Thermographic Analysis of Stress Distribution in Welded Joints

The fatigue life prediction of welded joints based on S-N curves in conjunction with nominal stresses generally is not reliable. Stress distribution in welded area affected by geometrical inhomogeneity, irregular welded surface and weld toe radius is quite complex, so the local (structural) stress concept is accepted in recent papers. The aim of this paper is to determine the stress distribution in plate type aluminum welded joints, to analyze the reliability of TSA (Thermal Stress Analysis) in this kind of investigations, and to obtain numerical values for stress concentration factors for practical use. Stress distribution in aluminum butt and fillet welded joints is determined by using the three different methods: strain gauges measurement, thermal stress analysis and FEM. Obtained results show good agreement - the TSA mutually confirmed the FEM model and stresses measured by strain gauges. According to obtained results, it may be stated that TSA, as a relatively new measurement technique may in the future become a standard tool for the experimental investigation of stress concentration and fatigue in welded joints that can help to develop more accurate numerical tools for fatigue life prediction