Weld Rod Fatigue Analysis Using Effective Notch Stress Method

2018 ◽  
Author(s):  
Kumarswamy Karpanan ◽  
Allison Weber Kirk ◽  
Gerald Hershman
Keyword(s):  
Fatigue Life ◽  
Welded Joints ◽  
Failure Modes ◽  
Welding Process ◽  
Fatigue Analysis ◽  
Fillet Welds ◽  
Notch Stress ◽  
Effective Notch Stress ◽  
Weld Fatigue ◽  
Weld Root

Welds are one of the commonly used joint types and are employed extensively in subsea oil and gas production equipment. Commonly used weld joints in subsea components are fillet, butt, full-penetration, plug, and girth. Fatigue is one of the critical failure modes for welded joints. Welded joints are complex to analyze for fatigue loading due to the microstructure change during the welding process. The welding process also induces residual stress in the heat affected zone (HAZ) surrounding the weld. This, in turn, can adversely affects the fatigue life of the joint. The S-N fatigue approach is commonly used for weld fatigue analysis due to the simplicity of this method. Industry standards such as DNV, IIW, BS-7608, and ASME BPVC Sec VIII Div. -2 or -3 are typical references for this type of analysis. For subsea specific applications, DNV-RP-C203 and BS-7608 are generally used because these two standards provide S-N curves for welds in “air” as well as in “seawater with cathodic protection”. These two codes also provide S-N curves for various weld geometries ranging from simple fillet welds to complex tubular joints. Some of the weld fatigue analysis techniques used in the subsea industry are the: nominal stress approach, structural hot spot stress approach, effective notch stress approach (ENS), structural stress method (ASME VIII-2, -3) and the Fracture mechanics based fatigue crack propagation (FCG) approach. This paper presents the fatigue analysis of fillet welds in bore inserts using the ENS method. In the ENS method, a 1mm radius notch is modelled at the weld root or toe, see Figure 1, which yields a finite weld root stress. The stress analysis is carried out using FEA and the stresses on the notch along with the appropriate fatigue curve are used to estimate the weld root fatigue life.

scholarly journals Fatigue Failure Analysis of Fillet Welded Joints Used in Offshore Structures

2014 ◽  
Author(s):  
Jonas W. Ringsberg ◽  
Majid Anvari ◽  
Djan Eirik Djavit ◽  
Erik Strande
Keyword(s):  
Fatigue Life ◽  
Fatigue Failure ◽  
Welded Joints ◽  
Parameter Study ◽  
Maritime Industry ◽  
Calculation Methods ◽  
Notch Stress ◽  
Weld Toe ◽  
Effective Notch Stress ◽  
Weld Root

This paper presents a comparison made of different fatigue calculation methods used in the maritime industry today, with the aim of having a higher control of a fatigue failure site. To provide an overview of the different fatigue calculation methods, a comparison study was performed, as well as a local weld parameter study for two typical fillet welded joints. The two methods used for this study were the structural hot spot and effective notch stress method. Two fillet welded joints were provided by Aker Solutions MMO AS, Bergen, Norway. The first joint is a rectangular hollow section from a davit, built as a truss. The second model is a part of a K-joint from a semi-submersible (Aker H3 design). Both joints were analysed using fine 3D finite element models. The two different fatigue life calculation methods yielded different fatigue lives for the weld toe, with inconclusive results regarding their conservatism which is discussed in the paper. An increased weld toe radius gave a higher fatigue life for the weld toe, while the larger weld size increased the fatigue life in the weld root. Any weld size effect regarding fatigue life in the weld toe could not be established. Based on the effective notch stress method calculations, there was an indication of weld root failure for the K-joint of the drilling unit. Fatigue life improvement methods only increasing weld toe fatigue life are not recommended based on these results.

scholarly journals Generalized SCF Formula of Out-Of-Plane Gusset Welded Joints and Assessment of Fatigue Life Extension by Additional Weld

Materials ◽  
2021 ◽  
Vol 14 (5) ◽  
pp. 1249
Author(s):  
Yixun Wang ◽  
Yuxiao Luo ◽  
Yuki Kotani ◽  
Seiichiro Tsutsumi
Keyword(s):  
Fatigue Life ◽  
Fatigue Resistance ◽  
Welded Joints ◽  
Life Extension ◽  
Leg Length ◽  
Notch Stress ◽  
Out Of Plane ◽  
Weld Toe ◽  
Effective Notch Stress ◽  
Geometric Effects

The existing S-N curves by effective notch stress to assess the fatigue life of gusset welded joints can result in reduced accuracy due to the oversimplification of bead geometries. The present work proposes the parametric formulae of stress concentration factor (SCF) for as-welded gusset joints based on the spline model, by which the effective notch stress can be accurately calculated for fatigue resistance assessment. The spline model is also modified to make it applicable to the additional weld. The fatigue resistance of as-welded and additional-welded specimens is assessed considering the geometric effects and weld profiles. The results show that the error of SCFs by the proposed formulae is proven to be smaller than 5%. The additional weld can increase the fatigue life by as great as 9.4 times, mainly because the increasing weld toe radius and weld leg length lead to the smaller SCF. The proposed series of S-N curves, considering different SCFs, can be used to assess the welded joints with various geometric parameters and weld profiles.

Fatigue Life Analysis of T-Type Fillet Welded Joints Using an Effective Notch Stress Method

2020 ◽  
Vol 37 (8) ◽  
pp. 601-606
Author(s):  
Minhyeok Heo ◽  
Changwan Han ◽  
Hanjong Kim ◽  
Seung-bin Jung ◽  
Seonghun Park
Keyword(s):  
Fatigue Life ◽  
Welded Joints ◽  
Notch Stress ◽  
Effective Notch Stress ◽  
Life Analysis ◽  
Fatigue Life Analysis

Assessment of Weld Fatigue by Effective Notch Stress Approach

2015 ◽  
Author(s):  
Majid Anvari ◽  
Øyvind Fagnastøl ◽  
Bernt J. Leira
Keyword(s):  
Linear Relation ◽  
Welded Joint ◽  
Hot Spot ◽  
Nominal Stress ◽  
Notch Stress ◽  
Nonlinear Relation ◽  
Effective Notch Stress ◽  
Weld Fatigue ◽  
Weld Root ◽  
Nominal Stress Approach

Applicability of different approaches, i.e. nominal stress-, structural hot spot- and effective notch stress approach, for fatigue assessment of welded structures has been discussed. The effective notch stress approach was validated for a cruciform fillet welded and fully penetration welded joint, according to DNV guideline [1]. The same fillet welded joint was further investigated for varying weld sizes. The results show that with changing weld size, there are considerable differences between calculated stresses, and specially calculated fatigue lives, when comparing with nominal stress approach. Further investigations revealed that there is a nonlinear relation between effective notch stress and weld sizes, while comparison of the notch stress and nominal stress approaches indicate that a linear relation is to be expected. Based on the established methodology for the cruciform joint, another joint, i.e. a knee plate located in a horizontal brace of a drilling vessel, was assessed for weld root fatigue. Based on the proposed equations and the linear relation found between the nominal- and the notch stress S-N curves, a weld size providing a longer fatigue life at the weld root, rather than that at the toe, was proposed.

scholarly journals Packaging Design, Weld Fatigue analysis and Validation of Diesel Exhaust After-treatment System

2018 ◽  
Vol 8 (2) ◽  
pp. 36
Author(s):  
Sonal Nareddiwar ◽  
Tapobrata Dey ◽  
R. Sunilkumar
Keyword(s):  
Fatigue Life ◽  
Fatigue Failure ◽  
Welded Joints ◽  
Diesel Exhaust ◽  
Bending Moment ◽  
Fatigue Analysis ◽  
Treatment System ◽  
Packaging Design ◽  
Weld Fatigue ◽  
Exhaust After Treatment

Diesel exhaust after treatment system is usually designed to meet stringent packaging constraints and emission norms. After treatment packaging has critical impact on the overall system efficiency and durability since many components in exhaust systems have welded joints. An after treatment inlet and outlet tube joints, connected to engine outlet and Original Equipment Manufacturer (OEM) tailpipe respectively are subjected to vibrations and bending moment leading to fatigue failure at the inlet/outlet welded joints. It has been observed over the years that the prevailing failure modes in after treatment systems are cracked welds at joints between inlet tubes and flanges, outlet tubes and connecting tailpipes. Fatigue failure is a complex and progressive form of local damage which occurs in welded components of exhaust after-treatment systems. Thus, this fatigue failure needs to be estimated accurately and at the early stage of design to save cost and time. But due to geometrical irregularities, compact packaging design and load transfer conditions, it becomes difficult to estimate accurate fatigue strength of the welded areas. Thus weld fatigue analysis, a high cycle fatigue test to validate inlet/outlet module of exhaust system against dynamic overturning bending moment and to calculate the location of minimum weld fatigue life within the inlet welded joints is performed. Weld fatigue analysis uses advanced fatigue assessment technique, BS 7608, Stress x Life (S x N) approach for accurate and precise estimation of welds. The present work deals with reducing the package volume of the after treatment system by applying different concepts, verifying design robustness by FEA simulation using ANSYS 18.2 and validating the structural durability of the system by testing. The objective of the present work is to estimate the fatigue life of the welded structures precisely and accurately, calculate the threshold bending moment to determine whether the design is robust to the bending moment loads seen over course of its life and make design modifications as per simulation result. Further the FEA and testing results of weld fatigue analysis are correlated.

Re-evaluation of weld root fatigue strength for load-carrying fillet welded joints using the notch stress concept

2021 ◽  
Vol 144 ◽  
pp. 106076
Author(s):  
Hamidreza Rohani Raftar ◽  
Mohammad Dabiri ◽  
Antti Ahola ◽  
Timo Björk
Keyword(s):  
Fatigue Strength ◽  
Welded Joints ◽  
Notch Stress ◽  
Load Carrying ◽  
Weld Root
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