Fatigue Performance of Friction Welds Manufactured Both in Air and Underwater

2017 ◽  
Author(s):  
Siak Manteghi ◽  
Dave Gibson ◽  
Carol Johnston
Keyword(s):  
Residual Stress ◽  
Fatigue Strength ◽  
Experimental Work ◽  
Welded Joints ◽  
Friction Welding ◽  
Arc Welding ◽  
Fatigue Performance ◽  
Cost Component ◽  
High Fatigue ◽  
Fatigue Endurance

Friction welding is being performed offshore in environments where arc welding may be difficult and where fatigue performance is critical. Friction welding underwater with Remotely Operated Vehicles (ROVs) can greatly reduce the cost of a project compared with using divers and arc welding because the support vessel, which is the major cost component in such an operation, is smaller. This paper describes two different programs of experimental work in which the fatigue endurance of friction welds were found to be better than that which could be expected from arc welded joints of similar geometry. The first program involved experimental work done with 25mm diameter steel bars. It found that, in the as-welded condition, friction welds have high fatigue strength. Residual stress measurements showed that this was due to a beneficial residual stress distribution in which compressive stresses are present at the surface adjacent to the failure site. Further evidence of this was obtained by subjecting some specimens to thermal stress relief. The fatigue strength of the stress relieved specimens was reduced compared with the as-welded joints but nevertheless the fatigue strength of these specimens was still high. The second program involved fatigue tests on friction stud welds in which the friction welding equipment was deployed offshore by divers or ROVs. The test specimens were made up of 19mm diameter studs friction welded onto structural steel plate. As with the first program, the specimens showed high fatigue endurance with results approximating to a DNV Class C1 curve. In some of the tests, the studs were preloaded in tension and results from specimens that were preloaded to the correct value specified for the joint were all stopped as run-outs, with specimens remaining unbroken.

Residual Stress Release and Its Effects on the Fatigue Strength of Typical Welded Joints in Cone-Cylinder Pressure Structures

2021 ◽  
Vol 111 ◽  
pp. 102673
Author(s):  
Liangbi Li ◽  
Jingxi Zhang ◽  
Yiwen Zhang ◽  
Deqin Zhu ◽  
Zhengquan Wan ◽  
...  
Keyword(s):  
Residual Stress ◽  
Fatigue Strength ◽  
Welded Joints ◽  
Cylinder Pressure ◽  
Stress Release

Fatigue Assessment of Welded Joints Taking Into Account Effects of Residual Stress

2010 ◽  
Author(s):  
Nur Syahroni ◽  
Stig Berge
Keyword(s):  
Residual Stress ◽  
Fatigue Strength ◽  
Welded Joints ◽  
Fatigue Testing ◽  
International Association ◽  
Hot Spot ◽  
Mean Stress ◽  
Element Analysis ◽  
Structural Rules ◽  
Fatigue Design

Residual stress may have a significant effect on the fatigue strength of welded joints. As a non-fluctuating stress, it has an effect similar to that of the mean stress. Recently the International Association of Ship Classification Societies (IACS) has issued Common Structural Rules (CSR) for respectively tankers (IACS 2006a) and bulk carriers (IACS 2006b). The effect of mean stress in fatigue design is taken into account in both sets of rules. However, the treatment is quite different, in particular with regard to residual stress and shakedown effects. In the present paper a comparative study of fatigue design procedures of the IACS rules is reported, with emphasis on residual stress effects. Testing was carried out with longitudinal attachment welds in the as-welded condition. The initial residual stress was measured by a sectioning method using strain gages. Hot spot stress was determined experimentally by strain gauges and numerically by finite element analysis using different types of elements. Fatigue testing was carried out and SN-curves were plotted according to the relevant stress as specified by the rules. In order to investigate the shake-down effect of residual stress, testing was performed for several pre-load conditions which could be taken to represent maximum load levels in a load history. The aim of the study is to contribute towards better understanding of the effect of residual stress and shakedown on fatigue strength of welded joints.

Differences in Fatigue Strength Between Arc and Laser Hybrid Welded Joints

2008 ◽  
Vol 24 (03) ◽  
pp. 139-146
Author(s):  
H. Remes ◽  
P. Varsta
Keyword(s):  
Fatigue Strength ◽  
Welded Joints ◽  
Fatigue Tests ◽  
Notch Depth ◽  
Butt Joints ◽  
Fatigue Design ◽  
Notch Stress ◽  
Notch Geometry ◽  
Laser Hybrid ◽  
Fatigue Endurance

This paper presents the results of fatigue tests, including tests of laser hybrid and arc welded butt joints, for two plate thicknesses, 6 and 12 mm. Pure laser welded joints were also tested. The S-N curves based on nominal stresses for the different welded joints are presented. The results were further analyzed using the notch stress approach, where the fatigue notch factors were determined from the measured geometries of the welded joints. Unexpected differences in the S-N curves based on the notch stresses were found between the laser hybrid and arc welded joints and between the laser hybrid and pure laser welded joints. The reasons for this difference were studied with the help of extensive measurements of weld notch geometries. Significant differences in the geometries were observed. Taking into account the notch geometry and the notch depth, the notch stress approach partially explains the differences between the fatigue endurance limits of the laser hybrid and arc welded joints. The applicability of the notch stress approach to the fatigue design of laser hybrid welded joints is also discussed.

scholarly journals Shielded Metal Arc and Thermite Welding Effect to Residual Stress, Hardness and Crack of R54-Rail Weld Joint

2020 ◽  
Vol 55 (4) ◽  
Author(s):  
Yurianto ◽  
Gunawan Dwi Haryadi ◽  
Sri Nugroho ◽  
Sulardjaka ◽  
Susilo Adi Widayanto
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Base Metal ◽  
Heat Affected Zone ◽  
Welded Joints ◽  
Arc Welding ◽  
Welding Process ◽  
Shielded Metal Arc Welding ◽  
Metal Arc Welding ◽  
Crack Susceptibility

The heating and cooling at the end of the welding process can cause residual stresses that are permanent and remain in the welded joint. This study aims to evaluate the magnitude and direction of residual stresses on the base metal and heat-affected zone of rail joints welded by the manual shielded metal arc and thermite welding. This research supports the feasibility of welding for rail. The material used in this study is the R-54 rail type, and the procedure used two rail samples of one meter long each, welded using manual shielded metal arc welding and thermite welding. The base metal and heat-affected zone of the welded joints were scanned with neutron ray diffraction. The scan produces a spectrum pattern and reveals the direction of the residual stress along with it. We found the strain value contained in both types of welded joints by looking at the microstrain values, which we obtained using the Bragg equation. The results show that the magnitude and direction of the residual stress produced by manual shielded metal arc welding and thermite welding are not the same. Thermite welding produces lower residual stress (lower crack susceptibility) than manual shielded metal arc welding. The melt's freezing starts from the edge to the center of the weld to create random residual stresses. The residual stress results of both the manual shielded metal arc welding and thermite welding are still below the yield strength of the base metal.

scholarly journals On the Fatigue Performance of Friction-Stir Welded Aluminum Alloys

Materials ◽  
2020 ◽  
Vol 13 (19) ◽  
pp. 4246
Author(s):  
Sergey Malopheyev ◽  
Igor Vysotskiy ◽  
Daria Zhemchuzhnikova ◽  
Sergey Mironov ◽  
Rustam Kaibyshev
Keyword(s):  
Residual Stress ◽  
Fatigue Strength ◽  
Aluminum Alloys ◽  
Fatigue Behavior ◽  
Base Material ◽  
Fatigue Performance ◽  
Coarse Grained ◽  
Original Material ◽  
Friction Stir ◽  
Macro Scale

This work was undertaken in an attempt to ascertain the generic characteristics of fatigue behavior of friction-stir welded aluminum alloys. To this end, different alloy grades belonging to both the heat-treatable and non-heat-treatable types in both the cast and wrought conditions were studied. The analysis was based on the premise that the fatigue endurance of sound welds (in which internal flaws and surface quality are not the major issues) is governed by residual stress and microstructure. Considering the relatively low magnitude of the residual stresses but drastic grain refinement attributable to friction-stir welding, the fatigue performance at relatively low cyclic stress was deduced to be dictated by the microstructural factor. Accordingly, the fatigue crack typically nucleated in relatively coarse-grained base material zone; thus, the fatigue strength of the welded joints was comparable to that of the parent metal. At relatively high fatigue stress, the summary (i.e., the cyclic-plus residual-) stress may exceed the material yield strength; thus, the fatigue cracking should result from the preceding macro-scale plastic deformation. Accordingly, the fatigue failure should occur in the softest microstructural region; thus; the fatigue strength of the welded joint may be inferior to that of the original material.

Effect of residual stress on fatigue strength of non-load-carrying fillet welded joints

1991 ◽  
Vol 5 (12) ◽  
pp. 936-943
Author(s):  
K Matsuoka ◽  
I Takahashi ◽  
T Yoshii ◽  
E Fujii
Keyword(s):  
Residual Stress ◽  
Fatigue Strength ◽  
Welded Joints ◽  
Load Carrying
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