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ABSTRACT. This is a study of fatigue shape and the specimen showed high fa- “Complete joint penetration groove
strength of weld deposits with transverse tigue strength, enough to reach the fa- welds in butt joints transverse to the di-
cracks in plate up to 50 mm (2 in.) thick. tigue limit within tolerance of design rection of computed tensile stress shall
It is concerned with the fatigue properties stresses. have no visible piping porosity,” accord-
of welds already with transverse cracks. ing to AWS D1.1, Structural Welding
A previous study of transverse crack oc- Introduction Code — Steel (Ref. 2). “For all other
currence, location and microstructure in groove welds and for fillet welds, the sum
accordance with welding conditions was As welded structures become bigger, of the visual piping porosity 1 mm (1⁄32 in.)
published in the Welding Journal (Ref. 1). thick-plate welding becomes more im- or greater in diameter shall not exceed 10
A fatigue crack develops as a result of portant. Thick-plate weldments have mm (3⁄8 in.) in any linear inch of weld and
stress concentration and extends with higher cooling rates and greater restraint shall not exceed 19 mm (3⁄4 in.) in any 305
each load cycle until failure occurs, or stresses than thin-plate weldments, mak- mm (12 in.) length of weld,” the Code
until the cyclic loads are transferred to re- ing it easier for cracks to occur in the continues.
dundant members. The fatigue perfor- thick welded parts. This is the weakest It is well known that porosity has a
mance of a member is more dependent area because its heating and cooling cre- round edge while a crack is sharp, mak-
on the localized state of stress than the ates inconsistent microstructure. Safety is ing it easy to propagate. Crack propaga-
static strength of the base metal or the very important in this type of weld fabri- tion is different depending on crack size
weld metal. cation. Cracking is not allowed in the and location. Fatigue in welded structures
Fatigue specimens were machined to weldment, although in some cases cer- has been studied extensively, especially
have transverse cracks located on the sur- tain porosity is allowed. with recent developments in fracture me-
face and inside the specimen. Evaluation chanics. Research on fatigue crack prop-
of fatigue strength depending on location agation is also extensive (Refs. 3–6). But
of transverse cracks was then performed. in most studies of fatigue, experiments
When transverse cracks were propa- were performed by machined notch or ar-
gated in a quarter- or half-circle shape, KEY WORDS tificially induced discontinuity.
the specimen broke at low cycle in the Up until now, few investigations of
presence of a surface crack. However, Transverse Cracks cracks occurring in the actual structure
when the crack was inside the specimen, Flux Cored Arc Welding (FCAW) have been undertaken. In this study,
it propagated in a circular or elliptical Weldment Fatigue therefore, specimens were fabricated
Resistance and welded like the actual structure and
H. W. LEE and J. U. PARK are with the Weld- Preheat machined to have transverse cracks on
ing Research Team of Samsung Heavy Indus- Weldment Fractography the surface and inside. Fatigue proper-
tries, Koje City, Korea. S. W. KANG is with the Fatigue Limit ties, depending on crack location, were
Research Institute of Mechanical Technology, Porosity then studied, as well as the distance be-
Pusan National University, Korea. tween the transverse crack and porosity.
Fig. 3 — Schematic of all-weld-metal fatigue test specimen. Fig. 2 — Schematic of weld metal deposit.
(%) C Si Mn P S Ni Mo V Ti TS YS El
(kgf/mm2) (kgf/mm2) (%)
EH32 TMCP 0.18 0.10 0.90 0.040 0.040 0.40 0.08 0.10 0.02 45 ~ 60 32.0 20.0
max. ~0.50 ~1.60 max. max. max. max. max. max.
Base metal 0.09 0.38 1.35 0.015 0.005 0.03 0.02 0.002 0.02 52.8 38.0 31.0
Weld A 0.04 0.29 1.05 0.012 0.017 1.32 0.02 0.017 0.01 69.4 63.7 22.8
metal B 0.04 0.29 1.03 0.013 0.016 1.31 0.02 0.018 0.01 66.3 61.4 23.4
Experimental Procedure ing conditions: 2000) was used to determine the chemi-
1) One was welded with preheating cal composition of the base and weld
Test Panel and interpass temperatures below 30°C metal. Mean values of the three speci-
(86°F). mens were then recorded in Table 1.
The size of the test panel was 2000 2) The other was welded with pre- Other test results such as hardness,
mm (79 in.) long x 1800 mm (71 in.) wide heating and interpass temperatures of microstructure, residual stresses, ab-
x 50 mm (2 in.) thick. The panel was fab- 100–120°C (212–248°F). sorbed energy, diffusible hydrogen con-
ricated from ABS EH32 TMCP, high- The preheat temperature of 100°C tent and crack position were published in
strength hull steel, to provide test condi- was obtained from the Yurioka ch a r t a previous study (Ref. 1).
tions similar to actual construction method (Ref. 7) (using Table 1, 50-mm-
conditions — Fig. 1. To magnify fabrica- thick steel plate, Ceq 0.34). The test spec- Fatigue Test
tion-related weld residual stresses, the imens were welded using 100–120°C
welding jig and test panel were fillet- (212–248°F) in consideration of ambient Fatigue specimens were collected
welded together. temperatures. The panel was welded ac- from samples welded with preheat and
cording to DS 81-K2 (AWS A5.29 interpass temperatures below 30°C.
Test Weldments E80T1-K2) specification, using the flux Test equipment was a ±20-ton capac-
cored arc welding (FCAW) process (1.2 ity, axial tension fatigue tester. Testing
Two sets of test panels were made of mm diameter, electrode extension was performed by load control at a stress
the same size and morphology as shown 25–30 mm). Welding parameters are ratio = 0.1 with sine wave and frequency
in Fig. 1, with specimen sections welded shown in Table 2. of 3 Hz, at room temperature. Fatigue test
in layers, as shown in Fig. 2. To compare specimens from deposit metal were
the residual stresses and position of oc- Chemical Composition/Strength made to have a tension loading condition
currence of the transverse cracks, the in order to clarify fatigue properties of
sections were welded under the follow- A spectroanalyzer (BAIRD Spectrovac- transverse cracks placed vertically along
REPRINTS REPRINTS
Fig. 9 — SEM morphology of cracks and porosity. A — Crack (16X); B — crack (500X); C —
crack (5000X); D — porosity (17X).