Effect of welding process on fatigue crack growth behaviour of austenitic stainless steel welds in a low alloy (Q & T) steel

Fatigue crack growth behaviour from a lack of penetration (LOP) defect in austenitic stainless steel weld metals of cruciform joints made of a low alloy high strength (Q & T) steel has been studied to understand the effect of two welding processes, namely, shielded metal arc welding (SMAW) and flux cored arc welding (FCAW). Fatigue crack growth studies were carried out at a stress ratio of R = 0 and a frequency of 90 to 110 Hz in a resonant testing equipment (Rumul, Model:8601). Crack growth rates were relatively lower in the weld metal obtained by flux cored arc welding process. Microstructural features observed revealed marked difference in the morphology of delta ferrite for the welded joints obtained from the above two welding processes. Long streaks of delta ferrite in austenite matrix were found in case of SMAW-weld metal which seem to have lowered the resistance to the fatigue crack propagation. A discontinuous network of delta ferrite found in austenite matrix in the case of FCAW-weld metal seems to have contributed to slower propagation of fatigue crack. Fractographic features also substantiate the observed trends in the fatigue crack growth behaviour.     

Effect of weld size on fatigue crack growth behaviour of cruciform joints by strain energy density factor approach

The effect of weld size on fatigue crack growth behaviour of cruciform joints containing lack of penetration defect has been analysed by using the strain energy density factor concept. Load carrying cruciform joints were fabricated from ASTM 517‘F' grade steel. Fatigue crack growth experiments were carried out in a mechanical resonance vertical pulsator (SCHENCK 200 kN capacity) with a frequency of 30 Hz under constant amplitude loading (R=0). It was found that the crack growth rates were relatively lower in the larger welds fabricated by multipass welding technique than the smaller welds fabricated by the single pass welding technique.     

Fatigue life estimate of C---Mn steel welded cruciform joints

The fatigue life of a manual metal arc welded cruciform joint failing from a root lack of the penetration region is estimated by the application of crack growth relations. A two-parameter relation was used. The initiation life and propagation life of the joint were taken into account to obtain the total fatigue life of the joint from the crack growth parameters. To test the accuracy of the method, the predicted data was compared with the experimental data for a C---Mn type steel welded joints. The results were in good agreement with the experimental data.     

Fatigue behaviour of FSW and MIG weldments for two aluminium alloys

The increasing use of aluminium alloys in transportation, such as railways, shipbuilding and aeronautics, calls for more efficient and reliable welding processes that would require more in depth understanding of fatigue failure. The objective of this work focuses on the contrasting difference of fatigue behaviour of joints made from the traditional process of metal inert gas (MIG) welding, and the emerging process of friction stir welding (FSW). Effort is made to relate the macroscopic mechanical behaviour to the microstructural feature of the weldments.     

Fracture mechanisms of CTOD samples of submerged and flux cored arc welding

Three welding procedures commonly used to rebuild worn shafts in sugar cane mills were analyzed: two processes of submerged arc welding and one of flux cored arc welding. Crack tip opening displacement for the welding was determined according to ASTM E 1290 standard. The fracture surface and microstructure of the samples were characterized using scanning electron microscopy and optical microscopy, respectively. The fracture parameter CTOD was correlated with the fracture surface and microstructures. The single deposit of FCAW process and the outer weld deposits of SAW process present acicular and blocky ferrite and non-metallic inclusions with spherical shape distributed randomly in the welding. The inner deposits for SAW process show equiaxed ferrite and pearlite with fine inclusions. Welding material B-MA 1 presented the highest CTOD_c with 0.2115 mm, followed by A-MA 2 with 0.1672 mm and A-MA 1 with 0.1238 mm. Each presented ductile fracture surfaces characterized by spherical dimples, microvoids nucleated in inclusions. Deposits B-MA2 and C-MA 1 presented lower CTOD_c, unstable crack growth and brittle fractures, characterized by intergranular failures due to fine inclusions in the grain boundaries.     

Analysis of temperature and stress field in Al alloy’s twin wire welding

By analyzing the shape of twin wire welding’s arcs and the track of droplets’ transition, the phenomenon that the twin wire welding’s fore arc and rear arc all deflect to the middle of the two arcs is found. Based on this the double ellipsoid heat source model is amended, and a heat source model which can apply to calculate the twin wire welding’s temperature field is put forward. This model is testified by actual experiment of temperature sampling. By comparing the temperature field of twin wire welding and single wire welding, the results show that twin wire welding has slender weld pool the end part of which is ellipsoid, and its HAZ is narrower than that of single wire welding. So, twin wire welding can not only reduce the Al alloy generating hot crack, but can also weaken the “overaging” softened phenomenon of heat treated strengthening Al alloy. In the end, the evolving rules of 2219 Al alloy’s longitudinal and transverse stress when welded with twin wire welding are analyzed.     

Constant amplitude and variable load history fatigue test results and predictions for cruciform and lap welds

Cruciform and lap welds were fatigue tested under constant amplitude axial load and SAE Bracket spectrum load conditions. For the cruciform joints, fatigue cracks generally initiate at the root but may initiate at the toe if higher bending stresses are induced by joint distortion. For lap welds, the stress ratio ($\text{R}$) and weld shape are the major factors influencing the fatigue crack initiation site.The fatigue test results were compared with predictions made using an analytical model developed by the authors, and good agreement between experiment and theory was observed. The model for the predictions assumes that the fatigue crack initiation period, which is the number of cycles for the initiation of a fatigue crack and its early growth and coalescence into a dominant fatigue crack, is the main portion of the total fatigue life at long lives.     

氩弧点焊薄片应变传感器性能实验研究

对氩弧点焊薄片应变传感器传递性能和疲劳性能进行了试验研究,试验结果表明氩 弧点焊薄片应变传感器具有稳定传递性能和可靠的疲劳性能,可以应用于实际工程应变测 量.     

Very high cycle fatigue behavior of bridge steel welded joint

Very high cycle fatigue (VHCF) behaviors of bridge steel (Q345) welded joints were investigated using an ultrasonic fatigue test system at room temperature with a stress ratio R = ?1. The results show that the fatigue strength of welded joints is dropped by an average of 60% comparing to the base metal and the fatigue failure still occurred beyond 10⁷ cycles. The fatigue fracture of welded joints in the low cycle regime generally occurred at the solder while at the heat-affected zone (HAZ) in the very high cycle regime. The fatigue fracture surface was analyzed with scanning electron microscopy (SEM), showing welding defects such as pore, micro-crack and inclusion were the main factors on decreasing the fatigue properties of welded joints. The effect of welding defects on the fatigue behaviors of welded joints was discussed in terms of experimental results and finite element simulations.     

Evaluation of fatigue strenght of welded structures by local strain measurements

The object of the paper is the experimental evaluation of the local strain conditions near the fatigue-crack starting zones in welded structures, at the toe of weld joints. These zones are characterized by steep gradients for strain and stress. The evaluation is performed using strain gages and finite-element techniques on real cruciform weld joints. The results illustrate the possibilities and the limitations posed by the use of local strain measurements to assess the fatigue strength of welded structures. These factors are usually estimated on the basis of a nominal stress approach.Paper was presented at 1983 SESA Spring Meeting held in Cleveland, OH on May 15–19, 1983.     

未熔透尺寸对十字焊接接头疲劳性能影响规律试验研究

针对某厂一压力机架的焊接结构，采用极大似然方法，进行了部分熔透焊接十字接头的拉—拉疲劳试验，得到了该类结构的Ｐ－Ｓ－Ｎ对数曲线。研究了未熔透尺寸对接头的应力集中系数、疲劳强度和试件疲劳破坏形式的影响规律，结果表明，在焊缝与母材等强的情况下，当未熔透尺寸２ａ／Ｔ＜０．５时，其疲劳性能无明显减弱；而当未熔透尺寸２ａ／Ｔ＞０．５时，则接头的抗疲劳性能有显著的改变。     

Fatigue characteristics of ‘bead-on-plate’ of aluminum and Al---Zn---Mg alloy

Fatigue life of ‘bead-on-plate’ on commercially pure aluminum and Al---Zn---Mg alloy have been investigated. In both cases, the fatigue life of ‘Bead-on-Plate’ specimen was drastically reduced. But when the same weld-bead was flushed off, a marginal improvement in fatigue life was observed. For Al---Zn---Mg alloy, the post weld heat treatment was less effective than flushing of weld-bead for improving the fatigue life of welded specimens. Results are analyzed with the help of S-N diagrams and microphotographs.     

Isothermal low-cycle fatigue testing of microscale solder interconnections

A series of isothermal low-cycle fatigue studies of small to extremely small-volume solder joints has been conducted. These solder microjoints were designed and fabricated using processing which duplicates the microelectronics interconnection structures that might be used in high density, highly integrated flip-chip packaging and all fatigue tests were conducted in fully reversed simple shear both with and without dwells at maximum strain. Results of low-cycle fatigue tests of both single and double-bump 95/5 Pb/Sn solder microjoints in the form of Manson-Coffin (plastic strain amplitude versus fatigue life) plots and post-test failure mode analysis (FMA) carried out using scanning electron microscope (SEM) fractography are presented and evaluated. Paper was presented at the 1991 SEM Spring Conference on Experimental Mechanics held in Milwaukee, WI on June 9–12.     

AN EXPERIMENTAL INVESTIGATION ON JOINTS QUALITY OF THE SPOT WELDED DP600

The effects of welding current and time on the joints quality of the resistance spot welded of DP600 by evaluating the welding nugget sizes and mechanical properties were investigated experimentally. The experiment results show that different welding current and time lead to different welding nugget sizes. There exists a critical welding parameter which can make the welding nugget size attain optimum. The welding nugget size is a critical control parameter of the mechanical properties of the spot welded joint.     

Fatigue life prediction of out-of-plane gusset welded joints using strain energy density factor approach

Fatigue growth behavior of out-of-plane gusset welded joints is studied using the strain energy density factor approach. Fatigue tests on two types of specimens with curvatures of ρ = 0 and ρ = 30 were performed in order to estimate fatigue strength under tension. Fatigue crack growth analysis is carried out to show the effects of initial crack shape, initial crack length and stress ratio. Fatigue crack growth parameters were obtained from crack growth curves assuming constant crack shapes. The results of analysis for the assumed crack shapes agreed well with the experimental data. Fatigue propagation life of the ρ = 30 specimen was larger than that of the ρ = 0 specimen.     

Mechanical response of thin SMAW arc welded structures: Experimental and numerical investigation

The mechanical response of thin welded plates made of Ck45 steel during shielded metal arc welding (SMAW) is investigated by employing data from numerical results using the finite element method and laboratory experimental measurements. The aim of this paper is to investigate the effect of the thermal uncertainty encountered during the thermal numerical analysis on the out-of-plane angular distortion of the welded panels. For this purpose a comparison between the numerical mechanical response (using the calibrated and as-predicted thermal history) and the experimental results is carried out. The effect of the microstructural transformations on the angular out-of-plane distortion is also investigated by introducing the material transformation within the numerical analysis by the simplest means in order to clearly demonstrate its influence. The same strategy is followed in order to investigate the effect of low-temperature martensitic transformation on the longitudinal residual stress field by properly combining experimental and numerical results and analyzing an idealized welding fabrication. Discussion is, finally, carried out regarding the design process of welded marine structures.     

热循环加载条件下空洞对EBGA焊点可靠性的影响

空洞是球栅阵列(BGA：Ball Grid Array)器件在装配过程中形成的主要缺陷之一,本文以增强性BGA(EBGA：Enhanced BGA)为研究对象,采用统一型粘塑性Anand本构方程描述Sn63Pb37的粘塑性力学行为,应用非线性有限元的方法分析了不同位置和大小的空洞对焊点疲劳寿命的影响,为制定装配后的BGA焊点接收标准提供理论参考。     

Dissimilar ultrasonic spot welding of Mg-Al and Mg-high strength low alloy steel

Sound dissimilar lap joints were achieved via ultrasonic spot welding (USW), which is a solid-state joining technique. The addition of Sn interlayer during USW effectively blocked the formation of brittle al₁₂Mg₁₇ intermetallic compound in the Mg-Al dissimilar joints without interlayer, and led to the presence of a distinctive composite-like Sn and Mg₂Sn eutectic structure in both Mg-Al and Mg-high strength low alloy (HSLA) steel joints. The lap shear strength of both types of dissimilar joints with a Sn interlayer was significantly higher than that of the corresponding dissimilar joints without interlayer. Failure during the tensile lap shear tests occurred mainly in the mode of cohesive failure in the Mg-Al dissimilar joints and in the mode of partial cohesive failure and partial nugget pull-out in the Mg-HSLA steel dissimilar joints.     

一种考虑拉伸保持效应的多轴疲劳寿命模型

通过定义考虑拉伸保载效应的CFI因子(creep-fatigue interaction factor)，将拉伸蠕变损伤和疲劳损伤进行非线性耦合. 根据断裂实验的观察，针对拉伸主 导的裂纹萌生、扩展及破坏的多轴疲劳问题，给出了一个基于临界面方法的能量型高温多轴 疲劳寿命预测模型. 所给出的模型可对不同温度、不同载荷特点、不同保载时间的多轴疲劳 寿命进行预测，模型的材料参数不依赖于温度和载荷. 并且此方法可以很方便地推广到其它 因素主导破坏的高温多轴疲劳寿命预测. 通过拟合高温合金Udimet720Li单轴带保持时间的 低循环疲劳(low cycle fatigue, LCF)寿命试验数据，得到了材料常数. 结合黏 塑性有限元分析方法，对高温双轴带保载循环载荷下Cruciform试件的寿命进行了 预测，预测结果基本落在2倍分散带内，达到工程的要求，证明了该模型的有效性.     

An investigation about interference fit effect on improving fatigue life of a holed single plate in joints

In this article, the effect of interference fit on fatigue life of holed plate of mechanical joints was investigated both experimentally and numerically. In the experimental part, fatigue tests were carried out on the holed specimens of Al 7075-T6 alloy in which oversized steel pins were force fitted to them. These fatigue tests were conducted on open hole specimen and specimens with 1, 1.5, 2 and 4% nominal interference fit sizes at different cyclic longitudinal loads. From these tests the stress-life (S–N) data for different interference fit sizes were obtained. The results show that interference fit increases fatigue life compared to open hole specimens. In the numerical part of the investigation, 3D finite element simulations have been performed to obtain stress (or strain) histories and distributions around the hole due to interference fit and subsequent cyclic longitudinal loading using FEM package. The stress history from finite element (FE) simulation was used to explain the reason for fatigue life improvement in the interference fitted specimens.