Developments in Weld Fatigue-J Wong

Recent developments in fatigue of
welds
Professor Greg Glinka - University of Waterloo

Dr. Mohamad El-zein – John Deere
Jim Wong - John Deere
SAE FD&E - 15 Oct 2008
Run Smart, Run Fast, Run Lean 1

Speaker Contact Info:
• Jim Wong
– WongJamesD@JohnDeere.com
– 309-765-3891
John Deere - MTIC

One John Deere Place
Moline IL 61265

Where are they now?

Deere Weld Modeling History
• 2000 - Investigation into using Shell FE Models
for use obtain local peak stresses for e-N fatigue
calculations
– Evaluated both Nominal and Hot Spot Stress Methods
– Kt’s were based on traditional definition of Nominal
stress

• 2003 - Investigation to determine Through-the-
Thickness stress distributions using Shell FE
– Established method to calculate actual stress field
– Kt library for various weld types created

• 2005 – Establishment of GY2 FE Shell Model
Technique
– Correlation to 3D-FE fine mesh solutions
– Residual Stress Effects Included

Weld Life Check List
Global Loads
Material Properties
Local Loads, Stresses or Strains
Stress concentration Factors
Peak stress at weld toe/critical points
Through thickness stress distribution
Residual Stresses
Calculate Weld Life

Load
F
peak
n
© 2008 Grzegorz Glinka. All rights reserved. 8

peak
nom
nom

tp
peak
D
r E
hs
h

p

n
M
h P
B
t
A
C
A) remote (nominal) through thickness stress, B) the actual through-

thickness stress distribution in the weld toe cross section, C)
linearized through-thickness stress distribution in the weld toe cross
section, D) the actual stress distribution in the plate surface, E)
extrapolated (linearly) stress distribution in the plate surface
V
n n
H
t
C
tp
r
V
n peak n
H
t
C

Shown are: the experimental definition and determination
of the hot spot stress, the actual through thickness stress
distribution and the hot spot stress resulting from the
y
linearization of the actual stress fields
peak The stress xx in the plate

surface is believed to be
linear in this region !
hs
xx(x)
x
t
0.4t Strain
Courtesy: E. Niemi
1.0t gauges

r n peak b
1
)
T
n2
The stress concentration

factors, , and
are not constant and not
the same!
They depend on the
geometry and on the
stress ratio: mn/ bn!
a) A body with an angular notch subjected to multiple loading modes

and resulting through-the-thickness stress distribution, b)
decomposition of the nominal (linear) stress distribution in the notch
cross section into the membrane and bending contribution
1)
y
a1= n1 1peak
x
t
b1
2)
y
b2 =n2
2pe
ak
x
t
b
2

y
a) Pure axial
hs m
m peak load
F
x
t
Stress concentration factors Kmt,hs and Kbt,hs

DO NOT DEPEND on the stress ratio mhs/ bhs
and they are constant for given geometry!!
b) y
b) Pure bending
hs b
bpeak load
M
x
t

a)
y
a pe b
ak )
x
T
b
c) d
)
The stress concentration factors and

depend only on the geometry and they
can be used for any stress ratio !!
a) T-butt weldment and resulting through-the-thickness stress distribution,

b) decomposition of the nominal (linear) stress distribution in the weld toe
plate cross section, c) the hot spot stress as a sum of the hot spot membrane
and bending stress, d) the actual peak stress as a sum of the stress
concentration on the hot spot membrane and bending stress
a) b)
y
y
P xL x L
P P P
(x,
t y) t
peak
(x,y)
h
s
- depends on L and is constant along the weld toe

line
Independent of L but it
changes along the weld toe
line
a) Stress distribution in the critical cross section near the cover plate ending
and the nominal or the hot spot stress n (independent of length L ) and hs
(independent of length L),
b) Stress distribution in the critical plane near the ending of a vertical
attachment (gusset) and the nominal or the hot spot stress n (dependent on
length L ) or hs (independent of length L)
The advantage of using expression
lies in the fact that the membrane stress hsm and the bending
stress hsb can be determined by simple decomposition of the
linearized through-thickness stress field, (x=0,y), which can be
directly obtained from the coarse mesh 3-D or shell Finite
Element (GY2) analysis. Thus the equation above provides the
link between the FE stress analysis data, hsm and hsb, and the
peak stress, peak, at the weld toe, necessary for the fatigue
analysis

GY2 Approach for Fatigue Life
Prediction Using Shell Finite
Element Results

• Multiaxial state of
stress at weld toe
• One shear and two zz
xx
normal stresses
• Due to stress
concentration, xx
is the largest
xz
component zx
– Predominantly responsible xx
for fatigue damage zz

Middle plane of the attachment
a) c)
tp
hp physical common plane
middle plane for the attachment and
of the main the main plate
plate
h
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t image may have been corrupted. Restart your computer, and then open the file again. If the red x still
appears, you may have to delete the image and then insert it again.
y
x
y d) 0
b) h
z
x
0
z
h/2
(h+t/2)
h/2
h/2
(h/2+tp/2) h/2 h/2 h/2
(h/2+t/2)
(h+tp/2)

The GY-2 Model
Middle plane of the attachment

T
tp h
e
i
m
a
g
e
c
h physical common
middle plane of a
n
n plane for the
the main plate o
t
b
e attachment and the
d
h i
s
main plate
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t corrupted. Restart your computer, and then open the file again. If the red x still appears, you may have to delete the image and
then insert it again.
Element Nodes
h
Reference points where
stress is to be determined h/2
(h+t/2)
h/2
h/2
(h/2+t/2)
(h/2+tp/2) h/2 h/2 h/2
(h+tp/2)

doubler
middle plane physical common plane
h for the doubler and
the main plate
tp
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image, or the image may have been corrupted. Restart your computer, and then open the file
again. If the red x still appears, you may have to delete the image and then insert it again. t
main plate
middle plane
(tp/2 + t/2)

t/2
t/2
h/2 t/2 t/2

Welded joint A- B-
A B
y t
t
h
x
Shell FE model

Shell Element Model Details
• The FE formulation for shell elements gives top and bottom

stresses, top, and bottom
• The stress distribution through the thickness is considered to
be linear
• The membrane and bending stresses are obtained from
top
Shell element at midplane
bottom
6 mm

Global loads
Material Properties
Local loads, stresses or strains
Stress concentration factors
Residual stresses
Calculate Weld Life

l = hp
r
g=h

t
P P
Range of application - reasonably designed weldments, (K.Iida and T. Uemura, ref. 11)

l = hp
r
g=h

t
M M
Range of application - reasonably well designed weldments, (K.Iida and T. Uemura, ref. 11)

t1= tp hp
Validated for : 0.02 r/t 0.16 and
30o 60o, source [11]
h

x
P P
t
y

Validated for : 0.02 r/t 0.16 t1= tp hp
and 30o 60o, source [11]
h

x
M
M
t
y
where:

r

Probability Density Function
0.05
r
0.04
MF-5 MF-1
0.03
f()
MF-4 MF-3
0.02
MF-2
MF-1: μ=4.0789, =0.1710
MF-2: μ=3.7854, =0.4668
MF-3: μ=3.9496, =0.2665
0.01
MF-4: μ=3.9669, =0.4135
MF-5: μ=4.0084, =0.2832
0.0
0.0 40.0 80.0 120.0 160.0 200.0
Angle, [deg]

r
f (r)

Probability Density Function – Log-normal
1.20
0.96
MF-3
0.72 MF-5
MF-4
f(Ktt)
MF-1
0.48
MF-2 MF-1: μ=0.9224, =0.1978

MF-2: μ=1.0180, =0.2834
MF-3: μ=0.7998, =0.1635
MF-4: μ=0.9602, =0.1835
MF-5: μ=0.8481, =0.1770
0.24
0.00
0.0 1.8 3.6 5.4 7.2 9.0
SCF, (Ktt)

Probability Density Function - Bending
0.80
MF-3
0.64
MF-5
MF-4
MF-1
0.48
f(Ktb)
MF-2
0.32
MF-1:
MF-2:
MF-3:
0.16 MF-4:
MF-5:
0.00
0.0 2.0 4.0 6.0 8.0
SCF, (Ktb)

Statistical distribution of weld toe radii measured on
similar weldments produced by three manufacturers
0.99
0.90
MQ2 – production line 0.80

MQ1 – R&D workshop 0.70
MQ5 – University 0.60

0.50
laboratory
0.40
Probability
0.30
0.25
0.20
0.15
0.10
0.08
0.06
0.04
0.02
0.01
0.1 0.2 0.4 0.7 1 2 4 7 1
0
Weld toe radius, r
[mm]
Global loads
Material properties
Local loads, stresses or strains
Stress concentration factors
Residual stresses
Calculate Weld Life

Where:
Derived
for:
Where:
Derived for:

Global Loads
Material Properties
Residual Stresses
Calculate Weld Life

Residual stresses

How to account for RS
The residual stress can not be added linearly to the actual stresses at the
notch tip. However, the residual stress effect can be accounted for by adding
it to the pseudo-elastic stress in the Neuber formula.
In general residual stresses change the

notch tip mean stress rather than the amplitude.

Residual stress effect on mean stress

Global Loads
Material Properties
Residual Stresses
Calculate Weld Life

EXAMPLES

The T-Joint Weldment

Weld Geometry (all locations)
=tp hp
t
y

GY2 - Shell Element Model Details
19,197 nodes
18,858 elements
114,069 dof
Material:
A22H Steel (ASTM A500 Cold Formed
Steel for Structural Tubing)

Shell Element Model Summary
top (MPa) bottom m (MPa) b (MPa) hs (MPa)

(MPa)
Location 1 -7.14 2.19 -2.48 4.67 15.7
Location 2 -7.43 2.04 -2.69 4.74 16.3
Location 3 -5.20 -1.59 -3.39 1.81 10.9

Solid Element Model Details
885,069 nodes
613,891 elements
2,700,000 dof
0.008” element size at

weld toe
Comparison GY2 shell vs. 3D fine mesh FEA
peak via Kt peak from 3-D FEA

(GY-2 with 1.5t weld)
Location 1 17.1 MPa 16.9 MPa

T-Joint stress distribution

T-joint

T-joint

Fatigue Analysis Results (-N Method)

T-Joint experimental vs predicted life
60
T-Joint experimental vs predicted life
61
Gusset Weld
62
Gusset – Out of Plane Loading
63
Gusset –In Plane Loading
64
Square tube on plate
Overview of the experimental set-up
65
Square tube on plate
Fig. 41. Calculated total fatigue live based on the GY2 hot spot stress approach and the experimental fatigue data
using the JD material data; Welded tube-on-plate specimen (fully reversed lateral load of 21350 N)
66
Global Loads
Material Properties
Residual Stresses
Calculate Weld Life

Conclusions
• The GY-2 method provided an accurate

and moderately simple way to obtain the
peak stress for fatigue evaluations
• The GY-2 method with a single set of
membrane and bending stress
concentration factors provided a good
representation for the through-thickness
stress field.

Other Areas of Investigation
Manufacturing Process Simulation:
• Prediction of local mechanical properties and microstructures, residual

stresses and distortions to decrease manufacturing costs and improve
durability calculations.
• Welding Simulations
• Heat Treat Simulation
• Castings
Structural Analysis
• Consolidation of Fatigue calculations : Initiation and Propagation

Thank You

Developments in Weld Fatigue-J Wong

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Recent developments in fatigue of

Professor Greg Glinka - University of Waterloo

Run Smart, Run Fast, Run Lean 1

John Deere - MTIC

Run Smart, Run Fast, Run Lean 2

Run Smart, Run Fast, Run Lean 3

Run Smart, Run Fast, Run Lean 4

Run Smart, Run Fast, Run Lean 5

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Calculate Weld Life

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© 2008 Grzegorz Glinka. All rights reserved. 8

© 2008 Grzegorz Glinka. All rights reserved. 9

A) remote (nominal) through thickness stress, B) the actual through-

© 2008 Grzegorz Glinka. All rights reserved. 11

peak The stress xx in the plate

© 2008 Grzegorz Glinka. All rights reserved. 12

The stress concentration

a) A body with an angular notch subjected to multiple loading modes

© 2008 Grzegorz Glinka. All rights reserved. 14

Stress concentration factors Kmt,hs and Kbt,hs

© 2008 Grzegorz Glinka. All rights reserved. 15

The stress concentration factors and

a) T-butt weldment and resulting through-the-thickness stress distribution,

- depends on L and is constant along the weld toe

© 2008 Grzegorz Glinka. All rights reserved. 18

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© 2008 Grzegorz Glinka. All rights reserved. 20

© 2008 Grzegorz Glinka. All rights reserved. 21

Middle plane of the attachment

(h/2+tp/2) h/2 h/2 h/2

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© 2008 Grzegorz Glinka. All rights reserved. 23

© 2008 Grzegorz Glinka. All rights reserved. 24

• The FE formulation for shell elements gives top and bottom

© 2008 Grzegorz Glinka. All rights reserved. 26

Calculate Weld Life

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© 2008 Grzegorz Glinka. All rights reserved. 29

© 2008 Grzegorz Glinka. All rights reserved. 30

© 2008 Grzegorz Glinka. All rights reserved. 31

© 2008 Grzegorz Glinka. All rights reserved. 32

© 2008 Grzegorz Glinka. All rights reserved. 33

© 2008 Grzegorz Glinka. All rights reserved. 34

© 2008 Grzegorz Glinka. All rights reserved. 35

MF-2 MF-1: μ=0.9224, =0.1978

© 2008 Grzegorz Glinka. All rights reserved. 36

© 2008 Grzegorz Glinka. All rights reserved. 37

MQ1 – R&D workshop 0.70

MQ5 – University 0.60

Calculate Weld Life

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© 2008 Grzegorz Glinka. All rights reserved. 41

Calculate Weld Life

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In general residual stresses change the

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Calculate Weld Life

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