Fatigue in Welded Structures

Lars Damkilde Section for Structural Mechanics Department of Civil Engineering, Aalborg University
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Stress state
Nominal stress, geometric stress and notch stress

Stress state

Nominal stresses will normally be based on beam theory, which is valid sufficiently long from the weld. The nominal stresses define the level of stress state. The geometric stresses or the stress concentration factor (SCF) is due to the geometrical changes in the structure near the weld. Neighbouring elements influence through the stiffness. The notch stress is the actual stress in the weld. Unfortunately this stress state is virtually impossible to calculate due to the weld process which both induce change in material properties and residual stresses due to heating/cooling.

Basis for fatigue design for welded structures

Experimentally based S-N curves for a number of different welding details. Calculation of the geometric stress level in the actual structural part. This can either be based on handcalculation with some semi-empirical corrections or by FEM. Match of the structural details to one of the known welding details. This step involves engineering judgement. Calculation of the damage accumulation taking into account the stress variation and the number of cycles. (based on Paris law)

Accumulation of damage from different stress levels (Palmgren-Miner).

Eurocode experimental curves

Some welding details

Tubular sections

Cumultative damage - Palmgren-Miners rule

Principle is to decompose the load history into a number of cycles at different stress level. The damage for each level of stress is calculated and the total damage is summed.

Assumption for Palmgren-Miners rule The order of loads is of no importants. That means that large load amplitudes followed by smaller load amplitudes are equal to smaller load amplitudes followed by larger amplitudes. Some research results indicate that the so-called non-uniformity index has importance, and will add to the accumulated index. In practise the experimental data are hard to get, and they have a large scatter.

Load history calculation

The load history shall be transformed into a number of cycles at different levels. Time under load is of no importance and only the amplitude stresses are of interest.
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The stress levels from a load history

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Rain Flow counting a method for dividing the load history into cycles.

The principle of dividing the process into closed loops.

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More complicated

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Rain-Flow counting can be programmed and calculated on the fly (continously).

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Tubular joints typical in many offshore structures.

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Structural analysis Global analysis based on 3-D Beam elements. Replacing rigid joint connections with joint flexibility is often beneficial. Detailed analysis of joints can either be based on semi-empirical formulas or Finite Element analysis. For non-planar joints the semi-empirical formulas are more questionable. For most offshore structures fatigue is of great importance.

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SCF-factors for tubular joints:

Some definitions

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Different joint types - planar joints

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SCF values are generally high.

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Calculation of hot-spot stresses

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SCF values depend on the joint type.

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Stress points in a K/Y-joint

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Decomposing of a joint into two loading types.

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Geometrical definitions.

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Formulas for the SCF-factors

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