Influence of inspection on the safety of fatigue loaded welded cruciform steel joints – comparison of simplified and advanced crack growth models

2021 ◽  
Author(s):  
Davide Leonetti ◽  
Johan Maljaars ◽  
Bert Snijder

<p>Probabilistic fatigue life prediction models of welded steel joints are often used to estimate the level of safety, which is given in terms of the probability of failure or the reliability index as a function of the applied load cycles. Prediction models based on fracture mechanics allow taking into account the effect of inspections on the estimated level of safety. Recent developments in fracture mechanics based fatigue prediction models allow modeling the behavior of short and long fatigue cracks under constant and variable amplitude loading. Short cracks are relevant since their growth characterizes most of the fatigue life, especially under service loading. A recently proposed model by the authors is considered and compared to a more traditional and simplified model as proposed in the standard BS7910, where no distinction is made between short and long cracks. The effect of the model uncertainty, the type of inspection, and the time of the inspection on the estimated level of safety are quantified for welded cruciform steel joints.</p>

1981 ◽  
Vol 103 (2) ◽  
pp. 91-96 ◽  
Author(s):  
M. H. El Haddad ◽  
T. H. Topper ◽  
T. N. Topper

An elastic plastic fracture mechanics solution for short fatigue cracks in smooth and notched specimens is presented which admits plasticity by replacing the conventional stress term with a strain term and accounts for the propagation of very short cracks by the introduction of an effective crack length which is equal to the actual length increased by length l0, the length constant l0 is characteristic of the material and material condition and is calculated from the smooth specimen endurance limit and the long crack threshold stress intensity. Crack growth results for cracks in both elastic and plastic strain fields of notched specimens when interpreted in terms of this strain based intensity factor showed excellent agreement with elastic long crack data. This intensity factor when combined with a propagation model that includes all stages of crack growth also successfully predicted the total fatigue life of the smooth and notched specimens studied here. The predicted propagation life of elliptical and circular notched specimens is in all cases within 50 percent of the actual fatigue lives.


2005 ◽  
Vol 482 ◽  
pp. 307-310
Author(s):  
Tomáš Denk ◽  
Vladislav Oliva ◽  
Aleš Materna

A two-parameter constraint-based fracture mechanics approach is used to explain the effect of the constraint on the apparently anomalous behavior of short fatigue cracks. The different levels of stress constraint are quantified by the T-stress, and microstructurally as well as mechanically short cracks are discussed. Short cracks generally behave more sensitively to the constraint than the long ones. It is shown that in most cases, the existence of short cracks goes hand in hand with an intrinsic loss of the constraint, which contributes to a decrease of their fatigue threshold values and accelerates their growth. In this paper, the above effect is quantified and conclusions concerning the applicability of the fracture mechanics parameters and approaches to the estimation of the residual fatigue life of structures are discussed.


Author(s):  
Muhammad A. Wahab ◽  
Vinay Raghuram

Abstract Among the recent research Friction-Stir-Welding (FSW) has been adopted worldwide as one of the dominant processes for welding lightweight aerospace Aluminum alloys. Al-2195 which is one of the new generation Aluminum alloys has been used in the external tank of the space shuttles. Aerospace fabricators are continuously pursuing FSW-technologies in its efforts to advance fabrication of the external tanks of the space shuttles. The future launch vehicles with reusable mandates require the structures to have excellent fatigue properties and improved fatigue lives. The butt-welded specimens of Al-2195 and Al-2219 are fatigue tested according to ASTM-E647. The effects of stress ratios, use of corrosion preventive compound (CPC), and the applications of periodic overloading on fatigue lives are investigated in this study. Scanning-electron-microscopy (SEM) is used to examine the criticality of the failure surfaces and the different modes of crack propagation that could have been initiated into the materials. It is found that fatigue life increases with the increase in stress ratio, and results show an increase in fatigue life ranging over 30% with the use of CPC, and the fatigue life increases even further with periodic overloading; whereas crack-closure phenomenon predominates the fatigue fracture. Fracture mechanics analysis and crack similitude was modified for fatigue cracks by Paris. Numerical studies using FEA has produced a model for fatigue life prediction scheme for these structures, where a novel strategy of the interface element technique with critical bonding strength criterion for formation of new fracture surfaces has been used to model fatigue crack propagation lives. The linear elastic fracture mechanics stress intensity factor is calculated using FEA and the fatigue life predictions made using this method are within 10–20% of the experimental fatigue life data obtained. This method overcomes the limitation of the traditional node-release scheme and closely matches the physics of the crack propagation.


Fatigue cracks occur at different locations at the toes of welded steel joints. With continued load cycling it is often found that the cracks grow towards each other and overlap in adjacent parallel planes. It is useful to be able to detect and measure overlapping cracks and in this paper the characteristic responses to be expected from these features are calculated for the alternating-current field-measurement method of non-destructive evaluation by thin-skin theory. Typical signal profiles are calculated for probe traverses across the cracks and parallel to the edges. These are compared with experimental data obtained by using three pairs of overlapping notches with different proportions, cut in a steel block. The notches were interrogated by a thin-skin field at a frequency of 6 kHz. The calculations show that overlapping cracks give rise to asymmetric cross-crack signal profiles, which do not occur for single cracks, and to characteristic changes in curvature in the probe response profiles. These features are well confirmed by the experiments. The results also show that traverses along the crack edges can be used to find the positions of the crack ends.


2012 ◽  
Vol 249-250 ◽  
pp. 36-39 ◽  
Author(s):  
Ai Jun Chen ◽  
Zi Chu Cha ◽  
Zhi Qun Wang

Based on the theory of probabilistic fracture mechanics and Monte Carlo simulation, reliability analysis method for fatigue life of autofrettaged thick-walled cylinder was given. The forms of fatigue cracks in bore of autofrettaged thick-walled cylinder were considered as semi-elliptical cracks. The autofrettage residual stress solution was suitable for the thick-walled cylinder made of steel with strain hardening and Bauschinger effect. The stress intensity factors of thick-walled cylinder were calculated according to weight function method. The analysis of the examples showed that lognormal distribution is the best fit for fatigue life. Finally, the fatigue life of autofrettaged thick-walled on the condition of different reliabilities and confidences were presented.


2009 ◽  
Vol 417-418 ◽  
pp. 901-904 ◽  
Author(s):  
Ricardo A. Cláudio ◽  
José M. Silva ◽  
Carlos M. Branco ◽  
Jim Byrne

It is well known that shot peening has a marked benefit on fatigue life for the majority of applications. This effect is attributed mainly due to the compressive residual stress state at the component’s surface due to shot peening. The present paper evaluates the ability of several fatigue life prediction models, commonly used for general analyses, to predict the behaviour of components with compressive residual stress due to shot peening. Advanced elastic-plastic finite element analyses were carried out in order to obtain stress, strain, strain energy and fracture mechanics parameters for cracks within a compressive residual stress field. With these results several total fatigue life prediction models (including critical distance methods) and fracture mechanics based models were applied in order to predict fatigue life. Fatigue life predictions were compared with several experimental fatigue tests carried out on specimens, representative of a critical region of a compressor disc in a gas turbine aero engine. The results obtained showed that total fatigue life methods, even if combined with critical distance methods, give conservative results when shot peening is considered. Fatigue life was successfully predicted using the method proposed by Cameron and Smith, by adding initiation life to crack propagation life. This last method was also successfully applied for the prediction of non-propagating cracks that were observed during the experimental tests.


2005 ◽  
Vol 482 ◽  
pp. 303-306
Author(s):  
Pavel Hutař ◽  
Stanislav Seitl ◽  
Zdeněk Knésl

A two-parameter constraint-based fracture mechanics approach is used to explain the effect of the constraint on the apparently anomalous behavior of short fatigue cracks. The different levels of stress constraint are quantified by the T-stress, and microstructurally as well as mechanically short cracks are discussed. Short cracks generally behave more sensitively to the constraint than the long ones. It is shown that in most cases, the existence of short cracks goes hand in hand with an intrinsic loss of the constraint, which contributes to a decrease of their fatigue threshold values and accelerates their growth. In this paper, the above effect is quantified and conclusions concerning the applicability of the fracture mechanics parameters and approaches to the estimation of the residual fatigue life of structures are discussed.


Author(s):  
Mequanent M. Alamnie ◽  
Yalelet Endalemaw

The initiation and growth of fatigue cracking is mainly due to high stress concentration, heterogeneity and poor quality of weld. The detection and rectification of such weld defects are major concerns of rail network managers to reduce potential risk of rail breaks and derailments. To estimate the fatigue life of welded joints and to analyze the progress of fatigue cracks, a fracture mechanics-based analysis and fatigue models were developed using Finite Element Analysis. The initial flaw is obtained from a sample weld using ultrasonic flaw detecting machine test. Linear Elastic Fracture Mechanics (LEFM) approach based on the Paris law was applied to determine critical crack size and the number of cycles to failure using FRANC3D software. The inspection interval of rail welds before fracture (failure) was suggested based on reliability and life cycle analysis that correspond with minimum overall cost and frequency interval. It is recommended that fracture-based models in combination with reliability analyses can be a sustainable infrastructure decision-making algorithm.


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