Fatigue Strenght of Welded Joints

1
1 1
Retrofit Engineering for Urban Infrastructures, Lecture #3
Chitoshi Miki
Fatigue Strength
of Welded J oints
Department of Civil Engineering
Tokyo Institute of Technology
2 2
Contents
Effects of Residual Welding Stresses
on Fatigue Crack Growth Rate
Size Effects
Full Size Fatigue Tests of Truss Chords
Fatigue Strength of Large-Size Gusset J oints
of 800MPa Class Steels
High Strength Steels
Longitudinal Welded J oints Containing Blowholes
Butt-Welded J oints Containing Various
Embedded Defects
Effects of Weld Defects on Fatigue Strengths
3 3
Effects of Residual Welding Stresses
on Fatigue Crack Growth Rate
Topic 1
4 4
Fatigue Crack Propagation Rate, da/dN
Fatigue Life
Crack Initiation Life, Ni
Crack Propagation Life, Np
Evaluation of Np
Kda/dN Relationship
Affected by Residual Welding Stresses?
Experimental Investigations
5 5
Specimen A
Specimen B : One Longitudinal Welding
Specimen C : Two Longitudinal Welding
I: A Crack on Base Metal
II: A Crack on Weld Metal
Specimens
800Mpa Class Steels
6 6
Measurements of Residual Stress
Location of Strain Gauges
2
7 7
Change of Residual Stress
Due to Crack Propagation
Half Length of Fatigue Crack (mm)
S
t
r
e
s
s
(
M
P
a
)
8 8
Change of Residual Stress Distribution
L
B-I Type Specimen
W
e
l
d
i
n
g
L=60 mm
S
t
r
e
s
s
L=0 mm
9 9
Change of Residual Stress Distribution
C-I Type Specimen
L
W
e
l
d
i
n
g
W
e
l
d
i
n
g
S
t
r
e
s
s
Wide Tensile Region
10 10
Kda/dN Relationship (1)
L
A-I Type Specimen
No Weld-Beads
K
d
a
/
d
N
( )
6
75 . 2
5 . 1 13
10 71 . 2 ] / [ 10 54 . 6 ] / [

= mm N K cycle mm
dN
da
Equation 1
11 11
Kda/dN Relationship (2)
d
a
/
d
N
K
( )
8
95 . 2
5 . 1 13
10 37 . 9 ] / [ 10 82 . 3 ] / [

= mm N K cycle mm
dN
da
A-I
Others
No Significant Differences
Between The Other Types
of Specimens
Equation 2
12 12
Estimation of Fatigue Crack Propagation Life, Np
( )
8
95 . 2
5 . 1 13
10 37 . 9 ] / [ 10 82 . 3 ] / [

= mm N K cycle mm
dN
da
( )
6
75 . 2
5 . 1 13
10 71 . 2 ] / [ 10 54 . 6 ] / [

= mm N K cycle mm
dN
da
Penny-Shaped
Fatigue Crack
(Radius:a)
Welded J oint Model
Equation 2
Equation 1
3
13 13
Estimation of Fatigue Crack Propagation Life, Np
Equation 1, ai=0.1
Equation 1, ai=1.0
Equation 2, ai=0.1
Equation 2, ai=1.0
Np
14 14
Longitudinal Welded J oints
Containing Blowholes
Topic 2
15 15
Welded J oint Specimen
Small Specimen
Specimens
16 16
Residual Stress Distribution
in The Welded J oint Specimen
17 17
Classification of Blowhole Sizes
No Blowholes
Small Blowholes b < 1mm
1 mm < b < 2mm Medium Blowholes
b: Blowhole Length
Large Blowholes b > 2mm
Base on Radiographic Examination
18 18
Large Blowholes
Small Blowholes
Category A
Category B
Fatigue Test Results
4
19 19
Fatigue Cracks Originated From Blowholes
Radiograph Radiograph
Crack CrackCrack
20 20
Fracture Surfaces with Beach Marks
21 21
Fatigue Crack
Propagation
from Blowholes
22 22
Fatigue Crack
Propagation Rate
from Blowholes
( )
0 . 3 13
10 97 . 2 K
dN
da
=

( )
0 . 3 13
10 90 . 0 K
dN
da
=

( )
8 0 . 3 13
10 34 . 8 10 73 . 1

= K
dN
da
23 23
Topic 2
Butt-Welded J oints
Containing Various Embedded Defects
24 24
Butt welded joint with V-groove
Incomplete
Penetration (IP)
Lack of Fusion
(LOF)
Blowhole
(BH)
Slag Inclusion
(SI)
Crack
(CR)
Various Embedded Weld Defects
5
25 25
Specimen Preparation Specimen Preparation
Cuttinglines
Z
X
Y
Weld defects
Specimen
Specimen
Specimen
J IS SM490A: 150 specimens
J IS SM570Q: 27 specimens
JIS SM570Q
567 567 497 497 DW DW- -Z100 Z100
532 532 343 343 SM490 SM490
TS(MPa TS(MPa) ) YP(MPa YP(MPa) )
614 614 534 534 DW DW- -60 60
660 660 588 588 SM570 SM570- -Q Q
TS(MPa TS(MPa) ) YP(MPa YP(MPa) )
JIS SM490A
Detected by RT
26 26
Specimen Configuration Specimen Configuration
25
As-welded condition
0
500
7
Root gap
R100
100 300
0
170
100
4
30
9 9 0
Weld bead
Uniformed section
30
Weld detail,
V-groove
25
7
27 27
Fatigue Test Fatigue Test
Testing machine Testing machine
Capacity: 300 kN Capacity: 300 kN
Testing conditions Testing conditions
Constant amplitude Constant amplitude
Stress ratio R=0 Stress ratio R=0
Maximum stress: Maximum stress:
100 100 - - 350 MPa 350 MPa
Specimen
28 28
Evaluation : defect length 2c is used.
Single defect Multi defects
RS
(Real size
measured on
failure
surface)
Length 2c
X
Z
2c
1
2c
2
RT
(Xray)
WES 2805
Real Size
S
S
0
= 0.25 x min (c
1
,c
2
)
S S
0
2c = 2c
1
+ 2c
2
+S
S > S
0
cracks are isolated
Depth
2a
29 29
Fatigue Test Result, CR Type Defect Fatigue Test Result, CR Type Defect
(SM490A) (SM490A)
10
4
10
5
10
6
10
7
60
70
80
90
100
200
300
400
FatigueLife(cycles)
S
t
r
e
s
s

R
a
n
g
e

(
M
P
a
)
20
9
9
6
7
9
11
13
23 28
26
40
40
15
15
15
10
2
10
24
29
5 3
C J SSC-class =>D
2
B A
RT RT Toe Toe
RS RS Defect Defect
length length initiation initiation
30 30
Fatigue Test Result, IP Type Defect Fatigue Test Result, IP Type Defect
(SM490A) (SM490A)
10
4
10
5
10
6
10
7
60
70
80
90
100
200
300
400
FatigueLife(cycles)
S
t
r
e
s
s

R
a
n
g
e

(
M
P
a
)
6 11
8.5
13
22
34.5
34.5
24
40
30
30
30
29
7 15
40
2
40
2
2
2 8
21
21.5
C J SSC-class =>D
10 26 20 25
A B
RT RT Toe Toe
RS RS Defect Defect
6
31 31
Fatigue Test Result, LOF Type Defect Fatigue Test Result, LOF Type Defect
(SM490A) (SM490A)
10
4
10
5
10
6
10
7
60
70
80
90
100
200
300
400
FatigueLife(cycles)
S
t
r
e
s
s

R
a
n
g
e

(
M
P
a
)
10
9
6
9.5
4 4
12
12 7.5
8
9 6.5
11.3
8.5
2
11.3
6.5
3
4.5 10.5
C J SSC-class =>D A B
RT RT Toe Toe
RS RS Defect Defect
32 32
Fatigue Test Result, SI Type Defect Fatigue Test Result, SI Type Defect
(SM490A) (SM490A)
10
4
10
5
10
6
10
7
60
70
80
90
100
200
300
400
FatigueLife(cycles)
S
t
r
e
s
s

R
a
n
g
e

(
M
P
a
)
8.5
5
15
15
21
23
24.5
16.2
7
32
19
19
21
21
21
21
13
18
21
21
6
12
13 25
C J SSC-class =>D
19
19
8
B A
RT RT Toe Toe
RS RS Defect Defect
33 33
Fatigue Test Result, BH Type Fatigue Test Result, BH Type
Defect(SM490A) Defect(SM490A)
10
4
10
5
10
6
10
7
60
70
80
90
100
200
300
400
FatigueLife(cycles)
S
t
r
e
s
s

R
a
n
g
e

(
M
P
a
)
10
5
5
14
14
2
2
16
2 4
4
3
1 25
11
2
2
3 1 1
C J SSC-class =>D B A
RT RT Toe Toe
RS RS Defect Defect
34 34
High Strength Steels
Fatigue Strength of Large-Size Gusset J oints
of 800MPa Class Steels
Topic 3
35 35
Types of Gusset J oints Types of Gusset J oints
36 36
Specimens Specimens
In-Plane Gusset
Out-of-Plane Gusset
7
37 37
Welding Details of Specimens Welding Details of Specimens
In-Plane
Gusset
Out-of-Plane
Gusset
38 38
The Used Steels The Used Steels
HT80, SM570Q
39 39
Stress Distribution at the End of Stress Distribution at the End of
the In the In- -Plane Gussets Plane Gussets
40 40
Stress Distribution at the End of Stress Distribution at the End of
the Out the Out- -of of- -Plane Gussets Plane Gussets
41 41
Fatigue Test Results Fatigue Test Results
42 42
Fatigue Test Results Fatigue Test Results
In-Plane
In-Plane
Effects of Finishing
In-Plane : Lower
8
43 43
Fatigue Crack in In Fatigue Crack in In- -Plane Gusset J oints Plane Gusset J oints
Fatigue Strength:
Category B
44 44
Fatigue Strength:
Category A
45 45
Fatigue Strength:
Category C and D
46 46
Fatigue Crack in Out Fatigue Crack in Out- -of of- -Plane Gusset J oints Plane Gusset J oints
Fatigue Strength:
Category D
From Root
47 47
Fatigue Strength:
Category C
The Unfused Part
of the Root
48 48
Fatigue Strength:
Category E
This Type was not used
in the Honshu-Shikoku Bridge
Project
9
49 49
Size Effects
Topic 4
50 50
Importance of Size Effects
Welded joint specimen
Large scaled specimen
Real scale floor beam of the Seto Bridge
51 51
Girder specimen at Lehigh University in the US
52 52
Full scale box section girder specimen of the Kurushima Bridge
53 53
Minato Ohashi
Constructed in 1974
(235m+510m+235m)
Outside: Partially Penetrated Groove Welds
Inside: Fillet Welds
The Corner J oints of Truss Chords
54 54
The Full Size Specimen of Truss Chords
4 Point Bending Tests
10
55 55
The Full Size Specimen of Truss Chords
56 56
The Used Steels
600MPa Class Steels
Thickness = 40, 60mm
57 57
The Welding Condition of The Corner J oints
58 58
Fatigue Cracks in The Corner J oints (4 Types)
Fatigue Crack from Blowhole
Fatigue Crack from Stop-and-Start
of Fillet Welding
59 59
Type 1 Fatigue Crack Originated from a Blowhole
60 60
Type 2 The Fatigue Crack Originated from
Stop-and-Start Positions
Crack
A Stop-and-Start Position
11
61 61
Type 2 The Fatigue Crack Originated from
Stop-and-Start Positions
62 62
Type 3 Collective Fatigue Cracks
At the Roots of Fillet Welds
63 63
Type 4 Fatigue Cracks
Along the Fillet Weld-Beads
64 64
Size Effects
65 65
Consideration of Size Effects
Change of Fatigue Design Code
J oint Type
Code Class
Fatiguestrength
at 2millioncycles(MPa)
Oldcode'60 D 120
Current code'92 F 65
Sleeper pad J oint Type
Code Class
Fatiguestrength
Oldcode'60 D 100
Out-planegusset (t=20mm)
J oint Type
Code Class
Fatiguestrength
Oldcode'60 B 150
Current code'92 C 125
Longitudinal welding
J oint Type
Code Class
Fatiguestrength
Oldcode'60 C 126
In-planegusset (t=20mm)
J oint Type
Code Class
Fatiguestrength
Oldcode'60 D 100
Current code'92 E 80
Cruciformweld
66 66
References
1. Chitoshi Miki, Fumio Nishino, Yasuaki Hirabayashi, Koei Takena:
Influence of Residual Welding Stress on Fatigue Crack Growth Rate,
Proc. of J SCE, No.330, 1983.2.
2. Chitoshi Miki, Fumio Nishino, Yasuaki Hirabayashi, Hiroyuki Ohga:
Fatigue Strength of Longitudinal Welded J oints Containing Blowholes,
Proc. of J SCE, No.325, 1982.9.
3. Chitoshi Miki, Fauzri Fahimuddin, Kengo Anami:
Fatigue Strength of Butt-Welded J oints
Containing Various Embedded Defects,
Structural Eng./Earthquake Eng., J SCE, oNo.668/I-54, 2001.1.
4. Hirosuke Shimokawa, Koei Takena, Fumio Itoh, Chitoshi Miki:
Fatigue Strength of Large Gusset J oints of 800MPa Class Steels,
Proc. of J SCE, Vol.2, No.1, 1985.4.
5. Hirosuke Shimokawa, Koei Takena, Makoto Fukazawa, Chitoshi Miki:
A Fatigue Test on the Full-Size Truss Chord,
Proc. of J SCE, No.344/I-1, 1984.4.

Fatigue Strenght of Welded Joints

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