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On creep-fatigue endurance of TIG-dressed weldments using the linear matching method

This paper is devoted to parametric study on creep-fatigue endurance of the steel type 316N(L) weldments at 550◦C identified as type 3 according to R5 Vol. 2/3 procedure classification. The study is implemented using a direct method known as the Linear Matching Method (LMM) and based upon the creep-fatigue evaluation procedure considering time fraction rule for creep-damage assessment. Seven configurations of the weldment, characterised by particular values of a geometrical parameter ρ, are proposed. Parameter ρ, which represents different grades of TIG dressing, is a ratio between the radius of the fillet of the remelted metal on a weld toe and the thickness of welded plates. For each configuration, the total number of cycles to failure N⋆ in creep-fatigue conditions is assessed numerically for different loading cases defined by normalised bending moment ˜M and dwell period t. The obtained set of N⋆ is extrapolated by the analytic function dependent on ˜M, t and parameter ρ. Proposed function for N⋆ shows good agreement with numerical results obtained by the LMM. Therefore, it is used for the identification of Fatigue Strength Reduction Factors (FSRFs) effected by creep, which are intended for design purposes, and dependent on t and ρ

Failure mode of laser welds in lap‐shear specimens of high strength low alloy (HSLA) steel sheets

In this paper, the failure mode of laser welds in lap‐shear specimens of non‐galvanized SAE J2340 300Y high strength low alloy steel sheets under quasi‐static loading conditions is examined based on experimental observations and finite element analyses. Laser welded lap‐shear specimens with reduced cross sections were made. Optical micrographs of the cross sections of the welds in the specimens before and after tests are examined to understand the microstructure and failure mode of the welds. Micro‐hardness tests were also conducted to provide an assessment of the mechanical properties in the base metal, heat‐affected and fusion zones. The micrographs indicate that the weld failure appears to be initiated from the base metal near the boundary of the base metal and the heat‐affected zone at a distance away from the pre‐existing crack tip, and the specimens fail due to the necking/shear of the lower left load carrying sheets. Finite element analyses based on non‐homogenous multi‐zone material models were conducted to model the ductile necking/shear failure and to obtain the J integral solutions for the pre‐existing cracks. The results of the finite element analyses are used to explain the ductile failure initiation sites and the necking/shear of the lower left load carrying sheets. The J integral solutions obtained from the finite element analyses based on the 3‐zone finite element model indicate that the J integral for the pre‐existing cracks at the failure loads are low compared to the fracture toughness and the specimens should fail in a plastic collapse or necking/shear mode. The effects of the sheet thickness on the failure mode were then investigated for laser welds with a fixed ratio of the weld width to the thickness. For the given non‐homogenous material model, the J integral solutions appear to be scaled by the sheet thickness. With consideration of the plastic collapse failure mode and fracture initiation failure mode, a critical thickness can be obtained for the transition of the plastic collapse or necking/shear failure mode to the fracture initiation failure mode. Finally, the failure load is expressed as a function of the sheet thickness according to the governing equations based on the two failure modes. The results demonstrate that the failure mode of welds of thin sheets depends on the sheet thickness, ductility of the base metal and fracture toughness of the heat‐affected zone. Therefore, failure criteria based on either the plastic collapse failure mode or the fracture initiation failure mode should be used cautiously for welds of thin sheets.Peer Reviewedhttp://deepblue.lib.umich.edu/bitstream/2027.42/90305/1/j.1460-2695.2011.01609.x.pd

Fatigue performance of friction stir welded marine grade steel

An extensive study on the fatigue performance of friction stir welded DH36 steel was carried out. The main focus of this experimental testing programme was fatigue testing accompanied by tensile tests, geometry measurements, hardness and residual stress measurements, and fracture surface examination. The S-N curve for friction stir butt welded joints was generated and compared with the International Institute of Welding recommendations for conventional fusion butt welds. Friction stir welds of marine grade steel exceeded the relevant rules for fusion welding. This newly developed S-N curve is being proposed for use in the relevant fatigue assessment guidelines for friction stir welding of low alloy steel. Fracture surfaces were examined to investigate the fatigue failure mechanism, which was found to be affected by the processing features generated by the friction stir welding tool

Probabilistic models to evaluate effectiveness of steel bridge weld fatigue retrofitting by peening

The purpose of this study was to evaluate, with two probabilistic analytical models, the effectiveness of several alternative fatigue management strategies for steel bridge welds. The investigated strategies employed, in various combinations, magnetic particle inspection, gouging and rewelding, and postweld treatment by peening. The analytical models included a probabilistic strain-based fracture mechanics model and a Markov chain model. For comparing the results obtained with the two models, the fatigue life was divided into a small, fixed number of condition states based on crack depth, similar to those often used by bridge management systems to model deterioration due to other processes, such as corrosion and road surface wear. The probabilistic strain-based fracture mechanics model was verified first by comparison with design S-N curves and test data for untreated welds. Next, the verified model was used to determine the probability that untreated and treated welds would be in each condition state in a given year; the probabilities were then used to calibrate transition probabilities for a much simpler Markov chain fatigue model. Then both models were used to simulate a number of fatigue management strategies. From the results of these simulations, the performance of the different strategies was compared, and the accuracy of the simpler Markov chain fatigue model was evaluated. In general, peening was more effective if preceded by inspection of the weld. The Markov chain fatigue model did a reasonable job of predicting the general trends and relative effectiveness of the different investigated strategies

Microstructure-sensitive estimation of small fatigue crack growth in bridge steel welds

A probabilistic finite element model is implemented to estimate microstructurally small fatigue crack growth in bridge steel welds. Simulations are based on a microstructure-sensitive crystal plasticity model to quantify fatigue indicator parameters (FIPs) at the slip system level and a fatigue model that relates FIPs to fatigue lives of individual grains. Microstructures from three weld zones, namely, fusion zone (FZ), heat affected zone (HAZ), and base metal (BM), are constructed based on their microstructural attributes such as grain morphology, size, and orientation. Statistical volume elements (SVEs) are generated and meshed independently for the three welding zones. Each grain within the SVEs is divided into several slip bands parallel to crystallographic planes. During the loading process, cracks nucleate at the slip bands (SBs) with the largest FIP next to the free surface. The crack extension path is assumed to be transgranular along SBs and the number of cycles required to crack the neighbor grain is calculated by the corresponding FIP-based crack growth rate equation. The simulation process is carried out using ABAQUS with a user defined subroutine UMAT for crystal plasticity. After the calibration of the constitutive model and irreversibility parameters, numerical simulations for small crack growth in three zones are presented. The crack length vs. the predicted fatigue resistance shows significant differences in the mean values and variability among the three weld zones

Multiaxial Fatigue Assessment of Friction Stir Welded Tubular Joints of Al 6082-T6

The present paper addresses the problem of designing aluminium friction stir (FS) welded joints against multiaxial fatigue. After developing a bespoke FS welding technology suitable for joining aluminium tubes, some one hundred welded tubular specimens of Al 6082-T6 were tested under pure axial, pure torsional and biaxial tension-torsion loading. The influence was explored of two independent variables, namely the proportional or nonproportional nature of the biaxial loading and the effect of axial and torsional non-zero mean stresses. The experimental results were re-analysed using the Modified Wöhler Curve Method (MWCM), with this bi-parametrical critical plane approach being applied in terms of nominal stresses, notch stresses, and also the Point Method. The validation exercise carried out using these experimental data demonstrated that the MWCM is applicable to prediction of the fatigue lives for these FS welded joints, with its use resulting in life estimates that fall within the uniaxial and torsional calibration scatter bands. The approach proposed in the present paper offers, for the first time, a complete solution to the problem of designing tubular FS welded joints against multiaxial fatigue loading

Optimization of different welding processes using statistical and numerical approaches – A reference guide

Welding input parameters play a very significant role in determining the quality of a weld joint. The joint quality can be defined in terms of properties such as weld-bead geometry, mechanical properties, and distortion. Generally, all welding processes are used with the aim of obtaining a welded joint with the desired weld-bead parameters, excellent mechanical properties with minimum distortion. Nowadays, application of design of experiment (DoE), evolutionary algorithms and computational network are widely used to develop a mathematical relationship between the welding process input parameters and the output variables of the weld joint in order to determine the welding input parameters that lead to the desired weld quality. A comprehensive literature review of the application of these methods in the area of welding has been introduced herein. This review was classified according to the output features of the weld, i.e. bead geometry and mechanical properties of the welds