Engineering Failure Analysis 10 (2003) 131151 www.elsevier.

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Eect of residual stresses on the fatigue of butt joints using thermal elasto-plastic and multiaxial fatigue theory
Tso-Liang Tenga,*, Chin-Ping Fungb, Peng-Hsiang Changb
a

Department of Mechanical Engineering, Da-Yeh University, Da-Tsuen, Changhua 515, Taiwan, ROC b University of National Defense Chung Cheng Institute of Technology, Ta-Shi, Taiwan, ROC Received 19 April 2002; accepted 13 October 2002

Abstract This investigation performs a thermal elasto-plastic analysis using nite element techniques to analyze thermomechanical behavior and evaluate residual stresses in weldments. An eective procedure is also developed by combining nite elements and multiaxial fatigue theory while considering the welding residual stress as the initial conditions in accurately predicting the fatigue life of welded joints. Herein, 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 eective strain) to predict the fatigue life of the butt-welded joints was fairly sensitive to welding residual stress. Furthermore, the maximum principal strain method led to conservative life estimates and the von Mises eective strain method oered the best agreement with the experimental data of butt-welded joints. # 2002 Elsevier Science Ltd. All rights reserved.
Keywords: Thermal history; Residual stress; Multiaxial fatigue; Weld fatigue; Finite element analysis

1. Introduction The safety and durability of welded structures are becoming important because the sudden failure of complex systems such as boiling water reactor piping systems, ground vehicles, aircraft, oshore structures, pipelines and pressure vessels may cause many injuries, much nancial loss and environmental damage. Many of these welded components are subjected to complicated states of stress and strain, due to complex loadings and welding residual stresses [1]. Fatigue under these conditions, as governed by multiaxial fatigue theory, is an important design consideration for reliable operation of many welded components. For predicting the multi-axial fatigue life of weldments, design codes [25] include various strength hypotheses, such as the distortion energy hypothesis according to von Mises, the shear stress hypothesis of Tresca and the normal stress hypothesis according to Galilei, to evaluate stressstrain states by means of an equivalent stress or equivalent strain. Moreover, Kang et al. [6] performed a set of experiments to determine the eects of combined tension and shear loads on the fatigue life of spot welded joints. However, to the best
* Corresponding author. Tel.: +886-4-8511221; fax: +886-4-8511224. E-mail address: tlteng@mail.dyu.edu.tw or g910404@ccit.edu.tw (T.-L. Teng). 1350-6307/03/$ - see front matter # 2002 Elsevier Science Ltd. All rights reserved. PII: S1350-6307(02)00068-7

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Nomenclature  C T t {q} Q  hf TB TA [N] {Te} [C] [K] {Fe} {P} {f} {u} {"} {} [B] density specic heat temperature time heat ux the rate of internal heat generation unit outward normal vector lm coecient bulk temperature of the adjacent uid temperature at the surface of the model element shape functions nodal temperature vector  V CNT NdV T T V B DBdV A hf NN dA V QNdV A hf TB NdA surface force vector body force vector displacement vector strain vector stress vector strain-displacement matrix

[L] {R} { e} {Dep} {De} {Dp} {Ue} {T} {Cth} {Te} [M] m+1 {K1} m+1 {K2} Y X NI f0 b "0f c r o "1, "2, "3 "e

dierential operator matrix T T A N fPgdA V N f dV nodal stress increment matrix {De}+{Dp} elastic stiness matrix plastic stiness matrix nodal displacement vector temperature increment matrix thermal stiness matrix nodal temperature increment matrix temperature shape function T ep g V BT fD th BdV B C MdV V longitudinal residual stress transverse residual stress fatigue crack initiation life uniaxial fatigue strength coecient uniaxial fatigue strength exponent uniaxial fatigue ductility coecient uniaxial fatigue ductility exponent residual stress mean stress principal strain von Mises eective strain

of the authors knowledge, no literature considers the multiaxial fatigue life of welded joints under combined welding residual stress and service loading. Therefore, an eective procedure for estimating the fatigue life of weldments is needed. This investigation performs a thermal elasto-plastic analysis using nite element techniques to analyze the thermomechanical behavior and assess residual stresses in weldments. An eective procedure combines the nite element, multiaxial fatigue theory and considers the residual stress eect to predict fatigue crack initiation (FCI) life in weldments. The residual stress is assumed to be one of the initial conditions in predicting fatigue life via the nite element method. The proposed procedure can determine the complete distribution of structural residual stress and strain-time history at the weld toe using the nite element method. Herein, the fatigue lives of the butt welded joints are predicted according to the proposed procedure, and the eect of welding residual stress on predicted fatigue is also discussed. Furthermore, the predictions of the proposed procedure are compared with the BS 5400 [2], AASHTO [7] standard specications, and experimental results [8]. Comparative results demonstrate that the estimates of fatigue life made by the novel procedure closely approximate to the experimental results.

2. Fatigue-analysis procedure The prediction of the fatigue life for weldments involves two steps. First, the welding residual stress distributions are calculated by a thermal elasto-plastic analysis using nite element method, as illustrated in Fig. 1. Second, the nite element method and multiaxial fatigue theory are combined, and the residual

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Fig. 1. Flow diagram of residual stress analysis.

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Fig. 2. Flow chart for predicting fatigue life for weldments.

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stress distributions determined in the rst step is considered as an initial condition in predicting the fatigue life of weldments, as shown in Fig. 2. 2.1. Residual stress analysis model Welding residual stresses are calculated using the nite element method. Fig. 1 presents the analytical procedures. During each weld pass, thermal stresses are calculated from the temperature distributions determined by the thermal model. The residual stresses from each temperature increment are then added to the nodal point location to update the behavior of the model before the next temperature increment.

Fig. 3. Geometry of multipass butt weld.

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2.1.1. Thermal model During each weld pass, the temperature distributions are calculated from the thermal model. This investigation simulates the increment of heat loading in the welding process via the lead temperature curve. The convective heat coecients on the surfaces were estimated (using engineering formulae for natural convection) to be 15 W/m2K. The initial temperature was taken to be 18  C. 2.1.2. Mechanical model In the mechanical analysis, the temperature history obtained from the thermal analysis was entered into the structural model as a thermal loading. The thermal strains and stresses can then be calculated at each time increment, and the nal state of the residual stresses will be accumulated by the thermal strains and stresses. During each weld pass, thermal stresses are calculated from the temperature distributions determined by the thermal model. The residual stresses from each temperature increment are then added to the nodal point location to update the behavior of the model before the next temperature increment. The material was assumed to follow the von Mises yield criterion and the associated ow rules. Linear kinematic hardening was assumed. Free boundary conditions were used for the free surfaces except at the centerline of the cross-section, where a symmetry condition was used. Initial stresses and strains were zero. Phase transformation eects were not considered herein, due to lack of material information, especially at high temperatures, such as near the melting point.

Fig. 4. Transverse residual stress at the top surface of the plate.

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2.1.3. Verication The proposed method was compared with ABAQUS nite element package and experimental results taken from Shim et al. [9] to conrm its accuracy. In Shim et al.s investigation, a specimen was constructed using multi-pass butt welding, as shown in Fig. 3. Figs. 4 and 5 portray the distribution of the transverse and longitudinal residual stress on the thick plate computed by Shim et al. and the present method. As Fig. 4 indicates, the ABAQUS package result showed slightly lower tensile transverse stress near the weld centerline. The present method tends to the experimental results near the surface. As Fig. 5 indicates, both analysis results show tensile stress near the weld centerline. The residual stress calculated using the present method correlates well with that determined using Shim et al.s experiments. Therefore, the procedure proposed here is considered appropriate for analyzing residual stresses due to welding. 2.2. Fatigue crack initiation analysis model Fatigue cracks are initiated most readily at the surface of the weld toe, and are concentrated by material or geometric stress raisers. Therefore, care must be taken in life prediction to account for processing and other factors that alter the surface and create stress raisers. Accordingly, in this study, predicting fatigue life for weldments involves structural and fatigue analysis of critical areas, as illustrated in Fig. 2.

Fig. 5. Longitudinal residual stress at the top surface of the plate.

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2.2.1. Structural analysis The structural analysis calculated the stresses and strains in a highly stressed region where slip concentrates from the input loads for a given material and geometry. In the structural analysis, the residual stress was considered as an initial condition in predicting the fatigue life. The structural analysis allows strains and stresses to be calculated at each time increment following a nite element method, in which loading history is the input of the welded structural model. The stress-strain eld in these critical areas within the weldments can also be found via the nite element method.

Fig. 6. Temperature-dependent material properties of ASTM A36 carbon steel.

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2.2.2. Fatigue analysis of critical areas Fatigue analysis of the critical areas approach involves the following technique for converting welding residual stresses, load history, weldment geometry, and material cyclic properties input into a prediction of fatigue life. The operations involved in the prediction must be performed sequentially, as shown in Fig. 2. First, the stress and strain at the critical site are estimated by the nite element method. The nite element method is then used to convert reduced load-time history into a strain-time history and calculate the stress and strain in the highly stressed area. Then the multiaxial fatigue theory is used to incorporate the strainlife approach to predict the fatigue life of the weldment. The simple linear damage hypothesis proposed by Palmgren and Miner is used to accumulate the fatigue damage. Finally, the stress and strain at the critical location are used to compute damage, and their historical values summed algebraically until a critical damage sum (failure criteria) is reached. The point at which the failure criteria is met is the predicted life. 2.2.3. Predicting life The fatigue resistance of metals can be characterized by a strain-life curve. These curves are derived from polished laboratory specimens that are tested under completely reversed strain control. The relationship between total strain amplitude, "=2, and reversals to failure, 2NI, can be expressed through the following form [10,11]: " f0 2NI b "0f 2NI c ; 2 E 1

The strain-life equation has been modied to account for mean stress eects. Morrow [12] suggested that the mean stress eect could be considered by modifying the elastic term in the strain-life equation by mean stress,  o: " f0 o 2NI b "0f 2NI c : 2 E 2

Manson and Halford [13] modied both the elastic and plastic terms of the strain-life equation to maintain the independence of the elasticplastic strain ratio from mean stress:  0  " f0 o  o c=b 2NI b "0f f 0 2NI c : 3 2 E f Meanwhile, Smith, Watson, and Topper (SWT) [14] proposed another equation to represent mean stress eects:

Fig. 7. Geometry of the butt joints.

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0 2  " f 2NI 2b f0 "0f 2NI bc ; max 2 E where

Table 1 Schematic of pass sequences along with welding parameters for each pass Pass sequence Pass no. Welding parameter Current (A) 1 23 4 56 190 215 190 215 Voltage (V) 25 26 25 26

Speed (mm/s) 3.34 4.70 3.34 4.70

Fig. 8. Weld thermal cycles of A36 carbon steel.

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max

 o : 2

Two parameters ("1,"e) of multi-axial damage are examined in predicting fatigue life. (a) The maximum principal strain parameter, "1. The maximum principal strain approach is analogous to the traditional use of the applied strain amplitude in uniaxial analysis. For welding residual stresses, geometries and loadings used in this study, and principal strain ("1, "2, "3) are determined by an appropriate transformation according to the nite element method. In correlating multiaxial fatigue tests, the range of the maximum principal strain on the plane that experiences the maximum principal strain is considered to be the dominant parameter describing damage, and is included in the strain life equation:

Fig. 9. Finite element meshes for the butt weld joint with 706 elements.

Fig. 10. Maximum principal stress distribution along the X-direction for dierent nite element meshes.

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"1 f0 2NI b "0f 2NI c : 2 E

(b) von Mises eective strain parameter, "e. The von Mises eective strain may be thought of as the root mean square of the maximum principal shear strains, normalized to axial loading. Also called the octahedral shear strain, this parameter is given by: 1=2 1 "e p "1 "2 2 "2 "3 2 "3 "1 2 : 21  The eective strain is used as an equivalent uniaxial strain amplitude with Eq. (1), in predicting fatigue life. The von Mises eective strain parameter can be directly correlated to the uniaxial Con-Manson strain -life equation: "e f0 2NI b "0f 2NI c : 2 E 6

When the fatigue properties of a given metal are known and the service environment is dened, the complicated problem of predicting fatigue life of weldments becomes a simple matter of determining the

Fig. 11. Maximum principal stresstime history for dierent nite element meshes.

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welding residual stress and local-strain amplitude for each reversal, so that Eqs. (1)(6) can be solved for fatigue life.

3. Analytical model To consider the inuence of residual stress on the predicted fatigue life of welds and conrm the accuracy of the present calculation procedure, this study develops an eective procedure for estimating the FCI life of butt-weld joints.

Fig. 12. Maximum principal stress distribution along the X-direction for nominal stress, S=146.4 MPa.

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3.1. Specimen and material properties The material used herein is ASTM A36 carbon steel. Its mechanical properties are dependent on temperature, as illustrated in Fig. 6 [9]. As Fig. 6 indicates, mechanical properties of metals change under various conditions when temperature increases, the modulus of elasticity, yield stress and thermal conductivity decrease while the thermal expansion and specic heat increase. Furthermore, the width of weld zone was assumed as that of the heat source. Fig. 7 displays the geometry and dimensions of two A36 plates, joined by a multipass butt-weld. Meanwhile, Ref. [15] species the cyclic strain-life properties and stressstrain curves of base metal (BM), weld-metal (WM), and the heat-aected zone (HAZ) for weldments of ASTM A36 carbon steel. Linear kinematic hardening was assumed. Therefore, these data are used here for the stress-strain and fatigue analysis of the butt-weld joints.

Fig. 13. Maximum principal stresstime history at point MX.

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3.2. Simulation of welding and fatigue loading Heat sources are applied along the weld path for practical welds. Pass sequences and welding parameters are shown in Table 1. However, this investigation simulates the increment of heat loading on the weld process via the weld thermal cycle curve, as shown in Fig. 8 [15]. A simple lumped pass model was developed to simulate the weld ller in butt-welded joints. Lump bead weld volumes for each pass in that layer were added and distributed over the top surface of the layer. This is a very ecient method for reducing the computational cost for both thermal and stress analysis, especially for thick plates. Following welding, this study has been constructed for constant-amplitude uniaxial loading (see Fig. 7) with a stress ratio of R=0 for butt-welded joints. 3.3. Finite element model for the butt-weld joints This investigation develops a two-dimensional symmetrical plane strain model to estimate the residual stresses and converts a load-time history into a strain-time history of the weldments using the nite element method. For predicting residual stress of weldments, a total of weld passes were lumped into 6 passes in all thick plate with a double V-groove. Fig. 9 demonstrates the nite element mesh for the welded joints, along

Fig. 14. Fatigue life of the presented procedure, combined with the maximum principal strain theories and strain-life equations (without considering the weld residual stress as the initial conditions).

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with the rened meshes used in the weld toe. The symmetric model has 706 elements and 775 nodes after meshing. 3.4. Mesh sensitivity study The inuence of mesh renement on the highly stressed area was studied to examine the adequacy of element sizes. The model with rened meshes consists of 810 elements and 886 nodes. Fig. 10 displays the distributions of the maximum principal residual stress,  1 along the X-direction with 706 and 810 nite element mesh models. Fig. 11 presents the maximum principal stress-time history of the weld toe for a nominal stress range, S=146.4 MPa with 706 and 810 nite element mesh models. Figs. 10 and 11 summarize the results obtained using models with two mesh densities, but with identical material models and geometries. Similar distributions of the results near the weld toe obtained from the simulations using these two nite element meshes are observed, and we remark that the model is not sensitive to the nite element mesh renement when the number of elements is equal to or greater than 706. Therefore, the original nite element model without mesh renement in the butt-welded joints can be worked for this study.

Fig. 15. Fatigue life of the presented procedure, combined with the maximum principal strain theories and strain-life equations (considering the weld residual stress as the initial conditions).

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4. Results and discussion 4.1. Residual stresses Welding residual stresses are calculated using thermal and mechanical analysis. Fig. 10 depicts the distributions of the top surface maximum principal residual stress,  1 along the X-direction. Owing to the locally concentrated heat source, the temperature near the weld bead and the heat-aected zone changes rapidly with distance from the heat source, i.e., the highest temperature is limited to the domain of the heat source, from which the lower temperature zones fan out. Owing to the temperature nonuniformity the shrinkage varies through the weldment thickness during cool-down and, consequently a high tensile residual stress occurs on the surface of the weld toes. As Fig. 11 indicates, a high tensile residual stress occurs near the weld toes, and its value of 219 MPa approaches the yield stress of the material. 4.2. Analysis of critical areas The residual stress distributions from Section 4.1 are considered as initial conditions in predicting fatigue life of weldments. Furthermore, the critical areas of the stressstrain eld of the weldments were found by

Fig. 16. Fatigue life of the presented procedure, combined with the von Mises eective strain theories and strain-life equations (without considering the weld residual stress as the initial conditions).

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the nite element method. Fig. 12 illustrates the contours of maximum principal stress,  1 for the analytical model in which nominal stress S=146.4 MPa. As Fig. 12 shows, a high tensile stress occurred at point MX near the weld toes. Fig. 13 displays the maximum principal stress-time history at point MX for various nominal stress ranges (S). The gure reveals that the mean stress increases with the nominal stress range. The proposed procedure can predict fatigue life for the weldments because the cyclic strain (stress)-time history and the strain (stress) range of the weldments on point MX are determined. 4.3. Predicting fatigue life for the butt-weld joints Results of the procedure proposed here are compared to experimental results to consider the inuence of residual stress on the predicted fatigue life of the weldments and conrm the accuracy of the present calculation procedure (Fig. 2). Fig. 14 illustrates the results of applying the proposed procedure (without considering the weld residual stress as initial conditions), combined with the multiaxial theories (maximum principal strain), MansonHalford and SWT strain-life equations to predict the fatigue life of the weldments. The analytical results are compared with experimental results taken from Lawrence. As Fig. 14 indicates, no results were conservative. Fig. 15 shows the results of applying the proposed procedure, combined with multiaxial theories

Fig. 17. Fatigue life of the presented procedure, combined with the von Mises eective strain theories and strain-life equations (considering the weld residual stress as the initial conditions).

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(maximum principal strain), Con-Manson, Manson-Halford and SWT strain-life equations to predict the fatigue life of the weldments and consider the inuence of weld residual stress. As the gure indicates, combining the proposed procedure (considering the residual stress as the initial condition) with the maximum principal strain parameter, "1, and the SWT strain-life equation above, yields results consistent with the experimental data. Fig. 16 presents the results of applying the proposed procedure (without considering the weld residual stress as initial conditions), combined with the multiaxial theories (von Mises eective strain), MansonHalford and SWT strain-life equations, to predict the fatigue life of the weldments. As Fig. 16 indicates, no results were conservative. Fig. 17 illustrates the results of applying the proposed procedure, combined with the multiaxial theories (von Mises eective strain), Con-Manson, Manson-Halford and SWT strain-life equations to predict the fatigue life of the weldments and to consider the eect of weld residual stress. According to Fig. 17, combining the proposed procedure (considering the residual stress as initial conditions) with the von Mises eective strain parameter, "e, and the SWT strain-life equation above, yields results that closely correspond to the experimental data. According to Figs. 1417, the proposed procedure following the conventional strain based method (maximum principal strain and von Mises eective strain), for predicting the fatigue life of the weldments was fairly sensitive to welding residual stress. Fig. 18 shows estimates of fatigue life by multiaxial fatigue theory (maximum principal strain and von Mises eective strain), and correlations of experimental data with such estimates. This gure reveals that

Fig. 18. Fatigue life estimates by multiaxial fatigue theory (maximum principal strain and von Mises eective strain).

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Fig. 19. Fatigue life prediction using the BS 5400, AASHTO standard specications method and the novel technique.

predictions of fatigue life by the maximum principal strain method were conservative, while predictions using the von Mises eective strain closely correspond to the experimental data. Many countries have standardized weldment design stresses, but since most national standards deal specically with the design of bridges and tubular structures, they are dicult to apply to the design of other types of welded structures. Fig. 19 presents the BS 5400, AASHTO standard specications for predicting the endurance of weldments under zero stress ratios. The gure indicates that predictions of fatigue life using the AASHTO standard method were excessively conservative, while predictions by the BS 5400 standard method were not conservative. The closest agreement with experimental data was achieved by the procedure herein presented, combined with the nite element method, multiaxial theories (von Mises eective strain), SWT strain-life relationship, and consideration of the eect of welding residual stress.

5. Conclusion This study combined the nite element method and multiaxial fatigue theory, while considering the welding residual stress as the initial conditions, to develop a simple and eective procedure for predicting the fatigue crack initiation life of butt-welded joints. Based on the results herein, the following conclusions are reached:

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1. Localized heating caused by welding and subsequent rapid cooling can cause tensile residual stresses at the weld toe of butt-welded joints. These tensile residual stresses were considered one of the major inuences on fatigue strength. 2. The proposed procedure that followed the conventional strain-based method (maximum principal strain and von Mises eective strain) to predict the fatigue life of the butt-welded joints was fairly sensitive to welding residual stress. 3. The maximum principal strain method led to conservative life estimates and the von Mises eective strain method oered the best agreement with the experimental data. 4. Combining the novel procedure with three dierent strain-life equations to evaluate the fatigue life and the SWT equation achieved the best agreement with the experimental data.

References
[1] Maddox SJ. Fatigue strength of welded structures. Abington: Cambridge University Press; 1991. [2] Specication for steel. Concrete and Composite Bridges. Code of Practice for Fatigue, BS 5400, British Standards Institution, London, 1980. [3] Eurocode Nr. 3, Gemeinsame einheitliche Regeln fur Stahlbauten Kommission der Europaischen Gemeinschaften, Bericht Nr, EUR 8849, DE, EN, FR, Stahlbau-Verlagsge-sellschaft mbH, Koln, 1984. [4] ASME Boiler and Pressure Vessel Code, section III, Division 1, Subsection NA, Article XIV-1212, Subsection NB-3352.4, New York, 1984. [5] AD-Merkblatt S 2, Berechnung gegen Schwingbeanspru-chung; Beuth-Verlag, Berlin/Koln; 1982. [6] Kang H, Barkey ME, Lee Y. Evaluation of multiaxial spot weld fatigue parameters for proportional loading. International Journal of Fatigue 2000;22:691702. [7] Standard Specications for Highway Bridges. American Association of State Highway and Transportation Ocials, 13th ed., 1983. [8] Lawrence FV, Burk JD, Yung JY. Inuence of residual stress on predicted fatigue life of weldments. Residual Stress Eects in Fatigue, ASTM STP 776. American Society for Testing and Materials, 1982. p. 3343. [9] Shim Y, Feng Z, Lee S, Kim D, Jaeger J, Papritan JC, et al. Determination of residual stresses in thick-section weldments. Welding Journal 1992:305s12s. [10] Con LF. A study of eects of cyclic thermal stresses on a ductile metal. Transactions of the American Society of Mechanical Engineers 1954;76:93150. [11] Manson SS. Behavior of materials under conditions of thermal stress. National Advisory Commission on Aeronautics, Report 1170, Cleveland: Lewis Flight Propulsion Laboratory, 1954. [12] Morrow J. Fatigue design handbook, advances in Engineering, Vol. 4. Warendale, Pa: Society of Automotive Engineers; 1968 Section 3.2, p. 21-29. [13] Manson SS, Halford GR. Practical implementation of the double linear damage rule and damage curve approach for treating cumulative fatigue damage. Int J Fract 1981;17(2):16972. [14] Smith KN, Watson P, Topper TH. A stressstrain function for the fatigue of materials. J Mater 1970;5(4):76778. [15] Higashida Y, Burk JD, Lawrence FV. Strain-controlled fatigue behavior of ASTM A36 and A514 grade F steels and -0 aluminum weld materials. Welding Research Supplement 5083;1978:334s44s.