulations to calculate SIF because there are:

No effect of, mesh size, densitry distributon and those save time and effort. Also no problem with badly shaped meshes elements have been disapperad.

*-Cornell Fracture Group,

http://www.cfg.cornell.edu

3. FRacture ANalysis Code (Finite Element Analysis FEA) Two Dimension

Simulation and prediction crack growth in welded and complex structures

4. Standard and fatigue design recommendations

- International insitute of Welding-IIW - British standards- BS - Japanese Society of Steel construction-JSSC

5. Results SIF calculation and comparison

-Non load carrying joint -Cruciform joint load carrying

800 700 600 K (Mpa.mm1/2) 500 400 300 200 100 0 0 2 4 a (mm) 6 8 10

45 40 35 SIF (Mpa.m^0.5) 30 25 20 FRANC2D 15 10 5 0 0 1 2 3 Crack length (mm) 4 5 6 New approach

Frank,Fisher,Modified BS.B=T=15,h=6mm

FRANC2D.B=T=15.h=6

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5. Results SIF calculation and comparison

-Butt weld (V-Butt,incomplete and complete penetration-machined and non machined flash)

140 120 FRANC2D Empirical solution.Ref.19 100 SIF (Mpa.m1/2) 80 60 40

20 0 0 1 2 3 4 5 6 7 8 Crack length (m m )

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5. Results Fatigue life calculation and comparison

-Non-load carrying cruciform joint. -Comparison with IIW. FAT 63 Mpa.
1000
1000

-Butt weld. -Comparison with IIW. FAT 80 Mpa.

Stress Rang (M pa.)

100

Stress Range (Mpa.)

100

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FAT63.IIW

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FAT80.IIW

FRANC2D
1 1,E+04 1,E+05 1,E+06 1,E+07 1,E+08
1 1,E+03

FRANC2D

1,E+04

1,E+05

1,E+06

1,E+07

1,E+08

1,E+09

1,E+10

Log N (Cycle)

Log N (Cycle)

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5. Results
-New Geometry not presenetd in IIW recommendations -Fatigue life calculation and comparison
provided a new value of FAT could be considered as the design value or lower bound. The new case with fillet radius not consider in IIW and in BS. (FAT=71 Mpa.)
1000

Radius Rt

100
Stress Rang (Mpa.)

Experimental

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FAT63.No toe radius.IIW

FRANC2D.C=5E13.m=3.ai=0.1mm.with toe radius C=1,85E-13.m=3.mean values

1 1,E+04

1,E+05

1,E+06
Log N (Cycle)

1,E+07

1,E+08

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6. Conclusions

1) Accurate SIF is calculated through FEM FRANC2D 2) Different weld geometries which are not yet listed in previous recommendations could be easily modeled to evaluate the fatigue life strength. Which means that, 2) The new approach saves the time and costs need for experimental testes

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Thank you for your attention

Vielen Dank fr Ihre Aufmerksamkeit

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