4102 - Chap 7 WLIT PDF

MAAE 4102
Strength & Fracture Analysis

Chapter 7
Weld Fatigue Life Improvement Techniques
Professor R. Bell
Department of Mechanical & Aerospace Engineering
Carleton University
2013
Chapter 7 - Weld fatigue Life
Improvement Techniques
Department of Mechanical &

Aerospace Engineering
Fatigue Strength of Weldments

Fatigue Strength of Steel is Reduced at Weldments
Fatigue Strength of Non-Welded Steel is Dominated by the
Crack Initiation Stage
Fatigue Life of Welded Steel is Dominated by the Crack
Propagation Stage due to;
Defects are initially present at the weld
The Geometric Discontinuity at the Joint
Residual stresses caused by the welding process
Fatigue Life of As-Welded Steel is Independent of Yield
Strength

Fatigue Strength of Weldments


Effect of Tensile Strength

g on the Fatigue
g
Strength of Steel


Typical TAPS Tanker Cracking Problems


Redesign of Weld Details


Weld Defects


Fatigue Life Improvement Techniques

Recover
Reco er the potential fatig
fatigue
e strength b
by
introducing a substantial crack initiation stage
Remove d
R
defects
f t
Improve weld geometry
Introduce favourable residual stresses
Fatigue Life Improvement Techniques have been
applied the Bridges, Offshore Structures and
Ships


Classification of Weld Improvement

p
Techniques
q


Weld Modification Techniques

Remove defects and reduce stress
concentration at weld toe by machining weld
surface
Burr grinding
Disk grinding
Water jet erosion

10

Burr Grinding

11

Burr Grinding Code Requirements
BS 7608, 1993

12

Abrasive Water Jet Toe Dressing

13


Advantages
g
Disadvantages
g
Relatively simple to
perform.
Large improvement.
Simple inspection criteria
((depth
p 0.020 in /0.5 mm
below plate surface or
undercut).
Applicable mainly to planar

joints that can be expected
to fail at weld toe.
May lose benefit if not
protected from corrosion.
All grinding techniques give
a poor working environment
regarding noise and dust.
Access to weld may be a
limiting factor.

14


q
Burr Grinding
g
Advantages
g
Disadvantages
g
Most effective of all grinding

methods with large and
repeatable improvement
benefit.
Equipment readily available.
Easier accessibility than
disc grinding.
Best for fillet welds
50 200% increase in
fatigue strength at 2x106
Very slow.
Expensive due to high labour
costs
high tool wear rate - many
consumables
consumables.
Difficult to maintain quality.
Surface scaling may reduce
benefit
cycles.
15


q
Disk Grinding
g
Advantages
g
Disadvantages
g
Very fast compared to burr

grinding.
Can cover large areas.
Equipment readily
available.
20 50% increase in
fatigue strength at 2x106
cycles
y
Score marks give lower

improvements than burr
grinding.
Improper use may introduce
serious defects - risk of over
grinding.
Restricted applicability due
to tool size

16

Weld Modification Techniques Water Jet Eroding
Advantages
g
Disadvantages
g
Very fast compared to other

fatigue improvement
techniques.
Good potential for
automation
Equipment not readily

available in most shipyards.
Difficult to control rate of
erosion - severe risk of over
abrasion.
Cleanup of water and
abrasive particles may limit
application

17

Weld Toe Remelting Techniques

Remelt Weld toe to remove defects, reduce
stress concentration at weld toe and increase
hardness of HAZ
Tungsten
g
Inert Gas (TIG)
(
) Dressing
g
Plasma Dressing

18

TIG Dressing Technique
(Haagensen 1991)
TIG Dressing
Modified TIG Dressing

19

TIG Dressing Technique

Position of TIG Electrode
( Kado et al 1975)
20

Improvements due to TIG Dressing
( Haagensen 1981)
21

Improvements
p
due to Plasma Dressing
g
( Shimada et al 1977)
22

Weld Toe Remelting

g Techniques
q
Advantages
Disadvantages
Large improvements possible .

Equipment readily available in
most shipyards. Suitable for
automation
TIG Dressing
Large improvements small
physical
h i l effort
ff t required
i d
inexpensive
Plasma Dressing
Easy to perform due to large weld
pool - Large improvementsSmaller risk of HAZ hardening
g
Operator need special training
Careful cleaning of weld and plate

necessary.
y Risk of local HAZ
hardening (cracking) in C-Mn
steels due to low heat input may
require a second TIG run
Careful cleaning of weld an plate
necessary

23

Special Welding Techniques

Fatigue Improvement introduced as part of the
welding process, therefore avoiding costly
post-weld
post
weld finishing
AWS Improved
p
Profile
Special Electrodes

24

Improved Weld Profile
(Improved Profile AWS 1985 )
Improved Weld Profile Results for

a 370 MPa Steel (Haagensen 1981)

25

(Improved Weld Toe Geometry

Kobayashi et al 1977 and Bignonnet 1987 )
(Fatigue Strength vs SCF for

Welds with Improved Electrodes
Kobayashi et al 1977 and Bignonnet 1987 )

26


27


28

Special
p
Welding
g Techniques
q
Advantages
Disadvantages
AWS Profile
Improvement is introduced in
welding process itself
Well defined inspection
process suitable for multipass welds
Special Electrodes
Easy to perform suitable
for small joints - Inexpensive
D
Defects
f
at toe not removed
d
Very large scatter in test results
due to weld toe effects
Consistent results if combined
with grinding or peening
Not suitable for small welds
Doubtful benefit small

improvement at best
Electrodes not widely available

29

Peening Methods
Introduction of compressive residual stresses
Blunts shape
p inclusions and defects and
smoothes the weld profile to reduce SCF
Shot peening
Hammer peening
Needle peening
Ultrasonic peening

30

Shot Peening
Small cast iron or steel shot is propelled against the surface
by a high velocity air stream. Shot size 0.2 1.0 mm,
velocity 40 60 m/s
Yielding of surface build up residual stresses of 70-80% of
yield stress
Effectiveness of shot peening measured by Almen strips
attached to the surface. The curvature of the strip gives a
measure of the intensity of the peening
100% coverage is when the dimple just overlap
Most effective on high strength steels
33% improvement in fatigue strength at 2x106 for yield
strengths of 260 -390 MPa
70% improvement in fatigue strength at 2x106 for yield
g
of 730 - 820 MPa
strengths
31

Improved Profile and Shot Peening
Bignonnet et al 1984)
32

Hammer Peening
Carried out manually using a pneumatic hammer at
approx 5000 blows/min
Hemispherical bit , 6 18 mm dia
Feed rate 25 mm/s, 4 passes for optimum application
Introduces large
g compressive
p
stresses, reduces SCF
by modifying weld toe geometry
Works best on high strength steels
Disadvantage
Di d
noise,
i
vibration
ib i

33

Hammer Peening
Tool Position for Hammer

Peening ( Haagensen
and Maddox 1995)
Improvement in Fatigue Strength due to Hammer

Peening (Booth 1977)
34

Ultrasonic Impact
p
Peening
g
Equipment consists of a
magneto constriction
transducer, a ultrasonic wave
transmitter and a peening tool
Single of multiple tool
vibrating at 27KHz
Single pass at rate of 0.5m/s
0 5m/s
Weld toe deformed 0.5 0.7
mm which introduces
compressive residual stresses
Improvement of 50 200%
Chapter - Weld fatigue Life

Improvement Techniques7
35

Peening
g Techniques
q
Advantages
Disadvantages
Shot Peening
Large Improvements best
with high strength steels
Well developed procedures.
Covers large areas.
Improves resistance to
stress corrosion cracking
Simple methods of quality
control Almen strips
Not suitable for low cycle (high

t
) applications
li ti
stress)
Beneficial effects may
disappear under variable
lit d lloading
di
amplitude
Special equipment required.
Messy
Best suited for mild notches
and localized areas with good
access

36

Peening
g Techniques
q
Advantages
Disadvantages
Hammer Peening
g
Good repeatable benefits best
with high strength steels
Equipment readily available
Simple inspection criteria
depth of groove (0.06 mm)
Noisy and tedious

Limited to toe treatment only
Excessive peening may cause
cracking
Needle Peening
Similar to hammer peening but
benefits less established
Similar to hammer peening
Ult
Ultrasonic
i Peening
P
i
Similar to hammer peening
without noise and operator
fatigue
Special equipment required

37

Stress Relief Methods

Remove tensile residual stresses at weld toe and /
or introduce compressive residual stresses
Spot Heating
Thermal Stress Relief (PWHT)
Vibratory Stress Relief
Gunnerts Method
Explosive Treatments

38


Thermal Stress Relief PWHT
Removes residual stresses
Tempers the microstructure

Residual stresses are relieved by the component at
frequencies near to the resonant frequency
Method not proven for welded structures
Vibratory
Vib t
stress
t
relief
li f ttechniques
h i
may use up a
considerable portion of the fatigue life

39

Stress Relief Methods Spot Heating

Spot heating involves local
heating to produce local
yielding
Residual stresses are
produced both tensile and
compressive
The compressive stresses
are used to improve fatigue
Expected path of crack
should pass through the
centre of the spot

40

Stress Relief Methods Spot Heating

41


Gunnert
Gunnerts
s Method
Requires local heating to cause plastic deformation
Eliminates exact positioning of the spot
Surface is rapidly cooled by jet of water
Rapid cooling causes compressive stress to form in
surface layers
Explosive Treatments
Based on premise that loading of this nature will induce
a stress state in the weld metal that is opposite to that
produced by the welding process

42

Explosive Treatment
(Petushkov 1993)
43

Stress Relief Techniques

q
Advantages
Disadvantages
PWHT
Doubtful benefit. Limited
applicability to large components
Well characterized
S
Spott Heating
H ti
Good repair technique. Best for
large plates
Gunnerts Method
Not necessary to know initiation
site. Strict temp control not
needed
d d
Doubtful benefit. Limited

applicability to large components.
Special equipment needed
Only very localized areas. Not
effective on transverse welds. Vert
thick plates require
req ire e
excessive
cessi e
energy
Special equipment. High temp
(550oC). Cooling must be localized

44

Overloading Techniques
Introduce compressive residual
stresses by loading the material
at the weld toe above the yield
stress
Local compression
Local yielding introduced by
compression between circular
dies
Prior static loading

The efficiency of this method
depends on the value of the
overload stress, the joint type
and the stress ration of the
cyclic loading

45

Overloading
g Treatments
Advantages
Disadvantages
Local Compression
Good benefits for high
strength steels
repair technique
Prior Static Overload

Good benefits for high
strength steels
Applicable to cracked
structures
Specialized equipment needed

Access to both sides of plate
required
Only suitable for localized
areas
Last chance technique
Enormous loads required for
full size structures
Application limited to small
components

46

Comparison of Techniques
Burr Toe and Disc Grinding (Knight 1978)

47

Effect of Free Corrosion in Seawater on Fatigue Strength

Of As-welded and Ground Specimens (Booth 1978)
48

Effect of Seawater Corrosion on the Fatigue Strength

of As-welded
As welded and TIG Dressed Specimens (Haagensen 1981)
49

Effect of Improvement Methods on High Strength Steels

(Shi d ett all 1977)
(Shimada
50

Effect of Improvement Methods Applied to Mild Steel

Transverse Non-Load-Carrying Fillet Joints (Booth 1981)
51

Effect of Improvement Methods Applied to Mild Steel

Longitudinal Non-Load-Carrying Fillet Joints (Booth 1981)
52

Combining Improvement Techniques
Improvement Using Grinding

and Hammer Peening
(G rne 1968)
(Gurney

53

Combining Improvement Techniques
Comparison of As-welded, Toe Ground, Repaired and Ground

and Hammer Peened Specimens (Haagensen 1993)
54

Offshore Design Codes

References:
See end of Chapter 8 notes
T. Gurney, Fatigue of welded Structures, Cambridge University
Press, 2nd Ed. 1979.
I. Lotsberg and H. Andersson, Section, Fatigue Design Handbook
(Ed. A. Almar-Naess), Tapir Publishers 1985.
AWS d1.1 (1983), Structural Welding Code, American Welding
Society

55

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MAAE 4102

Strength & Fracture Analysis

Department of Mechanical &

Fatigue Strength of Weldments

Department of Mechanical &

Fatigue Strength of Weldments

Chapter 7 - Weld fatigue Life

Department of Mechanical &

Effect of Tensile Strength

Chapter 7 - Weld fatigue Life

Department of Mechanical &

Typical TAPS Tanker Cracking Problems

Chapter 7 - Weld fatigue Life

Department of Mechanical &

Redesign of Weld Details

Chapter 7 - Weld fatigue Life

Department of Mechanical &

Chapter 7 - Weld fatigue Life

Department of Mechanical &

Fatigue Life Improvement Techniques

Chapter 7 - Weld fatigue Life

Department of Mechanical &

Classification of Weld Improvement

Chapter 7 - Weld fatigue Life

Department of Mechanical &

Weld Modification Techniques

Chapter 7 - Weld fatigue Life

Department of Mechanical &

Chapter 7 - Weld fatigue Life

Department of Mechanical &

Burr Grinding Code Requirements

Chapter 7 - Weld fatigue Life

Department of Mechanical &

Abrasive Water Jet Toe Dressing

Chapter 7 - Weld fatigue Life

Department of Mechanical &

Weld Modification Techniques

Applicable mainly to planar

Chapter 7 - Weld fatigue Life

Department of Mechanical &

Weld Modification Techniques

Most effective of all grinding

Department of Mechanical &

Weld Modification Techniques

Very fast compared to burr

Score marks give lower

Chapter 7 - Weld fatigue Life

Department of Mechanical &

Weld Modification Techniques Water Jet Eroding

Very fast compared to other

Equipment not readily

Chapter 7 - Weld fatigue Life

Department of Mechanical &

Weld Toe Remelting Techniques

Chapter 7 - Weld fatigue Life

Department of Mechanical &

TIG Dressing Technique

Modified TIG Dressing

Department of Mechanical &

TIG Dressing Technique

Department of Mechanical &

Improvements due to TIG Dressing