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PERGAMON Lngineeiing ailuie Analysis 6 (1999) 113130

S13506307,99,$ - see lionl mallei 1999 PuLlisled Ly Llseviei Science Ild. All iiglls ieseived
P!!: S1 3 5 0 6 3 0 7 ( 9 8 ) 0 0 0 2 5 9
aligue design ol welded aluminum ieclangulai lollow
seclion joinls
K.A. Macdonald, P.1. Haagensen
Norwegian Unirersiiy of Science ana Technology, Deparineni of Siruciural Engineering, Tich. Birkelanasrei 1a,
N-7034 Tronahein, Norway
Received 7 Augusl 1998; acceled 8 SelemLei 1998
Abstract
aligue design mellods loi welded aluminum joinls aie ieviewed, including vaiious aioacles lo laligue
lile eslimalion cuiienlly adoled in design codes acioss a iange ol indusliial alicalions. Tle alicaLilily
ol llese eslaLlisled mellodologies lo lle laligue design ol aulomolive sace liame sliucluies is ciilically
assessed. Tle lol sol sliess mellod is idenliled as lle mosl iomising in leims ol ioviding a coleienl
and comielensive aioacl lo design. Pailiculai ioLlems ielaled lo imlemenlalion aie consideied sucl
as lailuie siles and deleiminalion ol aioiiale sliess concenlialion laclois liom lysical models, lnile
elemenl calculalions oi aiameliic equalions. Pieliminaiy iesulls liom lnile elemenl sliess analyses and
laligue lesls aie also iesenled loi ieclangulai lollow seclions welded in a T-joinl conlguialion. Recom-
mendalions aie made loi a design mellodology loi welded ieclangulai lollow-seclion joinls in aluminum
sace liames, including use ol a single lol sol SN cuive. 1999 PuLlisled Ly Llseviei Science Ild. All
iiglls ieseived.
Keyworas. Aulomolive design; aligue design; SN cuives; Sace liames; Weld laligue
0[ Introduction
Aluminium welded lollow seclion (RHS) joinls aie lnding incieased use in ciane and Liidge
sliucluies, liansoil velicles and in aulomolive sliucluies. TuLulai sliucluies aie occasionally
laLiicaled using loiged oi casl nodes Lul llese aie moie exensive lo ioduce llan welded inlei-
luLe conneclions wlicl aie consequenlly moie common. Howevei, lle laligue design Lasis loi
welded RHS joinls in aluminium is limiled and no design iecommendalions cuiienlly exisl loi
sucl joinls. An aioiiale slailing lalloim liom wlicl lo eslaLlisl a laligue design mellodology
could Le lle exeiience iecenlly gained will similai sliucluies laLiicaled in sleel. !n ailiculai,
laligue assessmenl Lased on lle geomeliic lol sol sliess iange (oi lol sol sliess) concel could
Coiiesonding aulloi.
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 114
Le adoled loi aluminium sliucluies. Howevei, in aulomolive design lle maleiial lliclnesses lend
lo Le smallei llan llose used in civil engineeiing design and llis dieience migll limil lle
ossiLililies loi lianslei ol dala liom lle sleel indusliy.
Tlis aei gives a Liiel oveiview ol laligue assessmenl ioceduies used in lle design ol sleel
luLulai sliucluies. Tle limiled SN dala availaLle loi aluminium RHS joinls aie iesenled and
lle need loi luillei exeiimenlal ieseaicl is oullined.
Tiends in lle develomenl ol design codes aie also discussed in ligll ol lle lacl llal inleinalional
codes aie iaidly laimonising lliougl co-oeialion Lelween oiganisalions sucl as !SO (!nlei-
nalional Slandaids Oiganisalion), CL (Comile Luioeen de oimalisalion) iesonsiLle loi
Luiocodes, !!W (!nleinalional !nslilule ol Welding) and AP! (Ameiican Pelioleum !nslilule).
1[ Fatigue life assessment methods for welded tubular joints
!n lle majoiily ol cuiienl laligue design codes lleie aie lwo geneiic lyes ol SN cuive used.
!n convenlional welded sliucluies involving lales and Leams, lle noninal siress aioacl is
noimally emloyed wleie lle dieienl laligue Lelavioui ol vaiious sliucluial elemenls oi delails
is desciiLed Ly assigning lo llem dieienl SN cuives, leimed design calegoiies oi classes, and
comLining llese will nominal sliesses iemole liom lle weld. Since laligue lailuie in welded
consliuclions is nol only ielaled lo geomeliy, lle diieclion ol loading and lailuie sile also inuences
joinl calegoiisalion. Lxamles ol design calegoiies ol sucl Lasic conneclions aie joinls will Lull
oi lllel weld, laving dieienl design calegoiies deendenl on lle sliess diieclion. Tle main
advanlage ol lle nominal sliess aioacl is llal lle SN cuives loi eacl weld calegoiy (oi weld
class) include lle nolcl eecl ol lle weld as well as lle eecl ol lle comonenl geomeliy. Tle
main souices ol scallei due lo laLiicalion vaiiaLles aie llus included in lle lesl dala used lo cieale
lle cuive. ominal sliesses aie calculaled liom a sliucluial analysis and comiise lle memLiane
sliess iange, S
m
and lle Lending sliess iange S
L
in geneial SS
m
S
L
. Tle comlexilies ol and
inleiaclions Lelween geomeliy and loading lound in some sliucluies, e.g., in ciiculai seclion
luLulai joinls, give iise lo a lelloia ol ossiLle lailuie siles and leie lle hoi spoi siress aioacl
is used lo ieduce lle design lo a common Lasis. Addilionally, lle dimcullies encounleied in delning
a nominal sliess in comlex sliucluies also male lle lol sol aioacl lle only iaclicaLle
mellod. aligue lailuie will occui al siles ol ligl eal sliess in sucl joinls and il is assumed llal
laligue lile is ielaled lo lle magnilude ol llese eals. aligue design is accomlisled Ly comLining
lnowledge ol llese local sliess ealsusually in lle loim ol a sliess concenlialion lacloi (SCF)
loi a ailiculai load conlguialionwill an SN cuive ieiesenling a simle weld willoul any
sliucluial SCF.
2.1. The geoneiric hoi spoi siress approachcircular hollow-seciion (CHS) joinis
Tle lol sol aioacl las Leen used exlensively in lle osloie indusliy in lle analysis ol
iesulls liom lesls on sleel luLulai joinls [1. Sliesses in ciiculai lollow-seclion (CHS) joinls aiise
liom lliee main souices:
(i) Tle Lasic sliess iesonse due lo lle gloLal aclion ol lle iemole alied load, i.e., lle sliess
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 115
llal can Le calculaled liom a liame analysis disiegaiding lle sliess concenlialing eecls ol
Loll lle joinl and lle weld.
(ii) Tle geomeliic sliesses iesulling liom local Lending ol lle luLe walls lo mainlain comaliLilily
Lelween lle memLeis.
(iii) Tle liglly local sliess neai lle inleiseclion lines Lelween memLeis. Tlese local sliesses aie
sliongly inuenced Ly lle weld slae.
Tle maximum sliess (oi nolcl sliess), localed al lle weld loe is lle sum ol lle nominal sliess, lle
geomeliic sliess and lle local sliess comonenls. Tle geomeliic lol sol sliess iange oi lol sol
sliess concel las evolved as lle mosl iaclical Lasis loi laligue design ol welded joinls. !l caluies
lle lclilious local sliess llal claiacleiises lle laligue eiloimance ol lle joinl, Lul excludes lle
veiy local sliess eiluiLalions caused Ly clanges in lle weld loe geomeliy. Also excluded aie lle
eecls ol any undeleclaLle delecls. Tlese eecls aie included in lle SN cuive. Tle lol sol sliess
concel laces dieienl sliucluial geomeliies on a common Lasis, enaLling lle use ol a single
SN cuive. Tle lol sol sliess S
l
is ielaled lo lle gloLal loads in lle sliucluie lliougl:
S
l
SCFS
nom
(1)
wleie S
nom
is lle nominal sliess iange and lle sliess concenlialion lacloi (SCF) is noimally
oLlained liom eillei lnile elemenl analyses oi liom sliain gauge measuiemenls. !l is imoilanl
llal consislency will lle SN cuive is mainlained Ly using lle same mellod loi eslimaling lle
lol sol in lle laligue lesl as used in oLlaining SCFs. Tle lol sol sliess mellod loi sleel CHS
joinls las Leen validaled Ly SN dala loi dieienl lyes ol joinls and loading condilions llal lol
inlo a single scallei Land [1.
Tleie is geneial agieemenl llal lle lol sol is localed al lle weld loe Lul lleie aie many
oinions as lo lle ioei mellod ol deleimining lle lol sol liom sliain gauge measuiemenls. !n
lle eaily !S iaclice loi osloie sliucluies, lle AP! and AWS codes delned lle lol sol sliess
iange as lle lolal sliess iange measuied Ly a sliain gauge laced adjacenl lo lle weld loe,
eiendiculai lo lle weld. Tleieloie an alleml was made lo measuie lle maximum sliess al lle
weld loe, including lle nolcl eecl ol lle weld. Tyically lol sol gauges weie laced willin
6 mm lo 0.1zri ol lle weld loe will a gauge lengll ol 3 mm, r and i ieleiiing lo lle oulside iadius
and lliclness ol lle insliumenled memLei.
!n lle Luioean Coal and Sleel Communily (LCSC) mellod [2, also loi osloie sleel sliucluies,
an exliaolalion is made liom lwo sliain gauges laced jusl oulside lle weld nolcl zone and in
lle iegion ol sliess lineaiily lo deleimine lle geomeliic lol sol sliess iange. Tlis mellod is also
used loi non-lineai sliess disliiLulions. !n lle Del oisle Veiilas (DV) mellod [3 loi osloie
sliucluies, many sliain gauges aie laced neai lle weld lo allow loi a moie accuiale deleiminalion
ol lle iegion ol lol sol sliess. Tle LCSC and lle DV iecommended localions loi lle sliain
gauges aie slown in ig. 1. Tle LCSC delnilion is Lased on lle maximum iincial sliess, i.e.,
lle sliess comonenls aie exliaolaled lo lle weld loe and lle maximumiincial sliess calculaled.
Tle sliess noimal lo lle weld used in lle !S delnilion is somewlal lowei llan llis Lul in lle
iegions ol liglesl sliess, lle ciown and saddle localion lle lwo aie almosl idenlical.
!n lle !!W design iecommendalions [4, a non-lineai (quadialic) exliaolalion ioceduie is
iecommended loi cases ol ligl local slell Lending sliesses caused loi examle Ly eccenliic
allaclmenls in laige diamelei luLes oi lane lales. Tle quadialic exliaolalion iequiies a
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 116
ig. 1. Recommended localion ol sliain gauges lo measuie lol sol sliess in luLulai joinls, LCSC (lo) and DV
(Lollom) [2, 3.
minimum ol lliee sliain gauges and is Lased on oinls on a cuive, llled lo lle sliain gauge
measuiemenls Ly iegiession analysis.
Tle SCF is deleimined Ly seveial mellods:
(i) Plysical models using sliain gauges, as oullined aLove.
(ii) inile elemenl mellods using aioiiale mesles wlicl model lle oveiall joinl geomeliy
willoul aclually modelling lle weld.
(iii) Paiameliic loimulae Lased on eillei sliain gauge measuiemenls oi LM.
!n lle lnile elemenl analysis, caie musl Le lalen lo oLlain sliesses al osilions loi exliaolalion
llal aie consislenl will lle delnilion ol lle lol sol sliess used. !n lle !!W iecommendalions [4
delailed insliuclions aie given loi lle LM analysis.
Tle value ol lle SCF is ciilical loi lle accuiacy ol lle iedicled lile, and laige eoils lave
lleieloie Leen made lo assess availaLle dala lo delne sels ol aiameliic equalions loi use in design
codes. !n lle lalesl Healll and Salely Lxeculive ievision ol lle guidance loi osloie sliucluies
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 117
[5, lwo sels ol aiameliic equalions aie iecommended loi design ol luLulai CHS joinls [6, 7. A
comielensive suivey ol lle clanges in lle HSL guidance las iecenlly Leen iesenled [8. Clanges
similai lo llose in lle HSL guidance aie lilely lo Le imlemenled in lle AP! code [9 loi osloie
sliucluies wlicl is cuiienlly undeigoing exlensive ievisions wlicl aie aimed al ioducing a new
!SO code loi osloie sliucluies. Tle new !SO code is in luin inlended lo Lecome lle Luiocode 3
(sleel sliucluies) laligue clauses loi osloie sliucluies [10. Since lleie is a liend lowaids lai-
monisalion ol Luioean design iules, lle new !SO iovisions in Luiocode 3 loi lol sol Lased
laligue assessmenl ol luLulai sliucluies aie execled lo inuence lle lol sol assessmenl io-
ceduies in luluie veisions ol Luiocode 9 loi aluminium sliucluies [11.
Tle SN cuive lo Le used will lle lol sol concel is usually idenlical lo oi veiy similai lo lle
SN cuive loi a simle Lull weld. !n lle eaily (1984) Deailmenl ol Lneigy guidance on wlicl
S 3472 [12 loi sleel sliucluies aie Lased, lle T-cuive loi luLulai joinls is almosl idenlical lo lle
D-cuive wlicl alies lo liansveise Lull welds in lale sliucluies. Tlis lollows liom lle delnilion
ol lle lol sol sliess. oi a liansveise Lull weld in a lale oi ie lleie is no geomeliic sliess
concenlialion and lle SCF1. Tleieloie lle associaled lol sol sliess SN cuive slould only
include lle eecl ol lle weld, i.e., lle SN cuive loi a liansveise Lull weld slould Le used.
Tle lysical size ol lle joinl undei consideialion is imoilanl Lecause lle size ol lle sliain
gauge limils lle dislance liom lle weld lo lle localions ol lle gauge. !n llin-walled sliucluies lle
gauge las lleieloie lo Le laced laillei away liom lle weld llan las Leen ossiLle in osloie
sleel joinls, and secial guidance las lleieloie evolved loi llin seclion welded joinls.
Tle eecl ol lale lliclness is usually landled lle same way in design iecommendalions loi lle
lol sol sliess mellod as loi lle nominal sliess mellod. A lliclness enally lacloi is imosed loi
lale lliclnesses giealei llan lle ieleience lliclness, i
0
. Tle enally lacloi, wlen alied lo lle
sliess iange, is usually exiessed as:
S
S
9

0
i
9
i 1
q
(2)
wleie S is lle sliess iange al lliclness i. !n mosl ol lle oldei iules lle value ol lliclness exonenl
q is 0.25. Howevei, assessmenl ol iecenl ieseaicl dala las indicaled sliongei inuence ol lliclness
and in lle lalesl HSL and AP!,!SO ievision loi osloie sliucluies a liglei enally lacloi ol
q 0.30 is given.
2.2. Teciangular ana square hollow-seciion joinis
Tle consideiaLle lnowledge gained iegaiding lle slalic iesonse ol ciiculai lollow-seclion
joinls is unloilunalely nol diieclly liansleiaLle lo ieclangulai lollow-seclion joinls Lecause ol
mailed dieiences in lle Lelavioui ol lle lallei [13. Tle sliness disliiLulion in lle al sidewalls
is dieienl liom llal ol cylindiical slells and lle Liace coineis neai lo lle cloid walls lave a
sliong inuence on lle maximum sliess. !nleiesl in joinls ol llis lye las Leen conlned lo llose
made in sleel [14 and iecommendalions lave Leen made on lle seleclion ol lol sol sliess
delnilion, aiameliic equalions loi SCFs and on aioiiale SN cuives loi RHS joinls [15. !n
conliasl, slalic sliess and laligue guidance loi RHS joinls in aluminium aie aLsenl in lle lileialuie
and lillle dala exisls. Some laligue lesl iesulls lave Leen ieviewed [16, Lul lle dala aie nol analysed
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 118
ig. 2. olcl lol sol sliess [17.
in leims ol local oi lol sol sliess, Lul llese dala nonelleless indicale llal a design lol sol sliess
iange (AT value) ol 40 MPa would Le alicaLle lo welded squaie lollow-seclion joinls.
2.3. The hoi spoi siress concepi appliea io plaie joinis
Recenl laligue design guidance loi welded delails in sleel sli sliucluies [17, and similai
guidance loi aluminium slis [18, lave in Loll cases adoled a lol sol sliess aioacl. Tlis is
due mainly lo lle geomeliic comlexily ol lle inleinal lull sliucluie ol modein slis llal males
il dimcull lo delne nominal sliesses. Tle guidance lavouis lle maximum local sliess al lle weld
loe (called lle nolcl sliess) ovei lle exliaolaled geomeliic sliess desciiLed eailiei; see ig. 2. Tle
eecl ol lle local weld geomeliy is lleieloie included in lle nolcl sliess, diclaling llal lle same
eecls aie excluded liom lle SN cuive, wlicl is consequenlly elevaled aLove llal loi a Lull weld
Ly a lacloi ol aioximalely 1.5.
Tle nolcl sliess concel is alliaclive in llal il is an aclual sliess, in conliasl lo lle lclilious
exliaolaled lol sol sliess alieady desciiLed. !n Loll iaclical and numeiical alicalions,
lowevei, lle nolcl sliess aioacl is ioLlemalic. Tle lwo mosl imoilanl aiameleis inuencing
lle sliess concenlialion lacloi loi lle weld aie liglly vaiiaLle along lle weld lengll, lle weld loe
iadius, r, and lle weld angle a, and llese aiameleis can only Le ieadily desciiLed in leims ol
slalislical disliiLulion. Tleieloie, in a deleiminislic lnile elemenl analysis lle vaiialions in r and
a cannol Le modelled, and some desciilive values (aveiage oi maximum) aie emloyed as delaull
values. !n lle DV iules loi welded sleel sli sliucluies [18 llese delaull values aie r,i 0.15
and a 45 loi Lull welds, wleie i lale lliclness. Similai ioLlems aie encounleied wlen lle
nolcl sliess is lo Le deleimined exeiimenlally liom sliain gauge measuiemenls since il cannol Le
measuied diieclly al lle weld Lecause lle sliain gauge would lave lo sliaddle lle weld loe. !nslead
an exliaolaled lol sol sliess is oLlained liom sliain gauges laced al dislances ol 0.5i and 1.5i
liom lle weld. To accounl loi lle sliess concenlialion eecl ol lle weld lle lol sol sliess is
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 119
ig. 3. Tle DV design SN cuives loi aluminium slis [18.
mullilied Ly a delaull SCF ol K
w
1.5 loi lle weld. Tlus lle DV nolcl sliess aioacl is
eeclively lle same as lle lol sol aioacl since a lacloi ol 1.5 is lisl alied lo lle SN cuive,
llen il is accounled loi Ly mullilying lle lol sol sliess Ly lle same lacloi ol 1.5.
2.4. Hoi spoi S curres for aluniniun joinis
!n lle DV guidance loi welded aluminium sli sliucluies [18 lwo SN cuives aie given loi
welded joinls (lliee cuives including one loi welded joinls in a coiiosive enviionmenl), as slown
in ig. 3.
Tle alied sliess iange is lle noich siress ranqe as delned in ig. 2. Cuive ! alies lo Lase
maleiial. Tle liglesl cuive loi welds (Cuive !!) ieiesenls Lull welds wlile lle lowei cuive, Cuive
!!!, wlicl also las a sleeei sloe (n3.37), ieiesenls lllel welds as low sliengll (ligl seveiily)
joinls. Cuive !V is loi welds in a coiiosive enviionmenl. Since lle sloe ol Cuives !! and !!! is
close lo lle value ol n3 in lle !!W guidance, coiiesonding SN cuives, claiacleiised Ly lleii
AT value (ATsliess iange al N210
6
) can Le oLlained liom lle DV cuives. Tle sliess
iange ol cuive !!! al 210
6
cycles is 45 MPa Lul llis includes lle K
w
lacloi ol 1.5 so lle
coiiesonding AT value Lecomes 45,1.5 30 MPa. Similaily, lle AT value ol Cuive !! is
55,1.5 37 MPa. Tlese cuives can now Le comaied will ollei cuives loi aluminium welded
joinls Lased on lol sol sliesses.
SN dala liom a laige numLei ol welded aluminium lale secimens will a vaiiely ol geomeliies
and in lliclnesses u lo 6 mm lave iecenlly Leen collecled [19 and analysed in leims ol lol sol
sliesses oLlained eillei liom sliain gauge measuiemenls oi liom lnile elemenl analyses. Tle
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 120
ig. 4. SN dala loi small M!G welded aluminium lale secimens [19.
iesulls lolled as lol sol sliesses aie summaiised in ig. 4. !l was concluded llal a weld calegoiy
cuive coiiesonding lo AT 40 would conslilule a conseivalive lol sol Lased design cuive loi
welded aluminium sliucluies.
!n lle !S lle Calegoiy B cuive in lle Aluminum Associalion Design Manual las iecenlly Leen
ioosed [20 loi use as a geneial design lol sol sliess Lased design cuive loi welded aluminium
joinls. Tlis is lle SN cuive loi longiludinal Lull welds. !n Luiocode 9 [11 and in BS 8118 [21,
lle lol sol sliess mellod is menlioned Lul no advice is given on lle cloice ol SN cuive.
Tle DV classilcalion nole loi slis [18 is lle only lnown code llal uses lle lol sol
sliess concel loi welded aluminium sliucluies. Howevei, Ly analogy will design codes loi sleel
sliucluies wleie lle lol sol sliess SN cuives aie neaily idenlical lo lle cuives loi lwo sided Lull
welds, SN cuives loi lol sol sliess laligue design can Le oLlained liom ollei codes. SN cuives
oLlained in llis way aie comaied in TaLle 1.
2[ Finite element analyses
Tle deleiminalion ol lle slale ol sliess exeiienced Ly weldmenls is ciilical in design, Lul
esecially so wleie lle lol sol sliess mellod is used. Aioiiale SCFs aie ivolal in analysis
exeiimenlal laligue dala loi eslaLlisling lol sol SN cuives and aie also ciilical in leims ol
ielaling sliucluial oi nominal sliesses lo lol sol sliesses loi use in laligue design. Tle woil
ieoiled leie is iimaiily ol an exloialoiy naluie and was lislly aimed al deleimining lle SCF
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 121
TaLle 1
PossiLle lol sol sliess SN cuives loi laligue design ol welded aluminium sliucluies
Souice Sliess iange Design Sloe, Commenls
al lwo million calegoiy n
cycles, S
2 mill
(MPa)
Luiocode 9 [11 35 Class 35 4.0 Cuive loi lwo-sided Lull welds
BS 8118 [20 35 Class 35 3.2 Cuive loi lwo-sided Lull welds
!!W [4 32 oi 40 al 32 oi 40 3.0 Cuives loi lwo-sided Lull welds
Slai el al. [20 46 AA Cal. B 4.75 Vaiious lyes ol welds
Pailanen and iemi [19 46 3.0 Vaiious lyes ol welds
Del oise Vaiilas [18 30 oi 37 Cuive !!! oi !! 3.37 oi 4.32 illel oi Lull welds, ieseclively
Kosleas and Giell, 1995 [16 40 3.5 Based on dala loi lollow seclion
joinls
loi welded aluminium RHS T-joinls, ig. 5, undei simle memLiane and Lending loading ol lle
cloid memLei, and secondly lo eslaLlisl an SN cuive loi llis joinl.
3.1. Deierninaiion of SCs
inile elemenl analyses weie eiloimed using lle !-Deas and ALaqus commecial codes. Tliee-
dimensional solid models weie used ieiesenling a quailei ol lle lesl secimen geomeliy Ly
emloying symmeliy lanes. Geomeliically lineai elasloslalic analysis ioulines weie used. Two
sels ol models weie used: !-Deas Lased modelling ol aiameliic vaiialions in local weld geomeliy;
ALaqus Lased analyses ol lle nominal weld geomeliy lo indeendenlly veiily lle SCFs deleimined.
Tle lwo seiies ol analysis seaialely emloyed 10-node lelialedial and 20-node Liicl elemenls.
Mesling iules suggesled Ly !!W [22 weie emloyed and lle sliesses loi exliaolalion weie
also exliacled in accoidance will llese guidelines in oidei lo mainlain consislency Lelween L
iediclions and exeiimenlal sliess analyses.
Tle lollowing nominal aiameleis weie used loi lle model: weld loe iadius, r 0.8 mm; weld
angle, a 45; weld llioal size, a 3 mm; luLe wall lliclness, i 3 mm. SuLjecled lo uie
Lending ol lle cloid memLei, a weld loe SCF value ol 1.93 was calculaled Lased on exliaolalion.
Tle sile ol maximum sliess along lle weld loe is localed neai lo lle coinei ol lle Liace memLei
lowaids lle sidewall ol lle cloid. An enliiely seaiale L analysis ol lle same geomeliy using a
dieienl iogiam and dieienl solid elemenls ioduced SCF values ol 1.86 in Lending and 1.51
undei memLiane loading.
3.2. Paraneiric siuay
!n an invesligalion ol lle sensilivily ol lle calculaled SCF lo aiameliic vaiialions in lle weld
and seclion geomeliy, lle loui aiameleis r, a, a and i weie syslemalically vaiied. !denlical luLe
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 122
ig. 5. Secimen dimensions.
geomeliies weie used on Liace and cloid memLeis in a given analysis and duiing vaiialion ol i
lle exleinal dimensions iemained conslanl. Tle loe iadius, r, was vaiied Lelween 0.33.0 mm; a
was vaiied liom 3555; a ianged Lelween 24 mm; and i was vaiied Lelween 23.5 mm. Slalislical
analysis ol lle iesulling disliiLulion ol SCF
:
(in llis case delning lle maximum sliess al lle weld
loe), Lased on Loll maximum iincial sliess and axial sliess comonenl, ievealed llal r and i
lave lle sliongesl inuence, wlile lle SCF is only a weal lunclion ol Loll a and a. Lxamles aie
given in ig. 6. Models llled lo lle dala ioduced lle eqns:
SCF
:
1.790.332a0.73ie
1r
0.33ia, (3)
SCF
s0
1.170.759a0.898ie
1r
0.16a, (4)
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 123
ig. 6. Lxamles ol aiameliic vaiialion ol SCF (iadius and loe angle).
will a in iadians and i, r and a in mm. Lqualion (3) ieleis lo lle axial (Z-diieclion) sliess
comonenl and eqn (4) ieleis lo maximum iincial sliess al lle weld loe. Tle Lounds invesligaled
(slaled aLove) sliiclly aly as limils lo llese equalions. Tlese models Lelave in a similai way lo
eslaLlisled liealmenls loi liansveise lllel welds in lale [23 Lul, as lle joinl undei consideialions
leie is Lelween lollow-seclions, lleie is sliiclly no valid Lasis on wlicl lo male a diiecl com-
aiison. Tle vaiialion ol SCF will Loll r and i is lolled in ig. 7 wleie il is cleai llal, as could
Le loieseen, comLinalions ol small weld loe iadius and laige weld angle, weld llioal and wall
lliclness lead lo ligl SCFs. !n ailiculai, comLinalions ol r and i lave mosl inuence.
3[ Fatigue tests
aligue lesling ol T-joinl secimens was eiloimed on a seiies ol loui secimen gious coveiing
lwo weld melals (4043 and 5183), and as-welded and imioved (loe-giound) weldmenls. Tle
secimen geomeliy, ig. 5, is idenlical lo llal sludied eailiei using L; lowevei,lle unloaded
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 124
ig. 7. SCF as a lunclion ol r and i.
Liace memLei was sloilened in oidei lo lacililale lesling. Tle aienl maleiial exliusions weie
6082.26-T5 aluminium alloy llal las seciled minimum lensile ioeilies ol 290 MPa yield
sliengll and 340 MPa ullimale lensile sliengll. Tle secimens weie loaded in 4-oinl Lending ol
lle cloid memLei. All lesls weie caiiied oul al T0.1 and undei conslanl amlilude condilions
using a 5 Hz sinusoidal waveloim. Tle nominal sliesses weie calculaled liom simle elaslic
Lending lleoiy loi lle loaded cioss-seclion. Tle lol-sol sliesses weie deleimined liom a simle
mullilicalion ol lle nominal sliesses Ly an SCF ol 1.83, deiived liom lle L woil desciiLed
eailiei. A limiled numLei ol secimens weie insliumenled will sliain gauges on lle cloid, localed
close lo lle anlicialed lailuie sile using lle !!W guidelines [4 in oidei lo measuie lle lol sol
sliain, ig. 8. A olynomial cuive llled lo lle sliain dala was lineaily exliaolaled lo lle weld
loe. Good agieemenl was lound Lelween lle lol sol sliesses Lased on exeiimenlal (SCF1.83)
and numeiical (SCF1.93) sliess analyses. Lnduiance dala geneialed in lle lesl iogiamme aie
given in TaLles 25, iesenled in leims ol Loll nominal and lol sol sliess ianges, using an SCF
ol 1.83.
Tle dala exliLiled no cleai deendence on lle lllei melal so llese dala weie comLined. Iineai
iegiession analysis ol lle lesl dala ioduced lle design lines (mean minus lwo slandaid devialions)
lolled in ig. 9: lle coiiesonding SN conslanls aie noled in TaLle 6.
Some dala aie availaLle in lle lileialuie [24 loi welded T-joinls in aluminium lollow iolles.
Diieclly ielevanl dala ieviewed Ly Kosleas and Giell [16 weie alieady exiessed as local sliess
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 125
ig. 8. Sliain gauge localions.
TaLle 2
Resulls liom laligue lesling ol as-welded 5183 lllei melal secimens
ominal sliess Hol sol sliess Lnduiance
iange (MPa) iange (MPa) (cycles)
102.9 188.3 94.920
85.7 156.8 212.804
85.7 156.8 227.709
85.7 156.8 190.277
68.6 125.5 604.644
68.6 125.5 101.775
68.6 125.5 254.133
68.6 125.5 299.678
68.6 125.5 343.000
51.4 51.4 1179.325
ianges Lul lle Hagslio m and Sandslio m dala lad lo Le ieevalualed in leims ol lol sol sliess.
Tlis involved eiloiming an L analysis on lle lesl geomeliy used (axial loading ol lle Liace) lo
gel an SCF value ol 4.4. Tlese dala aie all lolled in ig. 10 Lased on lol-sol sliess iange will
lle iesulls ol lle iesenl sludy loi as-welded joinls wleie il is cleai llal lle lol sol sliess aioacl
aeais lo Le eiloiming well in leims ol ieducing dala liom dieienl loading conlguialions lo
a common Lasis.
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 126
TaLle 3
Resulls liom laligue lesling ol loe-giound 5183 lllei melal secimens
ominal sliess Hol sol sliess Lnduiance
iange (MPa) iange (MPa) (cycles)
120.0 219.6 103.261
120.0 219.6 109.186
120.0 219.6 82.064
85.7 156.8 329.978
85.7 156.8 439.241
85.7 156.8 415.224
85.7 156.8 417.792
68.6 125.5 1908.639
TaLle 4
Resulls liom laligue lesling ol as-welded 4043 lllei melal secimens
ominal sliess Hol sol sliess Lnduiance
iange (MPa) iange (MPa) (cycles)
107.1 196.0 63.070
107.1 196.0 99.170
85.7 156.8 197.040
85.7 156.8 177.460
64.3 156.8 163.140
64.3 117.7 418.430
64.3 117.7 682.220
64.3 117.7 485.600
64.3 117.7 509.880
64.3 117.7 1712.630
TaLle 5
Resulls liom laligue lesling ol loe-giound 4043 lllei melal secimens
ominal sliess Hol sol sliess Lnduiance
iange (MPa) iange (MPa) (cycles)
137.0 251.2 62.948
128.0 234.2 134.566
120.0 219.6 164.859
120.0 219.6 142.772
85.7 156.8 725.352
85.7 156.8 802.964
85.7 156.8 497.596
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 127
ig. 9. aligue lesl dala liom welded RHS T-joinls.
TaLle 6
aligue lesl iesulls, SN conslanls loi mean and design lines
Tesl seiies SN cuives
Iog C S
2 mill
(MPa) n
As-welded, mean line 13.79 3.87
As-welded, design line 13.42 69.1 3.87
Toe giound, mean line 14.75 4.12
Toe giound, design line 14.46 95.5 4.12
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 128
ig. 10. Comaiison ol lesl dala will uLlisled iesulls, all aie design (mean2 SD) cuives.
4[ Proposed design methodology
Based on an evalualion ol lle uLlisled lileialuie, lle lollowing iecommendalions aie made
loi lle lisl veision ol a design mellodology loi welded aluminium sace liames made ol iec-
langulai lollow seclion joinls:
5.1. Defniiion of hoi spoi siress
!se lle !!W [22 delnilion.
5.2. Deierninaiion of hoi spoi siress by sirain gauge neasurenenis
!se lle !!W [22 exliaolalion ioceduie
5.3. Finiie eleneni analysis io aeiernine SCs
Deleimine sliess disliiLulion Ly lliee-dimensional analysis, deleimine SCFs Ly lineai exlia-
olalion liom lwo oinls on lle cuive in accoidance will lle !!W ioceduie. !se !!W [22
guidance loi LM analysis.
K.H. Macaonala, P.1. Haaqensen,Enqineerinq Failure Hnalysis 6 (1998) 113130 129
5.4. Paraneiric fornulae for SCs
!se equalions ioosed Ly van Wingeide el al. [14 loi RHS T- and K-joinls as ieliminaiy
guidance.
5.5. Hoi spoi siress aesign S curre
!se lle Pailanen and iemi cuive will a sliess iange al 210
6
cycles ol 40 MPa and a sloe ol
one-lliid. Tlis cuive is sligllly liglei llan lle ioosed DV cuives loi examle wlen coiiecled
loi lle dieience Lelween lol sol and nolcl sliesses.
5[ Conclusions
Many dieienl delnilions ol lol sol sliess iange exisl and aie used in lle laligue design ol
welded sliucluies. Tle guidance iecenlly uLlisled Ly !!W loi deiivalion ol lle lol sol sliess
liom sliain gauge measuiemenls and LM analyses aie iecommended loi use loi ieliminaiy
laligue design ol llin walled aluminium sliucluies.
Tle lol sol sliess SN cuives loi welded aluminium sliucluies in design iecommendalions
llal give secilc advice aie iemailaLly similai, aaienlly conveiging on a design laligue sliess
iange al lwo million cycles in lle iegion ol 3040 MPa.
Tle lol sol mellod aeais well suiled lo welded aluminium RHS joinls, lowevei, lle design
dalaLase needs lo Le exanded. Secilc aiameliic equalions loi SCFs need lo Le develoed (oi
adaled liom exisling mellodologies loi sleel sliucluies).
Paiameliic L analysis ol a T-joinl conlguialion undei in-lane Lending ol lle cloid slowed
llal comLinalions ol small weld loe iadius and laige weld angle, weld llioal and wall lliclness
lead lo ligl SCFs. !n ailiculai, comLinalions ol r and i lave mosl inuence.
Sliess concenlialion laclois deleimined liom sliain gauge measuiemenls and L analysis weie
in good agieemenl.
Acknowledgements
Tle aullois wisl lo aclnowledge lle assislance ol R. M. Ldvaidsen and R. Tiandum Loll ol
wlom made conliiLulions lo lle woil ieoiled leie as ail ol lleii M.Sc. llesis woil.
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