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High-resolution 3D weld toe stress analysis and ACPD method for weld toe fatigue crack initiation

High-resolution 3D weld toe stress analysis and ACPD method for weld toe fatigue crack initiation
High-resolution 3D weld toe stress analysis and ACPD method for weld toe fatigue crack initiation
Weld toe fatigue crack initiation is highly dependent on the local weld toe stress-concentrating geometry including any inherent flaws. These flaws are responsible for premature fatigue crack initiation (FCI) and must be minimised to maximise the fatigue life of a welded joint. In this work, a data-rich methodology has been developed to capture the true weld toe geometry and resulting local weld toe stress-field and relate this to the FCI life of a steel arc-welded joint. To obtain FCI lives, interrupted fatigue test was performed on the welded joint monitored by a novel multi-probe array of alternating-current potential drop (ACPD) probes across the weld toe. This set-up enabled the FCI sites to be located, the FCI life to be determined and gave an indication of early fatigue crack propagation rates. To understand fully the local weld toe stress-field, high-resolution (5 μm) 3D linear-elastic finite-element (FE) models were generated from X-ray Micro-Computed Tomography (μ-CT) of each weld toe after fatigue testing. From these models, approximately 202 stress concentration factors (SCFs) were computed for every 1 mm of weld toe. These two novel methodologies successfully link to provide an assessment of the weld quality and this is correlated with the fatigue performance.
0043-2288
Chaudhuri, Somsubhro
9a203292-cf1a-476e-ac62-8bcac4eeb8d8
Crump, Jennifer
e3dd3710-0c55-4a97-b6a6-bf13617b7763
Reed, Philippa
8b79d87f-3288-4167-bcfc-c1de4b93ce17
Mellor, Brian
2b13b80f-880b-49ac-82fe-827a15dde2fe
Chaudhuri, Somsubhro
9a203292-cf1a-476e-ac62-8bcac4eeb8d8
Crump, Jennifer
e3dd3710-0c55-4a97-b6a6-bf13617b7763
Reed, Philippa
8b79d87f-3288-4167-bcfc-c1de4b93ce17
Mellor, Brian
2b13b80f-880b-49ac-82fe-827a15dde2fe

Chaudhuri, Somsubhro, Crump, Jennifer, Reed, Philippa and Mellor, Brian (2019) High-resolution 3D weld toe stress analysis and ACPD method for weld toe fatigue crack initiation. Welding in the World. (doi:10.1007/s40194-019-00792-3).

Record type: Article

Abstract

Weld toe fatigue crack initiation is highly dependent on the local weld toe stress-concentrating geometry including any inherent flaws. These flaws are responsible for premature fatigue crack initiation (FCI) and must be minimised to maximise the fatigue life of a welded joint. In this work, a data-rich methodology has been developed to capture the true weld toe geometry and resulting local weld toe stress-field and relate this to the FCI life of a steel arc-welded joint. To obtain FCI lives, interrupted fatigue test was performed on the welded joint monitored by a novel multi-probe array of alternating-current potential drop (ACPD) probes across the weld toe. This set-up enabled the FCI sites to be located, the FCI life to be determined and gave an indication of early fatigue crack propagation rates. To understand fully the local weld toe stress-field, high-resolution (5 μm) 3D linear-elastic finite-element (FE) models were generated from X-ray Micro-Computed Tomography (μ-CT) of each weld toe after fatigue testing. From these models, approximately 202 stress concentration factors (SCFs) were computed for every 1 mm of weld toe. These two novel methodologies successfully link to provide an assessment of the weld quality and this is correlated with the fatigue performance.

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Accepted/In Press date: 29 July 2019
e-pub ahead of print date: 9 August 2019

Identifiers

Local EPrints ID: 433564
URI: http://eprints.soton.ac.uk/id/eprint/433564
ISSN: 0043-2288
PURE UUID: 427795e2-8468-4d44-8317-5f07f4049963
ORCID for Somsubhro Chaudhuri: ORCID iD orcid.org/0000-0001-9849-5766
ORCID for Philippa Reed: ORCID iD orcid.org/0000-0002-2258-0347

Catalogue record

Date deposited: 27 Aug 2019 16:30
Last modified: 26 Nov 2021 02:36

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Contributors

Author: Somsubhro Chaudhuri ORCID iD
Author: Jennifer Crump
Author: Philippa Reed ORCID iD
Author: Brian Mellor

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