Fatigue Improvement of Welded Joints

by Ultrasonic Impact Treatment (UIT/UP)

Structural Integrity Technologies Inc. (SINTEC)

Represented by METRONIC S.A.
E-mail: info@metronicmetal.com
 Outline
1. Introduction

2. Principles, Technology and Equipment

for UIT/UP

3. Application of UIT/UP for Fatigue

Improvement of Welded Elements and
Structures
4. Summary
Fatigue Strength of Base Metal (BM)
and Welded Elements
 Technology and Equipment
for Ultrasonic Impact Treatment UIT
(Ultrasonic Peening UP)
of Welded elements
Schematic view of transducers for UIT/UP using
piezoelectric and magnetostrictive approaches
 Replaceable working heads
for different industrial applications
 PRINCIPLE OF ULTRASONIC PEENING

The technique is based on the combined

effect of:

1. High frequency impacts of the special

strikers

2. Ultrasonic oscillation in treated

material
MATERIAL/PART IMPROVED BY UP
 Profile of weld toe improved
by Ultrasonic Impact Treatment (UIT/UP)
 The view of the butt welds
in as-welded condition (left side sample)
and after application of UP (right side sample)
 The view of the fillet welds in as-welded
condition (left side sample) and
after application of UP (right side sample)
 Effectiveness of UIT/UP applied after welding
and 50% of expected fatigue life of welded
elements
Three series of welded samples were subjected to fatigue testing:
1 – in as welded condition,
2 – UP was applied before fatigue testing,
3 – UP was applied after fatigue loading with the number of cycles
corresponding to 50% of the expected fatigue life of samples in as-
welded condition.

The general view of welded sample for fatigue testing

 Fatigue Improvement by UIT/UP
250

200

2
σmax, MPa
150

100

5 2 3 4 5 6 7 8 9 6 2
10 10
N, cycles
Fatigue curves of welded element (transverse non-load-carrying attachment):
1 – in as welded condition,
2 – UP was applied before fatigue testing,
3 – UP was applied after fatigue loading with the number of cycles
corresponding to 50% of expected fatigue life of samples in as-welded
condition.
Application of UIT/UP for Weld Repair of
Fatigue Cracks in Welded Elements

Drawings of welded specimens for fatigue testing

at different conditions[20]:
W – as-welded condition;
R - repair by gouging and welding;
R/UP – repair by gouging, welding and UP
Application of Ultrasonic Peening for Weld Repair
of Fatigue Cracks in Welded Elements

R=0

Results of fatigue testing of welded elements:

1 - as-welded condition,
2, 3 and 4 – after first, second and third weld repair,
5, 6 and 7 - after first, second and third weld repair
with application of UP
Fatigue test results for 960 MPa yield strength
steel welded specimens [14]:
1- in as-welded condition,
2 and 3 - after UIT/UP based on using magnetostrictive
and piezoelectric transducers,
4- after application of LTT electrodes
Final Assembly and Tuning of UIT/UP Systems at SINTEC
Rehabilitation of Welded Bridge (Indiana, USA)
by UIT/UP
Total Length of UP Treated Welds - 500 meters
Number of UP Treated Welded Elements -2500
Application of UIT/UP for Rehabilitation of
Mining Equipment

UP of Fatigue Critical
Welds of a Grinding Mill
 Application of UIT/UP for
Rehabilitation of Stamping Equipment

UIT/UP of a Welded
Reinforcement Plate
 Summary
1. Ultrasonic Impact Treatment (UIT/UP) is a
relative new and promising technique for
fatigue life improvement of welded elements
and structures in materials of different strength
including HSS with the yield strength of 700-
1000 MPa. The results of fatigue testing show a
strong tendency of increasing of fatigue
strength of welded elements after application of
UP with the increase in mechanical properties
of the material used. It allows using to a greater
degree the advantages of the HSS in welded
elements, subjected to fatigue loading.
 Summary
2. The fatigue testing of welded
specimens also showed that the UIT/UP is
the most efficient improvement treatment
as compared with traditional techniques
such as grinding, TIG-dressing, heat
treatment, hammer peening, shot peening
or application of LTT electrodes.
 Summary
3. The developed computerized complex for UP
was successfully used in different applications for
increasing of the fatigue life of welded elements,
elimination of distortions caused by welding and
other technological processes, relieving of
residual stress, increasing of the hardness of
material surfaces. The areas/industries where the
UP was applied successfully include: Railway and
Highway Bridges, Mining, Construction
Equipment, Shipbuilding, Automotive and
Aerospace.
Fatigue test results for 350 and 700 MPa yield strength
steel welded specimens [11]:
1- in as-welded condition 350 MPa and 700 MPa yield strength steels,
2 - after UIT 350 MPa yield strength steel,
3 - after UIT/UP 700 MPa yield strength steels,
4- FAT 112 design curve
 Diagram showing the endurance
of welded element

I - fatigue crack is repaired by gouging and welding,

II - fatigue crack is repaired by gouging, welding and UP,
III – UP is applied before/during the first phase
of service life,
W – as-welded condition,
R - repair by gouging and welding,
R/UP – repair by gouging, welding and UP,
W/UP- welding and UP
Preparation for UIT/UP of Two New Brackets
Effect of UP Treatment on Corrosion of Metals

A2 Steel

Not treated by UP After UP treatment

HSLA Material

Not treated by UP After UP treatment

Eliminating of Distortions Caused by Welding

View of Welded Sample (Thickness of Plate - 6 mm)

Before (a) After UP (b, c)
 The UP Technology - Leading Technology
in Application of High Power Ultrasound (HPU)
for Fatigue Life Improvement
- The UP technology is based on more than 30 years extensive
experience and knowledge in Fatigue and HPU of an
international group of experts. One of the first publications on
this problem by one of the group leading scientists, Prof. G.
Prokopenko is dated back to 1974 [5].
- Power on Demand Concept - power and other parameters of
UP equipment correspond to the necessary changes in residual
stresses, stress concentration and mechanical properties of the
surface layers of materials to attain maximum possible
increase in fatigue life of welded elements.
- The effects of UP on the fatigue life of welded elements depend
on the mechanical properties of material, the type of welded
joints, parameters of cyclic loading and other factors. For the
effective application of the UP, depending on the above-
mentioned factors, a software package for Optimum
Application of UP was developed.
 The Advantages of UP:
– High (highest) efficiency
– Quick (treatment speed of ~ 0.5 m of weld/min)
– Considerably reduced vibrations and noise
levels, easier in use than for example hammer
peening
– Deeper penetration
– Computer controllable
– Robotic line - ready
– Lighter with no need in forced water-cooling as
compared with similar magnetostrictive
systems.

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