Weld World (2013) 57:495–506
DOI 10.1007/s40194-013-0043-5
RESEARCH PAPER
Fatigue strength behaviour of stud-arc welded joints
in load-carrying ship structures
Wolfgang Fricke & Didi Deflor Tchuindjang
Received: 22 October 2012 / Accepted: 8 March 2013 / Published online: 28 March 2013
# International Institute of Welding 2013
Abstract The application of stud-arc welding to cyclic
loaded primary ship structures was investigated. Thereby
M8- and M12 studs were welded on the bulb of Holland
profiles using the drawn stud-arc welding with ceramic
ferrules. Several fatigue tests were performed, varying the
stiffener size, the stud diameter, its position on the bulb,
the welding position, weld parameters, residual stress
state and the static load in the stud. The obtained fatigue
strength is above FAT 80 and only slightly affected by
these factors. Hence, the investigated stud-arc welding
can be applied at Holland profiles in primary ship struc-
tures, provided the quality criteria are met. In order to
transfer the results to other geometries and load situa-
tions, the applicability of the effective notch stress ap-
proach was investigated. The corresponding finite
element calculations using idealized weld shapes and a
reference weld toe radius of 1 mm showed an insignifi-
cant influence of the weld geometry on the notch stress.
The determined notch stresses for each test series was
above the design S-N curve FAT 225 for the notch stress
approach and make it also applicable to stud-arc welding.
Further computations were performed using the real weld
profile and the stress-averaging approach by Neuber,
showing similar results.
Doc. IIW-2360, recommended for publication by Commission XIII
"Fatigue of Welded Components and Structures".
W. Fricke (*) : D. D. Tchuindjang
Institute of Ship Structural Design and Analysis, Hamburg
University of Technology, Hamburg, Germany
e-mail: w.fricke@tu-harburg.de
Keywords Stud-arc welding . Fatigue strength . Bulb flat
profile . Effective notch stress approach
1 Introduction
Stud-arc welding in shipbuilding offers several advan-
tages with respect to production time and costs. These
are widely utilized during outfitting by fastening ca-
bles, pipes, ventilation ducts, insulation, etc. to the
ship structure. Normally, the fasteners are connected
with secondary structures such as the webs of stiffeners
as shown in the left part of Fig. 1 for the web of a
Holland profile.
However, it would be more advantageous to utilize the
flange or bulb of the stiffener for the connection. This raises
questions regarding the fatigue strength of the ship structure
and particularly of the relatively thick bulbs of the profiles,
which have to be clarified to avoid the risk of failure. In the
following, an overview about the results of a research pro-
ject is given, where fatigue tests have been performed with
component-like specimens (Holland profiles) containing
welded studs on the bulb surface.
Earlier investigations on welded studs showed de-
creased fatigue strength of the parent metal due to the
notch effect of the weld. Investigated were plates with
studs having diameters of 12, 16 and 22 mm. The
fatigue strength decreased with increasing stud diameter,
but recovered by post-heating [1, 2]. Furthermore, it has
been shown that the local weld geometry has only little
influence on the fatigue strength [1].
496
Fig. 1 Conventional (left) and
new arrangement (right) of pipe
fasteners below deck
Various investigations aimed at the shear strength of
the welded studs [3, 4] which are used as shear con-
nectors in steel-concrete structures. Some codes and
recommendations already contain the fatigue class
FAT 80 for welded studs on plates [5, 6]. However,
effects such as the thickness effects, which might be
relevant also in connection with the bulbs of Holland
profiles, or additional loads of the studs, are not yet
known. Furthermore, the applicability of the effective
notch stress approach [5] to structural members with
stud-welds has not yet been investigated which would
allow the transfer of results to other geometries and
load situations. The following investigations will focus
on these aspects.
Fig. 2 Test specimens with a
HP 200x9, b HP 100x6 and c
plate strip 54x6.1
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2 Preparation of the fatigue tests
2.1 Geometry and welding of specimens
The geometry of the test specimens is shown in Figs. 2
and 3. The studs were mainly welded in the downhand
welding position PA on the bulb of Holland profiles and
for comparison on plate strips with the common drawn
stud-arc welding process with ceramic ferrules. Two
additional series with welded studs in the vertical
welding position PC and in the overhead welding posi-
tion PE were also investigated to get knowledge about
the welding position effects on fatigue strength. Both
stud diameters M12 and M8 were chosen. Additional
Weld World (2013) 57:495–506 497

Fig. 3 Small test specimens for

stud load with d full and e
partial thread studs

effects on the examined fatigue strength were consid-
ered by varying the weld parameters, the transverse stud
position YB on the bulb and the residual stress state
(stress-relieved specimens). The chosen Holland profiles
HP200x9, HP100x6 and HP100x7 were made from
higher strength hull structural steel (see Table 1) and
the studs mostly from type DD (full thread stud) and
strength class 4.8.
The specimens of type (a), (b) and (c) aim at the
fatigue strength of the profiles and plates, whereas type
(d) and (e) aim at the fatigue strength of the studs
themselves. As also the stud from type PD (partial
thread stud) was used (specimen e) the influence of
thread at the transition stud to weld on the fatigue
strength of studs could be investigated.
During manufacture of the specimens, a simplified
production test with visual inspection and bend test
according to EN ISO 14555 [7] was performed—as
usual on shipyards—in order to ensure the weld quality.
Tested were the uniformity of the shape and the size of
the weld collar. Weld collars with irregular height due
to blow effects were accepted. Here, the collar had to
be completely closed around the stud which had to be
completely immersed. Also checked were the location,
length and angle of the studs which were within the
required tolerances. After fabrication test series and
specimens were codified as shown in Fig 4.
2.2 Material tests
The hardness and the microstructure of the stud-welds
were recorded. The hardness measurements were
performed for two rows per specimens (Fig. 5)
according to Vickers HV5. The first row ran along the
edge from the stud material through the weld to the
surface of the parent metal, whereas the second row ran
along the center from the stud through the weld to the
parent metal.
Figure 6 shows examples of the measured hardness
values along the center row 2 in Fig. 5 for different test
specimens with respect to the variation mentioned
above. Only row 2 is shown as the hardness values
between both rows 1 and 2 reveal insignificant differ-
ences. The highest values occur in the weld and in the
heat-affected zone (HAZ 2) between weld and parent
metal. The values of 200–400 HV are generally much
higher than in HAZ 1 between weld and stud, which is
due to the intensive heat transfer into the parent metal
[2]. Welding position effects on hardness are registered
in the HAZ 2 where the hardness values for the vertical
and overhead welding position PC and PE are higher
than those for the downhand position PA. The hardness
values in the weld and in HAZ 2 by welding with stud
diameter M8 are higher than those with M12 for the
investigated specimens.

Table 1 Material data of Holland profile, plate strip and stud materials

Steel grade Yield point ReH (MPa) Tensile strength Rm (Mpa) Elongation A5 (%) Charpy-V-notch

Temp (°C) Energy (J)

HP100x6 GL-A36 383 551 30 0 74–73–76

HP100x7 GL-D36 480 585 27 −20 53–56–50
HP200x9 GL-D36 452 537 35 −20 81–62–147
FL54x6.1 GL-A 335 428 27 –
M8 & M12 studs S235J2G3 428 520 22 –
498
Fig. 4 Test specimens nomenclature
In addition, the micro-structure was investigated at
micro-cuts of the weld. Figure 7 shows an example of
the micro-structure of a stud-weld between a M12 stud
and HP 200x9.
The parent metal of the Holland profile shows a ferritic–
pearlitic structure with recognizable lines due to rolling.
Both HAZ show a coarse-grained bainitic–martensitic struc-
ture together with some coarse-grained ferrite in HAZ 2
(weld–parent metal). The primary structure of the weld
metal appears mainly ferritic.
3 Fatigue tests
This chapter describes the fatigue tests where it has to
be distinguished between cyclic loading of the Holland
profiles or plates and that of the studs. The number of
test specimens for each test series is given in Tables 2,
3 and 4. The statistical evaluation of the fatigue test
Fig. 5 Macro-cut and hardness rows for a stud-weld with M8 studs
(row 1 along edge and row 2 in center)
Weld World (2013) 57:495–506
results was performed assuming a lognormal distribution
for fatigue lives. The slope exponent mcalc for each test
series from regression analysis is also given. In addi-
tion, the typical slope exponent m=3 of the S-N curve
for welded joints was adopted. The resulting character-
istic fatigue strength ΔσC for each test series at the
number of life cycles N=2·106 for probability of sur-
vival Ps =97.7 % was determined. Furthermore, the ratio
between the fatigue lives for Ps =90 and 10 % yields the
scatter ratio TN.
3.1 Performance and evaluation of the tests
The fatigue tests were performed with different resonance
testing machines in air and at room temperature. Constant
load amplitudes were applied. The test frequency was be-
tween 25 and 30 Hz.
A special problem of the tests was the crack detec-
tion and the failure criterion. The initial crack cannot be
detected visually due to the weld geometry. Therefore,
strain gauges were applied at the fatigue-critical loca-
tions to support the crack detection (Fig. 8). The mea-
sured strains were recorded during the tests. Figure 9
shows the strain history for an example, indicating an
early crack initiation and a long crack propagation
phase for stud-welds at Holland profiles.
In order to compare the fatigue test results for stud-
welds on Holland profiles and plates and to obtain
reasonable results for practical application, the approach
of a crack length 2c corresponding to the stud diameter
was chosen as failure criterion, i.e. 8 mm for M8 and
12 mm for M12 studs, see also the photo in Fig. 10.
Actually, the crack grew along the weld toe and became
visible when leaving it at its sides. Then, the length was
recorded using dye penetrant.
When reaching the crack length 2c corresponding to the
stud diameter, the fatigue test was stopped, and the actual
crack length 2c and depth a were memorized. For fatigue
tests where the crack length 2c did not fit with the assumed
failure criterion, the results were adjusted using the regres-
sion line in Fig. 10. The relation between the rate of change
of the crack length Δ2c with the number of cycles ΔN by
considering the nominal stress range and the fatigue test
results is presented in Fig. 10. The parameter on the
vertical axis is based on the Paris-Erdogan law, allowing
a linear relationship in the double-logarithmic scale to
be expected.
3.2 Fatigue tests with cyclic loaded Holland profiles
and plate strips
The fatigue tests with the specimens shown in Fig. 2
were performed with constant axial stress amplitudes in
Weld World (2013) 57:495–506
Fig. 6 Measured hardness for
selected specimens
the parent metal at the stud-weld. While it was possible
to subject the smaller Holland profiles HP 100x6 and
the plate strips to axial loads, four-point bending loads
were applied to the larger Holland profiles HP 200x9,
see Fig. 11. As shown in Fig. 11, two other series with
HP200x9 und HP100x6 and additionally loading of
studs were considered. The static axial stress in the
studs for both series was 273 N/mm2 and led to small
change of the stress ratio. The nominal stress in the
bulb or plate in line of the stud was taken as nominal
stress, being controlled by strain gauges.
All fatigue test results are plotted in the S-N diagram
in Fig. 12, being well above the characteristic fatigue
strength FAT 80 given in [5] and [6]. This means that
stud-welds on the relatively thick bulbs of Holland pro-
files show a satisfactory fatigue behaviour, which was
Fig. 7 Micro-structure of a stud-weld between HP 200x9 and
M12 stud
499
not expected in view of the thick bulbs. The investigat-
ed parameter variations did not show any significant
effect on fatigue. Tables 2 and 3 summarize the varied
parameters and the characteristic values of the S-N
curves derived from statistical evaluation. The calculated
slope exponent mcalc from regression analysis and char-
acteristic fatigue strength ΔσC at N=2·106 for 97.7 %
survival probability for each series is given. No correc-
tion with respect to the stress ratio was considered to be
necessary as the specimens are components in as-welded
state with fully developed residual stresses from rolling
and welding.
The scatter ratio TN between the fatigue lives for 90 and
10 % survival probability is rather small. The test results
confirm also the assumed slope exponent m=3. It is inter-
esting to see that stud-welds on Holland profiles show
higher fatigue strength than those on plate strips. The latter
may be slightly affected by the pre-deformation (bending) of
the plate strip.
The influence of the stud diameter is small; howev-
er, the M12 studs show a tendency towards smaller
fatigue strength. Another observation is that the series
with HP 200 show a better fatigue strength than those
with HP 100. Particularly the last series in Table 2
(H2M8_R_PA) shows a significantly higher fatigue
strength which is due to the different stud position. A
similar effect can be seen also for the M12 studs on
HP 200x9 (lines 5 and 6 in Table 3). More details of
the tests are documented in [8].
3.3 Fatigue tests with cyclic loaded studs
The fatigue tests with cyclic loaded studs were
performed with the small specimens shown in Fig. 3.
Stud fracture was assumed here as failure (see Fig. 13).
The nominal stress was based on the stress area of the
threaded studs M8 and M12. In addition, one test
series with partial thread studs, named PD, was tested.
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Table 2 Characteristic data of fatigue test with M8 studs and results of statistical evaluation (slope exponent mcalc, characteristic fatigue strength
ΔσC and scatter ratio TN)

Test series No. of Δσn (N/MM2) R m0 Δσc (N/mm2) TN for Δσc (N/mm2)
specimens for m=3 m=3 for m=3, TN =3

FLM8_M_PA: Plate strip with M8 stud, downhand 12 150.8–352.6 0 3.19 102.7 1:1.50 85.5
position PA
H1M8_M_PA: HP 100x6 with M8 stud, downhand 12 152.5–280.2 0 4.01 99.6 1:2.70 96.1
position PA
H1M8_M_PC: HP 100x6 with M8 stud, vertical 10 152.6–283.1 0 4.06 102.4 1:2.06 92.2
position PC
H1M8_M_PE: HP 100x6 with M8 stud, overhead 8 173.4–277.8 0 3.93 101.7 1:2.10 93.1
position PE
H1M8_M_PA_S: HP 100x6 with M8 stud, downhand 9 151.7–282.2 0 3.22 100.7 1:2.29 92.4
position PA and changed welding parameters
H1M8_M_PA_W:HP 100x6 with M8 stud, downhand 8 152.3–278.4 0 4.45 101.0 1:2.37 94.8
position PA and stress-relief annealing
H1M8_M_PA_ZA: HP 100x6 with M8 stud, downhand 10 189.6–216.0 ≈0.14 –a 91.5 1:3.65 94.6
position PA and additional loading of studs
H2M8_M_PA: HP 200x9 with M8 stud, downhand 9 239.1–250.8 ≈0.33 –a 128.8 1:2.24 118.1
position PA
H2M8_R_PA: HP 200x9 with M8 stud, downhand 9 215.2–265.7 ≈0.35 –a 138.9 1:2.63 132.3
position PA, stud near the moulded line
a
m not calculated because of small variation of load level

Table 3 Characteristic data of fatigue test with M12 studs and results of statistical evaluation (slope exponent mcalc, characteristic fatigue strength
ΔσC and scatter ratio TN)

Test series No. of Δσn (N/mm2) R mcalc ΔσC (N/mm2) TN for ΔσC (N/mm2)
specimens for m=3 m=3 for m=3, TN =3

FL_M12: Plate strip with M8 stud, downhand 11 151.8–352.4 0 2.99 94.8 1:1.62 80.2
position PA
H1M12_M_PA: HP 100x6 with M12 stud, downhand 10 173.8–242.4 0 3.17 99.4 1:1.74 85.6
position PA
H1M12_M_P_W: HP 100x6 with M12 stud, downhand 9 150.3–278.8 0 4.81 93.6 1:2.90 92.1
position PA and stress-relief annealing
H2M12_M_PA: HP 200x9 with M12 stud, downhand 8 214.7–264.0 ≈0.24 –a 116.4 1:2.49 109.3
position PA
H2M12_R_PA: HP 200x9 with M12 stud, downhand 9 169.1–281.7 ≈0.25 3.38 127.4 1:2.08 114.9
position PA, stud near the moulded line
H2M12_M_PA_S: HP 200x9 with M12 stud, downhand 8 182.4–253.0 ≈0.26 –a 113.3 1:3.18 113.0
position PA and changed welding parameters
H2M12_M_PA_ZA: HP 200x9 with M12 stud, 9 182.4–243.2 ≈0.34 –a 119.8 1:2.32 111.9
downhand position PA and additional loading of studs
a
m not calculated because of small variation of load level

Table 4 Characteristic data of fatigue test with cyclic loaded welded studs and results of statistical evaluation (slope exponent mcalc, characteristic
fatigue strength ΔσC and scatter ratio TN)

Test series No. of Δσn (N/mm2) R mcalc Δσc (N/mm2) TN for Δσc (N/mm2)
specimens for m=3 m=3 for m=3, TN =1:3

K_H1M8_DD: Small specimens, M8 stud, type DD 8 163.9–245.9 0.2 5.63 61.8 1:3.63 63.9
K_H2M12_DD: Small specimens, M12 stud, type DD 9 94.9–237.2 0.2 4.59 47.3 1:4.14 50.4
K_H2M12_PD: Small specimens, M12 stud, type PD 9 136.0–294.6 0.2 5.38 47.0 1:5.41 55.3
Weld World (2013) 57:495–506 501

The stress ratio was R≈0.2. Fracture occurred always at

the transition between the stud and the weld. Figure 14
shows all test results, which are well above FAT 36 specified
in [6]. Details of the statistical evaluation of the test series
are summarized in Table 4. The calculated scatter ratio TN of
the test series is rather large which can partly be attributed to
the irregular weld toe on the threaded studs.

4 Application of the effective notch stress approach

Another objective of the project was the application of the

Fig. 8 Applied strain gauges at the fatigue-critical locations on an HP
100x6 with M8 stud
effective notch stress approach to profiles and plates with
welded studs which was never tried before to the knowledge
of the authors. This would allow the transfer of results to
other geometries and load situations.
Decisive for the fatigue strength of a weld is the local
stress state at the weld toe or root. In the notch stress
approach, the local stress determined for the actual geometry
is considered as fatigue parameter. The real weld geometry
is idealized and the notch is fictitiously rounded with an
enlarged reference radius rref =1 mm to consider micro-
structural support effects [9]. The fatigue strength is
assessed with the notch stress computed with linear-elastic
material behaviour and an S-N curve corresponding to FAT
225 for steel [5].

4.1 Idealization of the weld shape

The local weld geometry of 14 selected stud-welds was

recorded with a laser scanner. The weld surface was mea-
sured by triangulation, creating a cloud of points. For ide-
Fig. 9 Typical strain history alization, sections were arranged around the stud (Fig. 15),
from which the following weld shape parameters were de-
rived being illustrated in Fig. 16:
hs Leg length in stud direction
ls Leg length in profile direction
Fig. 10 Relation between the
changes in the number of cycles
ΔN, crack length 2c and
nominal stress range Δσn
502
Fig. 11 Applied loads on Holland profiles and plate strips
θk Weld flank angle
rk Actual toe radius
rb Radius of weld collar
φ Transition angle to stud
rw Transition radius to stud (set to 1 mm for simplicity)
Figures 17, 18, 19 and 20 show the distribution of some
parameters within a sector of 60° around the fatigue-critical
positions of four stud-welds, two with M8 and two with
M12 studs. Zero degrees are the positions in longitudinal
direction of the Holland profiles. Each stud has two poten-
tial crack positions, thus yielding two curves in the figures,
denoted -1 and -2 in the designations below the figures.
The figures show remarkable differences, indicating the
irregularities of the weld shapes. Specimen H1M8_M_PA_19
shows large differences in the leg length hs in stud direction
(Fig. 18), which is due to blow effects, which means that the
weld collar is reinforced on one side.
For finite element modelling of an idealized weld
contour, the weld shape parameters are averaged within
Fig. 12 S-N diagram with fatigue test results for welded studs on
different Holland profiles and plate strips
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Fig. 13 Macro-cut with crack for a small specimen with M12 stud of
type PD on HP 200x9
the sector of 60°. When averaging all parameters, a
‘nominal’ idealized weld shape is achieved for M8 and
M12 studs. The values are summarized in Table 5,
including stud-welds on Holland profiles of the size
HP 200 and plate strips.
4.2 Finite element analysis of idealized stud-welds
The finite element analyses were performed with the
program ANSYS for the scanned welds using the ideal-
ized weld shape described above. The actual weld toe
radius rk was replaced by the reference radius rref =1 mm
for the effective notch stress approach [5, 9]. As
recommended in [10], a 20-noded solid element with
quadratic shape and an element size less than 0.25 mm
was chosen for the notch area. Remote areas were
modeled with tetrahedron elements.
Figure 21 shows the distribution of the max. principal
stress for a specimen with idealized geometry in and around
the notch area. The applied axial nominal stress of Δσn =
209 N/mm2 for this test specimen acts in the longitudinal
Fig. 14 S-N diagram with fatigue test results for cyclic loaded
welded studs
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Fig. 15 Scanned weld surface with sections for weld idealization
(0°=longitudinal direction of the bulb profile)
direction of the Holland profile HP 100x6 caused by the
load F in Fig. 11b). The notch stress can clearly be seen in
the reference radius.
Table 6 summarizes the idealized weld shape parameters
for the four scanned stud-welds described above as well as
the stress concentration factors. It can be seen that the
differences between the stress concentration factors for the
welded M8 studs as well as for the M12 studs are rather
small—in spite of the large geometrical differences. There-
fore, it is reasonable to define the idealized ‘nominal’ weld
shape parameters given in Table 5, which yield the stress
concentration factors in the last column of Table 6. Here, a
difference of about 10 % between M8 and M12 studs is
apparent, i.e. there is a size effect. For HP 200x9, stress
concentration factors of 2.49 and 2.8 for M8 and M12 stud
were determined.
4.3 Fatigue assessment with the effective notch stress
approach
The stress concentration factors for the idealized ‘nominal’
weld shapes were used to compute effective notch stresses
for all welded studs on Holland profiles HP 200x9 and HP
Fig. 16 Idealized weld contour and chosen weld shape parameters
503
Fig. 17 Distribution of the actual toe radii rk of four scanned stud-
welds (two for M8 and two for M12 studs, each with two crack fronts)
100x6 as well as on plate strips. These are plotted together
with the fatigue lives from the tests in Fig. 22.
It can be seen that all results except for one speci-
men are above the design S-N curve FAT 225 according
to [5]. This means that the effective notch stress ap-
proach is well suited for the fatigue strength assessment
of welded studs of the kind investigated here. This
allows the assessment also for different geometries and
load situations.
4.4 Finite element analysis of the real weld shape
In addition to the idealized weld shapes, also the scanned
real weld shapes were analysed with the finite element
method as the actual notch radii were partly far below
1 mm, see Fig. 17. The cloud of scanned surface points
was transferred into triangular planes forming the basis for a
finite element mesh.
In order to model the notch area with sufficient
fineness, the submodelling technique was utilized in
three steps. The submodels are loaded at the boundaries
by prescribed displacements taken from the superior
Fig. 18 Distribution of the leg length hs in stud direction of four
scanned stud-welds (two for M8 and two for M12 studs, each with
two crack fronts)
504
Fig. 19 Distribution of the leg length ls in profile direction of four
scanned stud-welds (two for M8 and two for M12 studs, each with two
crack fronts)
model. The agreement of the stresses at the boundaries
in the different models was controlled.
The average size of the triangles was less than 0.05 mm
in the notch area. The finite element mesh was modelled
using tetrahedron elements with quadratic shape function.
Figure 23 shows an example of the mesh together with
computed max. principal stress for a test specimen with M8
stud on HP 100x6. The applied axial nominal stress acts in
the Holland profile longitudinal direction. The most highly
stressed areas can clearly be identified, being located in way
of sharp notches.
For fatigue assessment, the basis for the effective notch
stress approach is utilized which can be related to Neuber
[11]. He proposed to average the stress over a substitute
micro-structural length ρ* perpendicular to the notch root as
illustrated in Fig. 24. An alternative to the averaging is the
fictitious enlargement of the notch radius by 1 mm proposed
later by Radaj [9]. For welds at steel, a substitute micro-
structural length of ρ*=0.4 mm was postulated.
The finite element analysis and stress averaging over ρ*
was performed for a total of six scanned stud-welds,
representing typical weld shapes investigated in the project.
Both fatigue-critical locations −1 and −2 were considered.
Table 7 summarizes the stress concentration factors obtained
Fig. 20 Distribution of the weld flank angle θk of four scanned stud-
welds (two for M8 and two for M12 studs, each with two crack fronts)
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Table 5 Weld shape parameters of idealized ‘nominal’ stud-welds
Stud hs [mm] ls (mm) rk (mm) rb (mm) θk (°) φ (°)
M8 2.0 1.5 0.2 1.0 86 14
M12 2.8 1.8 0.3 1.3 97 6
from the stress averaging over ρ* and from the aforemen-
tioned analysis with reference radius rref =1 mm.
The latter yields larger factors as the reference radius
rref =1 mm neglects the actual radius, i.e. it corresponds to the
worst case of actual zero radius in the approach by Radaj [9].
If this would have been added to rref =1 mm, smaller notch
stress concentration factors would be achieved. Insofar, the
values resulting from both approaches are comparable, which
means that the small toe radii do not affect the applicability of
the effective notch stress approach.
On the other hand, the finite element analysis of the real
weld shape offers the possibility to assess the effect of small
toe radii—of course with a correspondingly reduced fatigue
class—and to identify the most probable crack location. In
almost all six examples given in Table 7, the most critical
site (−1 or −2) was correctly identified.
In Fig. 25, the computed notch stresses with the
corresponding number of life cycles for the mentioned
specimens according to Neuber and IIW in Table 7 are
plotted in a S-N diagram. The resulting characteristic
fatigue strength with the standard scatter ratio TN =1:3
and m=3 for both approaches lead to a fatigue class
reduction of 16 %. This leads to the fatigue class FAT
200 regarding the Neuber approach.
5 Conclusions
The paper investigates the question whether the stud-arc
welding can be applied to cyclic loaded primary structures
Fig. 21 Cut-out and max. principal stress distribution of the idealized
weld for a specimen with M8 stud on HP 100x6
Weld World (2013) 57:495–506 505

Table 6 Idealized weld shape parameters and stress concentration factors for specimens with M8 and M12 stud on HP 100x6

Specimen name–crack front hs (mm) ls (mm) rk (mm) rb (mm) θk (°) φ (°) Kt (idealized shape) Kt (nominal shape)

H1M8_M_PA_02-1 1.95 1.90 0.29 0.7 86 −1.2 2.47 2.44

H1M8_M_PA_02-2 1.35 1.11 0.21 2.0 75 35.6 2.35
H1M8_M_PA_19-1 2.74 1.90 0.34 0.8 82 5.3 2.48 2.44
H1M8_M_PA_19-2 0.86 1.55 0.52 2.7 41 21.2 2.25
H1M12_M_PA_02-1 2.54 1.44 0.34 1.4 94 14.6 2.62 2.66
H1M12_M_PA_02-2 2.16 1.99 0.38 1.4 79 12.1 2.63
H1M12_M_PA_05-1 2.28 1.70 0.35 1.5 89 20.5 2.64 2.66
H1M12_M_PA_05-2 2.44 2.20 0.39 1.9 84 18.1 2.66

H1M8_M_PA M8 stud with HP 100x6 and downhand welding position PA, H1M12_M_PA M12 stud with HP 100x6 and downhand welding
position PA

of ships, especially to the relatively thick bulbs of Holland

profiles. The focus was on drawn stud-arc welding of M8-
and M12 studs with ceramic ferrules. Holland profiles of the
series HP 100 and HP 200 made of higher-tensile steel were
chosen from the ship structure.
The fatigue behaviour was investigated with extensive
fatigue tests. The main part concerned longitudinal loading
of the Holland profiles, varying their size, the stud diameter,
its position on the bulb, the welding position, weld param-
eters, residual stress state and the static load in the stud. The
different factors affect only slightly the fatigue strength
which is above the fatigue class FAT 80 referring to nominal
stress. The failure criterion chosen was a crack length equal
to the stud diameter. Furthermore, fatigue tests were
performed with a cyclic axial load on the studs, showing
fatigue strengths above FAT 36.
Fig. 22 S-N diagram based on effective notch stress with fatigue test
results for studs on Holland profiles and plate strips
Hence, the investigated stud-arc welding is well suited to
Holland profiles in primary ship structures. Compared to
stud-welds on plates, even a higher fatigue strength was
found, which was not expected in view of the bulb thickness

Fig. 23 Finite element

submodel of a stud-weld with
real weld profile and max.
principal stress distribution for
a specimen with M8 stud on HP
100x6
506 Weld World (2013) 57:495–506

Fig. 25 S-N diagram based on notch stress results according to the

Fig. 24 Example for stress averaging over the substitute micro-struc- Neuber and IIW approaches for the specimens mentioned in Table 7
tural length ρ*

on the micro-structural support hypothesis by Neuber by

and possible residual stresses from rolling. Prerequisite is, of averaging the local stress distribution over the substitute
course, a sufficient weld quality according to the require- structural length of the material. The agreement with the
ments in standards. Radaj approach is good if a correspondingly reduced S-
In order to transfer the results to other geometries and N curve is assumed.
load situations, the applicability of the notch stress approach
according to Radaj was investigated. Therefore, the surface Acknowledgments The investigations were performed within the
of several welds was completely scanned, and parameters project “Fatigue Strength Behaviour of Stud-Welds in Load-Carrying
for the description of an idealized weld shape were derived. Ship Structures” which was funded with public means within the
programme "Industrial Cooperative Research" by the German Federal
Finite element calculations with a reference weld toe radius Ministry of Economics and Technology via the AiF and was coordi-
of 1 mm showed only a small influence of the geometry on nated by the Center of Maritime Technologies (CMT) in Hamburg.
the notch stress, so that a nominal geometry of the weld
shape was proposed for M8- and M12 studs. The notch
stresses determined for the different test series were above
the design S-N curve FAT 225 for the notch stress approach References
so that this is also applicable to stud-arc welding.
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