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Numerical study on the effect of residual stresses on stress intensity factor and fatigue life for a surface-cracked T-butt welded joint using numerical influence function method

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Abstract

Fatigue crack propagation (FCP) is the most threatening failure to welded joints due to high local stress concentration and the effect of welding residual stress (WRS). Therefore, fatigue life assessment of welded joints considering residual stress distribution is an important procedure in designing and maintaining of welded structures. In this study, fatigue life of welded structures is evaluated using the fracture mechanics approach. The WRS is predicted by using the thermal elastic–plastic-finite element analysis (TEP-FEA). Stress intensity factors (SIFs) of surface-cracked welded joints under constant amplitude (CA) loadings are evaluated using the numerical Influence Function Method (IFM). The effects of WRS on the behavior of SIFs are discussed. Fatigue life estimations are calculated for CA loadings with different stress ranges using Paris-Elber law. Calculated fatigue life considering WRS is compared with those ignored WRS. The results show that the fatigue life of welded structure decreases significantly when the WRS is considered in the calculated SIFs. This study demonstrates the applicability of IFM-based SIF calculation system to the fatigue life estimation considering WRS. The proposed approach provides accurate solutions and an efficient calculation system for fatigue analysis under different loading conditions.

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source model [34]

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Availability of data and material

The data described in this manuscript are available from the corresponding author, upon reasonable request.

Code availability

The codes that support the findings in this manuscript are available from the corresponding author, upon reasonable request.

Abbreviations

a :

Crack depth, mm

a f :

Length of the front end of the heat source model, mm

a r :

Length of the rear end of the heat source model, mm

a/c :

Crack depth-to-crack length ratio

a/t :

Crack depth-to-model thickness ratio

b :

Half-breadth of the heat source model, mm

C :

Material constant in cyclic crack growth relationship (mm/(cycle MPa mm1/2))

c :

Crack half-length, mm

d :

Depth of the heat source model, mm

\(\frac{da}{dN}\) :

Crack growth rate with cycles, mm/cycle

E :

Young’s modulus, GPa

E * :

Effective Young’s modulus, GPa

\(I\left(s\right)\) :

Interaction integral at crack front location s

\({K}_{I}, {K}_{II}, {K}_{III}\) :

Mode-I, -II, and -III SIFs, MPa mm1/2

\({K}_{I\mathrm{min}}, {K}_{I\mathrm{max}}\) :

Minimum and maximum SIFs for mode-I, MPa mm1/2

\({K}_{In}, {K}_{IIn}, {K}_{IIIn}\) :

Normalized values of calculated SIFs, KI, KII, and KIII, respectively

\({K}_{I}^{\mathrm{aux}}, {K}_{II}^{\mathrm{aux}}, {K}_{III}^{\mathrm{aux}}\) :

Auxiliary mode-I, -II, and -III SIFs, MPa mm1/2

\({K}_{I}^{ij,PQ}, {K}_{II}^{ij,PQ}, {K}_{III}^{ij,PQ}\) :

SIFs along the crack front nodes (Qth node) due to six components of unit distributed load at the crack face node (Pth node), MPa mm1/2

\({K}_{I}^{Q}, {K}_{II}^{Q}, {K}_{III}^{Q}\) :

SIFs along the crack front nodes (Qth node) due to an applied arbitrary load, MPa mm1/2

m :

Exponent in crack growth law

N :

Number of fatigue life cycles, cycles

P :

Node on the crack face element defined in the influence function method

Q :

Node on the crack front defined in the influence function method

q :

Flaw shape parameter

R :

Stress ratio

U :

Stress range ratio

x, y, z :

Cartesian coordinates, mm

x’, y’, z’ :

Local coordinates, mm

ΔK :

SIF range, MPa mm1/2

ΔK eff :

Effective SIF range, MPa mm1/2

\(\eta , \xi\) :

Normalized coordinates

\(\theta\) :

Flank angle, degree

v :

Poisson’s ratio

σ :

External tensile loading, MPa

\({\sigma }_{xx}^{\mathrm{WRS}}\) :

Longitudinal WRS, MPa

\({\sigma }_{yy}^{\mathrm{WRS}}\) :

Transversal WRS, MPa

ρ :

Weld toe radius, mm

\({\sigma }_{ij,P}\) :

Six components of traction stress at the Pth node on the crack face, MPa

\(\varphi\) :

Location of crack front parametric angle, degree

CA:

Constant amplitude

CFT:

Crack face traction

FCP:

Fatigue crack propagation

FE:

Finite element

FEA:

Finite element analysis

FEM:

Finite element method

IC:

Influence coefficient

ICDB:

IC database

IFM:

Influence function method

IIM:

Interaction integral method

JWRI:

Joining and Welding Research Institute

MM-SIFs:

Mixed-mode SIFs

TEP:

Thermal elastic–plastic

WRS:

Welding residual stress

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Acknowledgements

The authors would like to thank Professor Hidekazu Murakawa (Osaka University) for his valuable advice, comments, and discussions regarding the welding simulations.

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Authors and Affiliations

  1. Graduate School of Engineering, Osaka University, Suita, Osaka, Japan

    Phyo Myat Kyaw & Naoki Osawa

  2. Graduate School of Advanced Science and Engineering, Hiroshima University, Higashi-Hiroshima, Hiroshima, Japan

    Satoyuki Tanaka

  3. Graduate School of Engineering, Osaka Prefecture University, Sakai, Osaka, Japan

    Ramy Gadallah

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Correspondence to Naoki Osawa.

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Kyaw, P.M., Osawa, N., Tanaka, S. et al. Numerical study on the effect of residual stresses on stress intensity factor and fatigue life for a surface-cracked T-butt welded joint using numerical influence function method. Weld World 65, 2169–2184 (2021). https://doi.org/10.1007/s40194-021-01172-6

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