R64 A CONSIDERATION OF ALLOWABLE EQUIVALENT STRESSES FOR FATIGUE DESIGN OF WELDED JOINTS

A CONSIDERATION OF ALLOWABLE EQUIVALENT

STRESSES FOR FATIGUE DESIGN OF WELDED
JOINTS ACCORDING TO THE NOTCH STRESS
CONCEPT WITH THE REFERENCE RADII
rref = 1.00 AND 0.05 mm

C.M. Sonsino

ABSTRACT

In the literature, allowable stresses (FAT-values) for the fatigue design of welded joints are established according to
the notch stress concept with the reference radii rref = 1.00 mm for thick connections (t ≥ 5 mm) and 0.05 mm for
thin connections (t < 5 mm). However, it is not clear for which strength hypothesis they are valid. As local equivalent
stresses may be calculated by the principal stress or von Mises hypotheses, it is necessary to distinguish between
the applied hypotheses. The FAT-values according to the principal stress and von Mises hypotheses are compiled
for steel, aluminium and magnesium for the reference radii rref = 1.00 and 0.05 mm. The allowable stresses are
derived from normal as well as from shear stresses. However, the values derived from pure normal loading (axial
or bending) and from pure torsion are not compatible when the principle stress or the von Mises hypotheses are
applied. Therefore, in case of biaxial loading, the stated incompatibility between the values obtained from different
loading modes should be overcome by the Gough-Pollard relationship.

IIW-Thesaurus keywords: Aluminium; Fatigue strength; Light metals; Magnesium; Mechanical properties; Notches;
Reference lists; Steels; Stress; Welded joints.

Nomenclature σsH Structural stress according to Haibach

r Radius
σ Normal stress k Slope of the SN-curve before the knee point
τ Shear stress k* Slope of the SN-curve after the knee point
σk Maximum notch stress k’ Slope of the SN-curve after the knee point for
σhs Hot-spot stress cumulative damage calculations
D Damage
F Load
Prof. Cetin Morris SONSINO (c.m.sonsino@lbf.fraunhofer. N, Nf Cycles to failure
de) is with Fraunhofer Institute for Structural Durability Nk Knee point of the SN-curve
and System Reliability LBF, Darmstadt (Germany). Mb, Mt Bending moment, torque
t Thickness
Doc. IIW-1950-08 (ex-doc. XIII-2216r1-08/XV-1285r1-08) R Load or stress ratio Fmin / Fmax or σmin / σmax
recommended for publication by Commission XIII Ps Probability of survival
“Fatigue behaviour of welded components and struc- M Mean-stress sensitivity
tures” and Commission XV “Design, Analysis and [σa(R = -1) / σa(R = 0)]-1
fabrication of welded structures”. E Young’s modulus
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A CONSIDERATION OF ALLOWABLE EQUIVALENT STRESSES FOR FATIGUE DESIGN OF WELDED JOINTS R65

μ Poisson’s constant
Kt Theoretical stress concentration factor
ε Strain
Δ Range
Tx Scatter 1 : [X (Ps = 10 %) / X (Ps = 90 %)]

Indexes
a Amplitude
b Bending
t Theoretical, torsion
x,y Coordinates
loc Local
ref Reference
n Nominal
m Mean
PM Palmgren-Miner
MA Multiaxial σk Maximum notch stress
σsH Structural stress calculated from structural strain
SN Stress-number of cycles curve
after Haibach
σhs Hot-spot stress

Figure 1 – Definition of the notch stress

1 INTRODUCTION
Principally, the weld toe or root of a joint is submitted to
a multiaxial stress state, caused by the constraint under
uniaxial loading or by multiaxial loads, e.g. combined
bending and torsion [1, 2]. When the notch stress con-
cept, Figure 1, with the reference radius rref = 1.00 mm
for thick-walled components (t ≥ 5 mm) or 0.05 mm
for thin-walled structures (t < 5 mm) [3], is applied, the
local multiaxial stress state must be evaluated using an
appropriate strength hypothesis. For this, an equivalent
local stress is usually calculated, either a principal or
a von Mises stress.
However, the IIW-Recommendations [4] offer allowable
stress ranges for rref = 1.00 mm for steel and aluminium
welds, i.e. FAT-values (Δσloc for N = 2 x 106, R = 0.5,
Ps = 97.7 %), but do not explain what kind of equivalent
stresses they are. In recent publications concerning the
application of notch stress concepts for welded joints
of aluminium and magnesium [5-10], in earlier ones [2,
11, 12] and finally in [13, 14] it is well documented
how these values are derived. Therefore, these sour-
Normalized stress range Δσ, Δτ
for the local stress concept
and of structural stresses [3]
ces, through the applied numerical models, allow the
presentation of the FAT-values for both reference radii
as equivalent stresses according to the principal stress
hypothesis (PSH) as well as to the von Mises hypo-
thesis. Depending on how the local equivalent notch
stresses were calculated for their assessment, the
appertaining FAT-values can then be selected.
In this paper, not only will the equivalent FAT-values
for pure axial loading or normal stresses be compiled,
but also FAT-values for pure torsion (shear stresses)
for both of the aforementioned reference radii will be
derived from the few available sources [1, 2, 15-20].
The course of the SN-curves suggested in the IIW-
Recommendations [4], Figure 2, will also be kept for
the local stress system. On this basis, the assessment
of multiaxial stress states with changing principal stress
directions under combined unproportional loading will
also be possible [1, 2, 15, 18, 19].

10.0

5.0
3.0
k= normal stress
5.0
2.0
shear stress FAT
1.0
k* = 22.0
0.5

0.2 k‘ = 5.0

0.1
104 2 5 105 2 5 106 2 5 107 2 5 108 2 5 109

Cycles to failure Nf

Figure 2 – Normalized SN-curves for welded joints under normal and shear stresses
Welding in the World, Vol. 53, n° 3/4, 2009 – Peer-reviewed Section
R66 A CONSIDERATION OF ALLOWABLE EQUIVALENT STRESSES FOR FATIGUE DESIGN OF WELDED JOINTS
In this context it should be added that the aforemen-
tioned reference radii are based on very different hypo-
theses: The reference radius rref = 1.00 mm is the ficti-
tious radius rf = 1.00 mm derived from the hypothesis
of micro-support for the worst case of a notch with
the real radius rreal = 0 [21, 22]. The background of the
smaller reference radius rref = 0.05 mm is the crack
tip blunting [23]. The micro-support hypothesis consi-
ders theoretically the influence of stress gradients on
the local bearable fatigue strength. This influence of
stress gradients is theoretically also considered by the
description of the stresses at the crack tip [24].
However, the selection of the values rref = 1.00 and
0.05 mm is also based on empirical observations and
assumptions: The radius of 1.00 mm was often obser-
ved at welded joints of structural steels with a thick-
ness t > 5 mm [13, 14]. The size of the smaller radius
for thin plates (t < 3 mm) of low and medium strength
ferritic car body steels corresponds approximately to
their grain size [25] and in many cases to the radius of
the notch root of spot welds [26].
The introduction of the reference radius rref = 0.05 mm
also has its justification in avoiding the weakening of
cross sections of plates with t < 5 mm if the radius of
1.00 mm is applied. Despite the different theoretical
backgrounds, the general use of rref = 0.05 mm can be
accepted also for thicker plates, if the effect of stress
gradients on fatigue strength is also properly conside-
red with regard to the influence of the highly stressed
material volume [20] on fatigue life.
The main motivation for applying reference radii is the
evaluation of fatigue strength of hidden slit notches i.e.
notch roots, which are not accessible by the nominal
stress concept or hot-spot concept with linearization
of the stress distribution along the surface, Figure 3.
a) Suitable for the hot-spot stress concept
b) Not suitable for the hot-spot stress concept
Figure 3 – Limitations in the application of hot-spot and local stress concepts
Welding in the World, Vol. 53, n° 3/4, 2009 – Peer-reviewed Section
For the sake of completeness, the further develop-
ment of the hot-spot stress concept by linearization of
the stress distribution along the thickness should also
be mentioned [27], by which notch roots may also be
assessed. However, this concept variant is not yet suf-
ficiently mature for application because of missing allo-
wable stresses. Thus, the reference radii can also be
used for the evaluation of weld toes with significantly
lower stress concentrations than slit notches. However,
for this, more research work is necessary in order to
incorporate the aforementioned effects of stress gradi-
ents on local bearable stresses as a function of thick-
ness, stress concentration and loading mode.
2 SHORT OVERVIEW
ON KNOWN FAT-VALUES
FOR THE NOTCH STRESS CONCEPT
The very first introduction of an allowable stress for
welded joints, according to the notch stress concept
for the reference radius rref = 1.00 mm, originates from
[22]. Based on the results obtained in [13, 14] for steel
joints, the value FAT 225 (Δσloc = 225 MPa) was imple-
mented into the IIW-Recommendations [4]. This value is
a principal stress due to the applied 2D-model in which
the plane strain condition (constraint) was considered.
Also, the recently published values for aluminium and
magnesium joints FAT 71 and 28, were derived from
2D-models but for plane stress [5-10], Table 1.
Further, in [8, 9] from tests carried out in [5, 8], allo-
wable stresses for the reference radius rref = 0.05 mm
are derived: for aluminium Δσloc = 178 MPa and for
magnesium 73 MPa, Table 1. These values are also
principal stresses. The value 575 MPa for steel is obtai-
A CONSIDERATION OF ALLOWABLE EQUIVALENT STRESSES FOR FATIGUE DESIGN OF WELDED JOINTS R67

Table 1 – Known FAT-values for welded joints Table 2 – FAT-values according to the notch stress
according to the notch stress concept concept for different reference radii and strength
for different reference radii hypotheses

rref E rref in mm 1.00 1.00 0.05 0.05

in mm 1.00 0.05 in GPa von von
Hypothesis PSH PSH
Steel 225 575 206 Mises Mises

Aluminium 71 178 70 Steel 225 200 575 512

Aluminium 71 63 178 158
Magnesium 28 73 43.5
All FAT-values are allowable stress ranges Δσloc in MPa according to Magnesium 28 25 73 65
the principal stress hypothesis for N = 2 x 106; R = 0.5; Ps = 97.7 %; All given allowable stress ranges Δσloc are in MPa for N = 2 x 106;
k = 3.0; Nk = 1 x 107; k* = 22.0; k‘ = 5.0. R = 0.5; Ps = 97.7 %; k = 3.0; Nk = 1 x 107; k* = 22.0; k‘ = 5.0.

ned from Δσloc = 225 MPa considering the ratio of the
local stresses for aluminium and magnesium for the
reference radii rref = 0.05 and 1.00 mm [8], as in [13,
14], a value for the smaller radius was not derived. All
these stresses were calculated linear – elastically and
therefore they are fictitious stresses exceeding the par-
ticular yield stresses.
The models applied for obtaining the particular values
are described in [5-14]. In [27] modelling guidelines for
the notch stress concept are compiled; this guideline
recommends FAT-values derived here.
3 DETERMINATION
OF LOCAL VON MISES STRESSES
FOR THE NOTCH STRESS CONCEPT
On the surface of a notch, the following relations bet-
ween the local deformation and stress components
exist:
E Respecting these requirements, firstly, from SN-cur-
Vx = (Hx + PHy) (1)
1  P2
E stress ranges at N = 2 x 106 cycles were selected; for
Vy = (PHx + Hy)
1  P2
For the plane strain condition with εy = 0, usually for
Kt > 2.0 [21], the transversal stress reads:
σy = μ · σ x
From this, the equivalent von Mises stress can be deri-
ved as:
Table 2 contains the von Mises stresses as well as the
principal stresses for the reference radii rref = 0.05 and
1.00 mm.
Figure 4 displays the linear dependence between these
values and the Young’s modulus.
In Section 2 it has already been explained how the
allowable stress Δσloc = 575 MPa for steel joints with
rref = 0.05 mm was estimated. To check the plausibility
of this value, the results of another investigation, car-
ried out with overlapped laser beam welded steel and
aluminium joints (plates and tubes with thin cross sec-
tions t < 3 mm) [11], are also analyzed. These results
are presented in Figure 5 as von Mises stresses for the
reference radius rref = 0.05 mm. All tests were carried
out under pulsating loading (R = 0).
The IIW-Recommendations [4] require the following
prerequisites for allowable stress ranges: The values
must be valid for high tensile residual stresses, which
may be covered by tests with R = 0.5. The allowable
stresses must be derived for Ps = 97.7 % (or 95 %).
ves with Ps = 50 % given in Figure 5 the equivalent
(2) aluminium the curve had to be extrapolated. Through
consideration of the particular mean stress sensitivi-
ties of steel, aluminium and magnesium [5, 8, 28, 29]
between R = 0 and 0.5 (M2 = 0.10 and 0.33), Figure 6,
and of the safety factor jσ = 1.37 (ratio between the
(3) values with Ps = 50 and 97.7 %) assuming a Gaussian
log-normal distribution with a scatter of Tσ = 1:1.50 for
welded joints, the allowable equivalent stress ranges

σeq,von Mises = Vx 2  V y 2  V x ˜ V y  3Wxy 2

(4)
= Vx ·   P  P 2  3Wxy 2 / V X 2

The coordinate stresses are also principal stresses,

when no shear stresses (τxy = 0) on the surface exist:
σ1 = σx and σ2 = σy
According to the principal stress hypothesis (PSH), the
equivalent stress is the largest principal stress.
With the Poisson’s constant μ = 0.30 as an average
value for the materials considered here, the following
relationship between the von Mises equivalent stress
and the principal stress is obtained:
σeq,von Mises = 0.89 · σx = 0.89 · σ1
(5)
Figure 4 – Dependence between FAT-values
according to different strength hypotheses
and Young’s Modulus for the reference radii
(6) rref = 1.00 and 0.05 mm
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R68 A CONSIDERATION OF ALLOWABLE EQUIVALENT STRESSES FOR FATIGUE DESIGN OF WELDED JOINTS

2000 the overlapped joints of steel and aluminium may be

Equivalent notch stress amplitude (von Mises) σk,a

RF = 0 responsible for these differences.

PS [%]: rref = 0.05 mm
MPa
10 k=
6 .2 Tσ = 1:1.30 σk,a = 512 MPa
1000 50
900 90 (PS = 50%,
800
Steel Nk =2⋅10 )
6 4 ALLOWABLE SHEAR STRESSES
700
600
500 There exist very few publications regarding the fatigue
PS [%]:
400 behaviour of welded joints under torsion. For steel, the
10 k=
50
4 .6
Tσ = 1:1.36 σk,a = 159 MPa investigations [1, 2, 11, 12, 17-20] are relevant and, for
300 90 (PS = 50%, aluminium, only [15, 16] can be cited. Further, there is
Nk = 7⋅10 )
5
no knowledge regarding the mean stress sensitivity of
200
Aluminium welded joints under torsion. As the mean stress sensiti-
vity in the non-welded state is lower under torsion than
under axial loading or bending [28], this experience can
100
4 5 6 7
also be adopted for welded joints, Figure 6. So far, the
10 10 10 10
Cycles to rupture NR values derived in the following for torsion should be
Ref.: M. Eibl
considered as an estimate.
Figure 5 – Master SN-curves according
Firstly, the known nominal stress ranges for steel and
to the notch stress concept with the reference
aluminium are compiled and that for magnesium is esti-
radius rref = 0.05 mm for laser beam
mated, Table 4. This estimation is based on the simila-
welded thin sheets
rity of allowable normal and shear stresses for steel as
for Ps = 97.7 % were derived. These values are com- well as aluminium butt welds in the IIW Recommenda-
pared in Table 3 with those from Table 2. tions [4]. So the suggested allowable normal stress for
magnesium in [10] was also taken as a shear stress.
The values derived from [11], Figure 5, are about 31 %
These values are valid for butt welds with complete
higher than the estimated values for steel. Their alloca-
penetration. The allowable stresses for partial penetra-
tion in Figure 4 would reveal a significant deviation from
tion are 20 % lower [4].
the graphs. Therefore, the estimated lower values seem
to be more plausible. The differences stated cannot be As, under torsion, the stress distribution does not
explained by size effects because the values for laser show an increase of the stresses when the weld toe is
beam welded thin aluminium joints in Table 3 are lower approached, the presented nominal stress ranges are
by 13 %. Different contact and stiffness conditions at also equal to hot-spot stress ranges.

Table 3 – Comparison of allowable stress ranges for the reference radius rref = 0.05 mm determined
for different strength hypotheses

Material Steel Steel Aluminium Aluminium

Hypothesis PSH von Mises PSH von Mises
Δσloc, Eibl
755 672 154 137
in MPa
FAT
575 512 178 158
in MPa
'V
Δσloc,
loc,Eibl
Eibl
1.31 1.31 0.87 0.87
FAT
All given allowable stress ranges Δσloc are in MPa for N = 2 x 106; R = 0.5; Ps = 97.7 %; k = 3.0; Nk = 1 x 107; k* = 22.0; k‘ = 5.0.

St Al and Mg
Stress amplitude σa

f σ τ σ τ
M1 f1
f1 1.20 1.10 1.42 1.20
f3
f2 1.10 1.06 1.33 1.10
f2
R = -1

R=0 M2
f3 1.32 1.17 1.88 1.32

R = 0.5 St Al and Mg
M σ τ σ τ
M1 0.20 0.10 0.42 0.20

M2 0.10 0.06 0.33 0.10

0 Mean stress σm

Figure 6 – Mean stress sensitivity of welded joints

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A CONSIDERATION OF ALLOWABLE EQUIVALENT STRESSES FOR FATIGUE DESIGN OF WELDED JOINTS R69

Table 4 – Allowable shear stress ranges 95 MPa are calculated for the steel joints and, from
for butt welded joints according to the nominal τna = 38 MPa in Figure 8, 42 to 29.5 MPa are calculated
and hot-spot stress concepts for the aluminium joints for R = 0.5, N = 2 x 106 cycles
and Ps = 97.7 %. The FAT-values in Table 4, Δτn = 100
Material Steel Aluminium Magnesium and 36 MPa respectively, lie very well within these cal-
culated ranges and are plausible.
Δτn, Δτhs
100 36 14
in MPa (FAT) After this plausibility analysis, the stress concentration
factors for the reference radii rref = 0.05 and 1.00 mm
All given shear stress ranges are for N = 2 x 106; R = 0.5 and
Ps = 97.7 %. can be calculated from FE modelling of the flange-tube
The course of the SN-curve is determined by k = 5.0; Nk = 1 x 108; specimens, Figures 9 and 10. They are presented in
k* = 22.0; k‘ = 5.0. Table 5.

Before determining notch stresses from these stresses,

the plausibility should also be checked. For this, the Table 5 – Stress concentration factors
few available test results, Figures 7 and 8, obtained for welded flange tube connections
under pure torsion of steel and aluminium flange-tube
r
connections, are used [15-20]. 1.00 0.05
in mm
With the mean-stress sensitivities for normal and shear K 3.23 7.05
tb
stresses, compiled in Figure 6, from τna = 86 MPa
in Figure 7, allowable stress ranges of Δτn = 107 to K tt
1.67 2.52

Figure 7 – Fatigue testing results obtained on as-welded steel specimens under pure torsion

Figure 8 – Fatigue testing results obtained on as-welded aluminium specimens under pure torsion
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R70 A CONSIDERATION OF ALLOWABLE EQUIVALENT STRESSES FOR FATIGUE DESIGN OF WELDED JOINTS

rm = 0.45 mm, θ = 45° rm = 17.0 mm, θ = 38°

Ktb = 3.93, Ktt = 1.85 Ktb = 1.62, Ktt = 1.14
a) Steel St E 460 b) Aluminium AISi1MgMn T6
Figure 9 – Geometry of the welds

10.0

Bending
Stress concentration factor Kt

5.0
D = 89 mm
Ktb t = 25 mm s = 10 mm

Torsion
2.0
Ktt

1.0
0.01 0.02 0.05 0.1 0.2 0.5 1.0 2.0 5.0 10 20 mm 50
Notch radius r
Figure 10 – Stress concentration factors of welded flange tube connections

The allowable local shear stress ranges can now be
determined with the stress concentration factors
in Table 5 from the nominal values in Table 4 and
expressed as principal or von Mises stresses:
τxy = Ktt · σn = σ1
The local shear stress range is equal to the princi-
pal stresses under pure torsion because σx = σy = 0.
From Equation (4) the von Mises equivalent stress
results:
Veq, von Mises = 3 ˜Wxy
The corresponding values are compiled in Table 6 as
well as in Figure 11.
The allowable shear stress Δσloc,PSH = Δτloc = 167 MPa in
Table 6 for steel and the reference radius rref = 1.00 mm
is in excellent agreement with a former proposal in [30].
In [30] the amplitude τa,loc = 95 MPa with Ps = 97.7 %
Welding in the World, Vol. 53, n° 3/4, 2009 – Peer-reviewed Section
for R = -1 is given. This value is also adopted by the
German FKM-fatigue design recommendations [29] for
the notch stress concept with rref = 1.00 mm. From this
value, Δτloc = 162 MPa is obtained with the mean stress
(7) sensitivity for steel under shear for R = 0.5. The slightly
higher allowable shear stress range is more plausible
because in [30] a larger scatter Tτ = 1:1.92 (instead of
1:1.50) was used.
The FAT-von Mises value for steel at rref = 0.05 mm,
436 MPa, can also be checked for plausibility.
(8) From the equivalent von Mises stress amplitude
σa, von Mises = 435 MPa (R = -1, Ps = 50 %, N = 2 x 106)
in [2], depending on the assumed mean-stress sensiti-
vity, Figure 6, allowable equivalent von Mises stress ran-
ges between 481 and 542 MPa (R = 0.5, Ps = 97.7 %,
N = 2 x 106) are calculated. These values are by 10 to
24 % higher than 436 MPa. A reason for this might
be the different joint dimensions. In [23] the data was
A CONSIDERATION OF ALLOWABLE EQUIVALENT STRESSES FOR FATIGUE DESIGN OF WELDED JOINTS R71

Table 6 – FAT values derived from shear stresses for reference radii rref = 1.00 and 0.05 mm
according to different strength hypotheses

rref in mm 1.00 1.00 0.05 0.05

Hypothesis PSH von Mises PSH von Mises
Stresses in MPa Δσloc, PSH = Δτloc Δσloc, von Mises
Δσloc, PSH = Δτloc Δσloc, von Mises
Steel 167 289 252 436
Aluminium 60 104 91 157
Magnesium 23 40 35 61
6
All given allowable stress ranges are for N = 2 x 10 ; R = 0.5 and Ps = 97.7 %.
The course of the SN-curve is determined by k = 5.0; Nk = 1 x 108; k* = 22.0; k‘ = 5.0.

Figure 11 – Dependence between FAT-values derived from shear stresses according

to different strength hypotheses and Young’s Modulus

obtained with thin (t = 2 mm) laser beam welded over-
lapped hollow specimens; however, in [15-20], MAG-
welded flange-tube specimens with a much greater
thickness (t = 10 mm) were investigated. Nevertheless,
these differences are still tolerable.
5 COMPARISON OF EQUIVALENT
STRESS RANGES DERIVED
FROM TESTS UNDER BENDING
OR AXIAL LOADING AND TORSION
Strength hypotheses claim that multiaxial stress states
caused by different uni- or multiaxial loading conditions
must result, for a required fatigue life, e.g. N = 2 x 106,
Table 7 – Derived equivalent stress ranges according to the principal stress hypothesis from test
under bending or axial loading and torsion
in the same equivalent stresses. In the following it will
be discussed to what extent the values presented in
Tables 1 to 6 for axial loading or bending and torsion
fulfil this claim independently of the loading mode. In
Table 7 the values evaluated by the PSH and in Table 8
by von Mises are displayed.
As the equivalent stress for pure torsion is equal to
the shear stress, according to the PSH, Equation (7),
but is 3 higher, according to von Mises, Equation (8),
and, under normal stresses (pure bending or axial loa-
ding). the von Mises equivalent stress is smaller than
the principal stress by a factor of 0.89, Equation (6),
different values result depending on the applied hypo-
thesis. From the standpoint of material mechanics, for
ductile materials like steels and for materials with suf-

rref in mm 1.00 1.00 0.05 0.05

Test mode Bending or axial Torsion Bending or axial Torsion

Steel
225 167 575 252
Δσ loc, PSH in MPa

Aluminium
71 60 178 91
Δσ loc, PSH in MPa

Magnesium
28 23 73 35
Δσ loc, PSH in MPa
All given allowable stress ranges Δσloc are in MPa for N = 2 x 106; R = 0.5; Ps = 97.7 %.

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R72 A CONSIDERATION OF ALLOWABLE EQUIVALENT STRESSES FOR FATIGUE DESIGN OF WELDED JOINTS

Table 8 – Derived equivalent stress ranges according to the von Mises hypothesis from tests
under bending or axial loading and torsion

rref in mm 1.00 1.00 0.05 0.05

Test mode Bending or axial Torsion Bending or axial Torsion

Steel
200 289 512 436
Δσ loc, von Mises in MPa

Aluminum
63 104 158 157
Δσ loc, von Mises in MPa

Magnesium
25 40 65 61
Δσ loc, von Mises in MPa
All given allowable stress ranges Δσloc are in MPa for N = 2 x 106; R = 0.5; Ps = 97.7 %.

ficient ductility like aluminium and magnesium alloys,
the von Mises hypothesis is more appropriate than the
PSH, which is physically more valid for brittle materials
[1, 2, 15, 16, 20].
Therefore, the comparison of the equivalent stresses
from axial loading or bending and from torsion according
to the PSH in Table 7 should not be allowable because
of the aforementioned reasons. Also the justified appli-
cation of the von Mises hypothesis, Table 8, delivers
stress ranges for the different loading modes that are
not equal, Figure 12. Especially for steel, the differences
resulting from the loading modes are much larger than
for magnesium or aluminium. It is also remarkable that,
for the reference radius rref = 1.00 mm, all values from
torsion are 60 % higher than from bending or axial loa-
ding while, for the reference radius rref = 0.05 mm, the
values from torsion are 15 % lower.
6 EVALUATION OF COMBINED NORMAL
AND SHEAR STRESSES
kV kW
§ 'VLoad · § 'WLoad ·
¨ ¸ ¨ ¸ d DMA (9)
'V
© SN ¹(N) © 'WSN (N) ¹
At N = 2 x 106 cycles, ΔσSN (N) and ΔτSN (N) are the par-
ticular FAT-values. Equation (9) can be used for nominal
as well as for hot-spot or local stresses. In the local
system, ΔτLoad is the shear stress component Δτxy,Load
of the stress tensor, Equation (10), resulting from the
external multiaxial loading. The allowable shear stress
ΔτSN (N) is selected from the IIW-SN-curve, Figure 2,
i.e. for N = 2 x 106 cycles, the Δτloc-values in Table 6.
Thus, for normal stresses a decision must be made
for ΔσLoad. Either the maximum principal stress ΔσLoad,1,
Equation (11) must be inserted or the von Mises stress
ΔσLoad, von Mises, Equation (12), calculated from the nor-
mal stress components of the stress tensor. Depending
on the decision, either the allowable principal stress
range or the allowable von Mises stress range from
axial loading or bending, Table 2, must be assigned. In
the coordinate system of the stress tensor, x is defined
as the perpendicular direction to the weld toe or root
and y as the parallel direction.

For the evaluation of biaxial stress states with com- (10)

bined normal and shear stresses the Gough-Pollard
Equation (9) and Table 9 [31-34], incorporated in the ΔσLoad = ΔσLoad,1 = Δσx,Load (11)
IIW-Recommendations as well as in the Finish Design
'VLoad 'VLoad,vonMises 'V2x,Load  'V 2y,Load  'V x,Load ˜ 'V y,Load (12)
Code [4, 35], can be applied.

Figure 12 – Equivalent stress ranges according to the von Mises hypothesis from tests
under bending or axial loading and torsion
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A CONSIDERATION OF ALLOWABLE EQUIVALENT STRESSES FOR FATIGUE DESIGN OF WELDED JOINTS R73

Table 9 – Recommended assessment procedure for multiaxial loading

kσ = kτ = 2 Exponents of the Gough-Pollard equation

For constant principal stress directions, in-phase (proportional) loading for steel (Eurocode 3,
DMA = 1.0 IIW) and aluminium; for changing directions, out-of-phase (unproportional) loading only for alu-
minium

DMA = 0.5 For changing principal stress directions, out-of-phase (unproportional) loading only for steel

ΔσLoad = 2·σa,Load Nominal, hot-spot or local stress components of the biaxial stress state induced by external
ΔτLoad = 2·τa,Load loading

ΔσSN(N) = 2·σa,SN(N) Endurable nominal, hot-spot or local stresses at N cycles under pure axial loading (or bending)
ΔτSN (N) = 2·τa,SN(N) and pure torsion

With this procedure, at least the observed incompatibi-
lities between the allowable stresses derived from axial
loading or bending and from torsion according to the
PSH or von Mises should be overcome. This bases on
conservative experiences applying the Gough-Pollard
relationship as described with incompatible FAT-values
for normal and shear stresses in the nominal as well as
structural stress systems [32-34].
7 SUMMARY AND OUTLOOK
From the investigations on welded steel, aluminium
and magnesium joints actually available, local allowable
normal and shear stress ranges were derived for the
reference radii rref = 0.05 and 1.00 mm according to
the PSH and von Mises hypotheses. Because of the
small amount of data, some values were estimated
conservatively. As, for the IIW-Recommendations, the
allowable stress ranges must be given after a fixed
numeric system, not corresponding values in Tables 2
and 6 were fitted accordingly and suggested finally as
IIW-FAT-values, Tables 10 and 11.
Table 10 – FAT-normal stresses according to the IIW-Schema for the notch stress concept,
different reference radii and strength hypotheses
Despite performing plausibility checks, the present
results do not yet allow the indication of consistent
local allowable equivalent stress ranges for pure tor-
sion. For combined biaxial loading, the incompatibi-
lity between the derived values from pure normal and
shear loading should be overcome by the Gough-Pol-
lard relationship. Also the fact that, for shear stress,
the SN-curve reveals another slope and knee point
compared to axial loading or bending, Figure 2, is
another obstacle to obtaining a consistent compati-
bility of allowable equivalent stresses for different loa-
ding modes. The addressed problem is even deeper,
because the slope does not depend on the loading
mode only, but also on geometry, stiffness, stress con-
centration and, in consequence, on the ratio between
crack propagation and total life. In this context, the
influence of residual stresses on fatigue life must also
be considered [36].
The failure criterion in the IIW-Recommendations [4] is
rupture. For a crack initiation criterion, e.g. a technically
detectable crack of a ≈ 1.00 mm depth (surface length
l ≈ 2.00 mm), the SN-curves, especially under bending
or axial loading, would have a shallower slope before

rref in mm 1.00 1.00 0.05 0.05

Hypothesis PSH von Mises PSH von Mises
Steel 225 200 630 560
Aluminium 71 63 180 160
Magnesium 28 25 71 63
All given allowable stress ranges Δσloc are in MPa for N = 2 x 106; R = 0.5; Ps = 97.7 %; k = 3.0; Nk = 1 x 107; k* = 22.0; k‘ = 5.0.

Table 11 – FAT-values according to the IIW-schema derived from shear stresses

for reference radii rref = 1.00 and 0.05 mm and different strength hypotheses

rref in mm 1.00 1.00 0.05 0.05

Hypothesis PSH von Mises PSH von Mises

Stresses in MPa Δσloc, PSH = Δτloc Δσloc, von Mises Δσloc, PSH = Δτloc Δσloc, von Mises

Steel 160 280 250 450

Aluminium 63 112 90 160

Magnesium 25 45 36 63
6
All given allowable stress ranges are for N = 2 x 10 ; R = 0.5 and Ps = 97.7 %.
The course of the SN-curve is determined by k = 5.0; Nk = 1 x 108; k* = 22.0; k‘ = 5.0.

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R74 A CONSIDERATION OF ALLOWABLE EQUIVALENT STRESSES FOR FATIGUE DESIGN OF WELDED JOINTS
the knee point N < Nk [5, 15, 20]. This behaviour should
also be considered more in the future.
Because of these reasons the values compiled in this
paper should be considered more as preliminary sug-
gestions for a predimensioning requiring more consi-
stent knowledge on the fatigue behaviour of welded
joints under torsion and shear stresses.
ACKNOWLEDGEMENTS
The author acknowledges Prof. D. Radaj, Prof. T. See-
ger and Prof. W. Fricke for their fruitful and stimulating
discussions during the generation of this paper.
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