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Welding procedures for fatigue life improvement of the weld toe
University West, Department of Engineering Science, Research Enviroment Production Technology West. Volvo Construction Equipment AB, Braås, Sweden .ORCID iD: 0000-0002-5290-6619
Royal Institute of Technology (KTH), Department of Aeronautical and Vehicle Engineering, Division of Lightweight Structures, Stockholm, Sweden .
Volvo Construction Equipment AB, Braås, Sweden .
Royal Institute of Technology (KTH), Department of Aeronautical and Vehicle Engineering, Division of Lightweight Structures, Stockholm, Sweden .
2016 (English)In: Welding in the World, ISSN 0043-2288, E-ISSN 1878-6669, Vol. 60, no 3, 573-580 p.Article in journal (Refereed) Published
Resource type
Text
Abstract [en]

This paper presents the results of an experimental study of gas metal arc welded, GMAW, cruciform joints made of common construction steel S355. The hypothesis is that smooth undercuts in as welded conditions can give enhanced fatigue properties similarly as post treated welds. Undercuts are generally seen as a defect or imperfection. Welders try to avoid these and repair them when they occur, which result in increased production lead time. Post weld improvement methods i.e. grinding or high-frequency-impact treatment (HFMI) as fatigue-enhancing post-treatment methods enforce amongst other effects a certain smooth undercut-shaped groove in the treated weld toe region. The obtained shallower weld toe transition reduces the geometrical notch effect and increases fatigue strength. This paper presents a study whereas welded specimens with a weld toe geometry similar to what is obtained by weld toe grinding or HFMI-treatment, has been produced, fatigue tested and analyzed. The improvement of the fatigue strength is comparable to post-weld treated specimens. It has proven to be an efficient way to achieve high-quality welds without introducing any additional operations in production, thus enabling weight reduction using cost-effective methods.

Place, publisher, year, edition, pages
2016. Vol. 60, no 3, 573-580 p.
Keyword [en]
Weld toes, Weld shape, Fatigue improvement, Fillet welds, GMA welding
National Category
Manufacturing, Surface and Joining Technology Applied Mechanics
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-9298DOI: 10.1007/s40194-016-0309-9ISI: 000379434400016Scopus ID: 2-s2.0-84966378339OAI: oai:DiVA.org:hv-9298DiVA: diva2:917753
Note

First online: 22 February 2016

Available from: 2016-04-07 Created: 2016-04-07 Last updated: 2016-12-16Bibliographically approved
In thesis
1. A Framework for optimised welding of fatigue loaded structures: Applied to gas metal arc welding of fillet welds
Open this publication in new window or tab >>A Framework for optimised welding of fatigue loaded structures: Applied to gas metal arc welding of fillet welds
2016 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Welding is a key process for heavy steel structures, but it is also a weak link in the structure since fatigue fractures in welds are a common cause of failure. This thesis proposes several changes in order to improve the fatigue properties in acost effective way, enabling reduced weight and reduced cost of welded structures. The main idea is to adapt the weld requirements and welding procedures to the load conditions of the weld. This approach ensures that the main focus in the welding process is the critical characteristics of the welds fatigue life properties. The fatigue life critical properties are most often related to the geometrical factors of the weld such as the radius at the weld toe or the penetration in the root. The thesis describes a holistic view of the subject and covers fatigue, weld quality, weld requirements and welding procedures. It becomes evident that the traditional way of working without a direct connection to fatigue is not the best. With an adaptation to the load conditions and fatigue, it is possible to enhance the fatigue life and reduce the welding cost. The main challenge is to connect the welding process, weld requirements and fatigue life properties. It is needed for an optimised welding process of heavy structures subjected to fatigue and toget a predictable fatigue life. Welds optimised for enhanced fatigue life properties are not necessary accepted according to the requirements in a current standard. Several welding procedures are proposed for improving the fatigue life properties of the weld, which indicate a high potential for enhanced fatigue lifeof fillet welds. The idea is to replace the "standard" fillet weld with three different weld types: (i) Welds with deep penetration, (ii) Welds with large weld toe radius and (iii) Welds produced with low cost. Together with customised requirements and reduced over-welding there is a vast potential for reduced weight, reduced cost and increased productivity.The main contribution of this thesis work is the cross-functional studies including design, analysis, production and quality control. This gives a framework for improvements supporting reduced cost and reduced weight of VIII welded structures without reducing the fatigue strength. Many shortcomings have been highlighted to change the welding from a state where welds are done in a way as they "always" have, by tradition, to a more contemporary situation where weld requirements and welding procedures are actively chosen to match the load conditions of the weld. This result in requirements and welding procedures which actually are connected to the fatigue properties as defined by the loading conditions, and where auditors with high probability can say that an accepted weld actually is better than a rejected weld.

Place, publisher, year, edition, pages
Trollhättan: University West, 2016. 94 p.
Series
PhD Thesis: University West, 7
Keyword
GMAW, Fatigue, Welding procedures, Fillet welds, Weld quality
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-9339 (URN)978-91-87531-26-2 (ISBN)978-91-87531-27-9 (ISBN)
Public defence
2016-05-31, C118, Trollhättan, 13:15 (English)
Opponent
Supervisors
Available from: 2016-05-04 Created: 2016-05-02 Last updated: 2016-10-31Bibliographically approved

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