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This paper was presented at the 18th Annual OTC in Houston, Texas, May 5-8, 1986. The material is sUbject to correction by the author. Permission
to copy is restricted to an abstract of not more 1!.1arL~Q.o_.w~as. ~. ,,'. - - ... _. '-C - • :. _.~~_ . _._--=-:._..
Fatigue test results can be presented as S-N To calculate the stress intensity factors the
lines (Wohler-lines). For designing against fatigue formulae for a semi-elliptical crack in an infinite
failure these S-N lines can be used. plate are basically used. The influence of the weld
This presentation and analysis is completely based geometry is taken into account using a magnification
on experiments and gives only information' about 'the factor. For the crack propagation of the semi-
fatigue life for the specific detail and material. elliptical crack, Paris' law (equation 1) is applied
in two directions with a possible reduction factor
By using fracture mechani~s the fatigue crack for the surface crack growth. The fact that smaller
growth in an arbitrary structural. detail can be cracks grow faster is simulated by an additional
calculated. Furthermore the remaining fatigue life crack length.
of a cracked structure can be calculated.
The fatigue crack propagation rate"
o'f the material
can be derived by standard fatigue tests. CRACK' GROWrHASPECTS . AND cALcuLATION PROCEDURE
This means that basically fracture mechanics is a
more powerful tool to handle fatigue problems. In this section the different aspects of the
crack growth calculation for the simplified geometry
The fatigue crack growth can be calculated are discussed. The calculation procedure is .treated
using relations giving the fatigue crack propagation at the end of this section.
rate as a function of the stress intensity" factor
range. A variety of these relations are" given in
literature. The relation given by Paris is the most
elementary one and can in most cases be applied The crack growth calculation model is developed
sa tisfactorily. for a semi-elliptical crack at the weld toe of a
continuous plate to which an attachment is welded
da m
dN = c( L\K) • • • • • • • • • • • • • • (1) (figure 2). The continuous plate can be seen as the
chord wall of a tubular joint and the attachment as
the brace wall.
References and illustrations at end of paper.
573
2 THE CALCULATION OF FATIGUE CRACK GROWTH IN WELDED OTC 5352
TUBULAR JOINTS USING FRACTURE MECHANICS
The fatigue loading on the continuous plate Stress intensity factors for a semi-elliptical crack
causes the semi-elliptical crack to propagate. The ----------------------------------------------------
attachment is not loaded, so the welds are non load In order to calculate the crack extension using
carrying. equations 2, the stress intensity factor range for
This seems to be contradictory to the situa~ion in a both directions must be known. The ranges follow
tubular joint where the stresses are introduced by from the stress intensity factors at maximum and
the loading in the brace also. However, finite minimum loading during one cycle.
element calculations of the stresses at the vicinity
of the weld toes [1], showed that the stress The stress intensity factor solutions for a
situation at the chord weld toe is mainly determined semi-elliptical crack in a plate subjected to
by the forces in the chord wall and is hardly tension or bending forces are evaluated by Scott and
affected by the stress situation in the brace wall. Thorpe [3]. For the crack tip at the deepest point
The same applies for the brace weld toe in relation of the crack (6 '" 11/2) and for the crack tip at the
to the forces in the brace- and chord wall free surface (6 '" 0) they can be expressed as:
respectively.
Therefore, the crack growth at a weld toe, which is
for the larger part caused by the stress situation
in the wall of the relevant member of a tubular
joint, is comparable with the situation of the
simplified geometry given in figure 2. (J
m + M-
--b(o)
P.?-=_~!~~~_J.>!~R~~.!:~~!~.!:=_
where:
The fatigue crack growth of the semi-elliptical a '" crack depth.
crack can be described by applying Paris' law
(equation 1) in the two directions of the principle = the elliptical integral of _the second
axes of the elliptical crack: kind which can be approximated by:
575
4 THE CALCULATION Ol?FATIGUE CRACK GROWTH IN WELDED OTC 5352
----------
TITRITT.AR .TllTNTS
-“+ . . ..-
TISTN(2
-------
17RAP7’ITRR
.+-. ”----
MR(WANTCS
------------
6. Calculation of the new crack size and number of 25 mm depth the deviation is quite large, whereas
cycles to be used as new starting point: until this depth the difference is neglectible.
This implies that we may expect that the crack
=ai+Aa growth model describes the actual crack depth less
ai
accurate after a depth of 25 mm.
ci=ci+Ac
The stress situation
.--.----—-------—
=Ni+AN. . . . . . . . . . . . (12)
Ni
The stress range (Ao), relevant for the crack
growth calculations, is given by the so called hot-
7. Repeat the steps 2 to 6 until one of the required spot stress range (AUHs) as defined in reference
limits for a, c or N is met. [8]. This because for tubular joints, this hot-spot
stress range is the nominal stress range caused by
The accuracy of the crack growth calculation is the section forces in the chord wall, without the
dependent on the crack size increment and thus the stress raising effect of the weld geometry.
factor f. It was found that for f is about 0.02
accurate results were obtained with moderate This hot-spot stress range (AaHS) can be
computer costs. derived from the hot-spot strain range (AsHs)
determined from strain gauge measurements on the
specimen, by multiplying by Youngs’ modulus (E).
TNE CALCULATIONSFOR VERIFYING THE M3DEL Moreover due to the bi-axi.al stress state at the
hot-spot the results must be raised about 10% for
General
------- this type of joint. This means that the relevan
-k
stress range (Au) for B3 having a ASHS of 588*1O
In order to verify the fatigue crack growth follows from:
calculation model described in the previous
sections, crack growth calculations were carried out
for a fatigue tested tubular welded joint of which ‘u = ‘“lO*E*A&HS =
detailed crack growth data were available. The s I.10*0.21*106*588*10‘6 ~ 135 [N/mm2] (13)
crack growth data of this specimen (B3) were
obtained from the crack marks which were introduced For the crack growth calculations it is neceaaary to
during testing. The specimen B3 is one of the know which amount of Au is the bending stress range
fatigue tested specimen of the second phase ECSC (Aub) part and which amount is the tensile stress
offshore research programme [7]. The fatigue range (Aum) part. Finite element calculation and
results of B3 have also been reported in an earlier photo-elastic tests for this type of joint [12]
OTC paper [8]. The crack growth are reported indicate that the ratio of the tensile and bending
separately [9]. stress at the chord wall can be esttmated as:
Using this modification, the Mk-value at the The resulting crack growth in depth (a) and in
free surface is 2.1 which is in agreement with the length direction (c) is plotted in figure 8 and 9
local stress concentration factor of about 2 - 2.5 respectively. The stress intensity factors and
determined by strain gauge measurements [8] for the crack shape (a/c) are plotted in figure 10 and 11
ground specimens. respectively as a function of the relative crack
For specimen 13, 14 and 15 the unmodified 45” line depth (a/t).
is used.
The crack mark measurements for the toe ground
Material constantsfor the crack mova~ation rate situation are also given in figure 8, 9 and 11.
For the as-welded situation the moment of. crack
The rate of crack propagation given by the through (given by the number of cycles adjusted
equations 2 is dependent on the material constants C according to equation 16) is plotted in figure 8 for
and m. Based on crack propagation tests on welded the three test specimens (13, 14 and 15).
specimen Maddox [13] concluded these constants for
the average crack propagation rate to be:
DISCUSSIONOF THE RESULTS
C= 1.08 * 10’13 (units: N, mm)
The crack growth for the ground situation
-----------------------------------------
m = 3.07 . . . . . (171
up to a fatigue life of 1000 kc the both
calculations for the ground situation (I, II) hardly
The El Haddad correction
------------------------ differ from each other and from the actual measured
crack growth data. This means that an El Haddad
The additional crack length 10 as suggested by correction or an initial crack size of 0.25 mm
El Haddad ia depending on the threshold stress results in equivalent crack growth. Moreover this
intensity factor (AKth) and the fatigue limit (Aue) estimate of 0.25 mm leads to crack growth results
according to equation 6. Both are to be considered that fit the actual crack growth data quite well.
as material constants but quite difficult to obtain
from tests. Garwood [14] arrived at the following For the fatigue life over 1000 kc the results
average threshold value for mild steels: of calculation 11 are in good agreement with the
-3/2 actual crack growth data. Calculation I does agree
AKth=240-175R[Nmm ] . . . . . ..(18) with the actual crack growth in depth direction
also, but overestimates the crack growth in length
The load ratio (R) of the specimen B3 was O but due direction. So,it seems that using the crack growth
to residual stresses even after grinding this value reduction factor Fc in II leads to better results.
will be higher. Estimating the stress ratio (R) at
the weld toe for this case at 0.35 leads to: At the end phase of the fatigue life both crack
-3/2 growth calculations give a fatigue growth which is
AKth - 180 [Nmm ] . . . . . . . . . * ..(19). more than measured. Possibly, at this stage the
crack size is such that redistribution of the load
The fatigue limit (AcI) for the material with the carrying area’s of the joint is overcompensating the
same surface conditio?is as at the weld toe is reduction of the net section originally carrying the
approximately: load. Fortunately the crack growth model gives a
conservative prediction of the crack growth.
Aoe = 200 [Nmm-2] . . . . . .=. . . . . . . (20>
Recapitulating the results of calculation II,
These values substituted in equation 6 leads to the it can be concluded that the crack growth model
following estimation: predicts the actual crack growth very accurately up
to 80% of the fatigue life (crack through) and
1g)2=0.25[mm] . . . . . . . .. (21) beyond that stage the model tends to be conservative
10 ‘F (200
(overestimating the crack growth).
It is mentioned here that this value is only a rough
estimation because the values AKth, Aae and R for The crack growth for the as-welded situation
--------------------------------------------
the situation at the weld toe are not very well
known. The comparison of calculation III with the
results of specimens 13, 14 and 15 in the crack
The crack growth calculationresults
------------------------------------ depth direction (see fig. 8) shows a rather good
agreement between calculation and experiments. The
Two crack growth calculations for the ground experimental results in the crack length direction
weld toe are carried out. Calculation I differs from (not presented here) vary for the three specimens.
calculation II by the fact that instead of the El In general the measured crack length is larger than
Haddad correction (l.) an initial crack of the same the calculated length. It is supposed that a part of
size is assumed and by the fact that no reduction the discrepancy can be explained by multi-
(Fc) for the crack extension at the free surface is initiation. So, although the model predicts the
applied. ~is in order to study-the effect of these fatigue life of as welded specimens rather well, the
two refinements. crack length prediction is probably disturbed by
For the as-welded situation a third calculation multi-initiation.
(III) is carried out. The input of the three
calculations is summarized in table II.
6 THE CALCULATION OF FATIGUE CRACK GROWTH IN WELDED OTC 5352
TUBULAR JOINTS USIN{ ?.ACTUREM?,CHANICS
The crack growth calculation for the ground The work described in this paper was carried
situation of B3 (talc. II) differs from the out for the bridge department of the Dutch
calculation for the as-welded situation (talc. III) governamental organisation “Rijkswaterstaat”. The
only by the fact that the Mk-value is modified for authors wish to thank Rijkswaterstaat for their
small crack depths (see figure 5). By comparing the permission to publish this paper.
results it is evident that the influence of the Mk-
values is quite substantially.
REFERENCES
Nevertheless there are a some uncertainties
about the M -values. [11 DeIft, D.R.V. van. : “A two dimensional
First of a5 1 the Mk-values are determined for a analysis of the stresses at the vicinity of
constant depth surface crack (a/c = O) instead of a the weld toes of welded tubular joints”.
semi-elliptical crack. TH-Stevin report 6-81-8, June 1981.
Furthermore the values presented by Maddox are for a
tensile loaded plate. It may be expected that in [2] Raju, 1.S.; Newman, J.C. : “An empirical
case of bending the ~-values are different. stress-intensity factor equation for the
And the influence of the radius at the weld toe is surface crack.” Engineering Fracture
not investigated. Because of this it is likely that Mechanics, Vol. 15 (1981), pp. 185-192.
calculations With this model will show less
thickness effect than in reality. [3] Scott, P.M.; Thorpe, T.W.: “A critical review
This means that, although the model describes the of crack tip stress intensity factors for
early stage of crack growth for the verified cases semi-elliptic cracks”. The Int. Journal
very well, research on the Mk-value is of major “Fatigue and engineering materials and
importance. structures”. 1981, Vol. 4, No.4, pp. 291-309.
A simple crack growth model for a tubular joint [7 De Back, J., Vaessen G.H.G., et al.: “Fatigue
based on fracture mechanics is developed in which: and corrosion fatigue behaviour of offshore
steel structures”. ECSC convention 7210 -
The welded connection of the brace- and chord wall KB/6/602 (J.7.lf/76), Delft, Apeldoorn, 1981.
is schematized to a plate with an attachment.
At the weld toe location, a semi-elliptical crack [8] Dijkstra, O.D. and Noordhoek, C.: “The Effect
is assumed. of Grinding and a Special Weld Profile on the
Stress intensity factors for depth and length Fatigue Behaviour of Large-Scale Tubular
directions are calculated using formulae collected Joints.” OTC 4866, 1985.
from literature.
For the crack propagation, Paris’ law is applied [9] Noordhoek, C.; Verheul, A.: “Comparison of the
in two directions with a reduction factor for the ACPD-method of in-depth fatigue crack
crack propagation at the free surface. monitoring with the crack front marking
An additional crack depth of 0.25 mm is added for technique.” Delft,1984.TH-Stevin rep. 6-84-13.
short cracks.
[10] De Back, J., Vaessen G.H.G., et al.: “Effect
This crack growth model is verified by comparing the of plate thickness, temperature and weld toe
the results, with actual crack growth in a fatigue profile on the fatigue and corroston fatigue
tested tubular joint. The calculated crack shape and behaviour of welded offshore structures”.
crack size as a function of the number of load ESCS convention 7210-KG/601 (F7. 4/81), Delft,
cycles are in accurate agreement with the measured Apeldoorn, May, 1984.
crack growth data of a toe grounitubular joint.
The calculated fatigue life of en as-welded joint is [11 Dijkstra, O.D. and de Back, J.: “Fatigue
also in good agreement with test results. strength of tubular T- and X-joints”.
OTC 3696, 1980
OTC 5352 D.R.V. van DeIft; O.D. Dijkstra; H.H. Snijder 7
[12] Clayton, A.M.: “Effect of weld profile on [14] Garwood, S.J.: “Fatigue crack growth threshold
stresses in tubular T-joints”. Interim - a simple estimation technique.” The Welding
Technical report UKOSRP 2/03. Instit-uteResearch Bulletin, 1979.
[13] Maddox, S.J.: “A fracture mechanics analysis [15] I&ft, D.R.V. van, Noordhoek, C. and Back, J.
of the fatigue behaviour of a fillet welded : “Evaluation of the European Fatigue Test
joint.” Welding Research International., Vol. Data on Large-Size Welded Tubular Joints for
6, No. 5. pp. 1-34. Offshore Structures”. OTC 4999, 1985.
TABLE 1 TABLE 11
CNACR GROWTR DATA FOR SPECIMEN B3 INPUT DATA FOR CRACK GROWTN CALCULATIONS
OBTAINED ET CRACK MARKING
-—-
579
n8RME
WALL
/“1
GJJJB.AL
WELD AffiLE
.LOCAL:
.
WELO AN6~
%. \
%Q CRACK
RME
CHORO
&~.
Fig. 1—Tubular T-joint with fatigue crack at hot spot. Fig. 2-.Slmplified geometry for crack growth model.
0.0
f.5 -
alc=f’o alc.l. o
alc .0.1
z
CIIC=O .02
z
~ t
o o 02 0.4 06 08 1
alt
a/,
A
0
F+
,
u
—.—. +. —. —.. .
F
(l/f —-
t“’’’””’’’’’’’’’”” i
35 ~ A
A
30:
25~
E 20:
E 111
15:
10:
5: A CRRCK MRRKS
I
o 500 1000 1500 2000
NUHBER OF CYCLE3 (KC] _
“w
x
;
“m
“m
“0