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Crack Propagation in Weldments

The document discusses fracture and crack propagation in weldments. It covers specific aspects of weldments, determining fracture toughness and crack driving forces, and shallow crack propagation and fatigue strength. Methods for evaluating weld imperfections and their effects on mechanical integrity are also presented.

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Balaji Lubricants & Chemicals
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© © All Rights Reserved
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27 views

Crack Propagation in Weldments

The document discusses fracture and crack propagation in weldments. It covers specific aspects of weldments, determining fracture toughness and crack driving forces, and shallow crack propagation and fatigue strength. Methods for evaluating weld imperfections and their effects on mechanical integrity are also presented.

Uploaded by

Balaji Lubricants & Chemicals
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Fracture and Crack

Propagation in Weldments

Prepared by: DSc Dževad Hadžihafizović (DEng)

Sarajevo 2023
Fracture and Crack Propagation in Weldments

1
Introduction
• Content

 Specific aspects of weldments


 Determination of fracture toughness
 Determination of the crack driving force
 Shallow crack propagation and fatigue
strength
 Shallow crack propagation and fatigue
strength

2
Fracture mechanics of weldments: Specific aspects

3
Potential welding defects of manual arc (stick) welding of typical mild steels from the
point of view of a failure analyst; according to Gagg (2005).

4
ISO 5817: Arc welded joints in steel -Guidance on
quality levels for imperfections
• 26 different types of weld imperfections
• Can be assigned to distinct groups from the perspective of mechanical integrity
(a)Cracks and crack-like imperfections have to be avoided or –if they occur –are
immediately subject to fracture mechanics analysis
(b) Material imperfections which act as crack initiation sites of paramount
importance for fatigue strength and fatigue life analyses of paramount importance
for fatigue strength and fatigue life analyses
(c) Geometric discontinuities increase the local stresses, affect crack initiation,
propagation and final failure
(d) Imperfections which probably are of no effect on fracture or fatigue life

5
Fracture mechanics of weldments: Specific aspects
• Inhomogeneous
• microstructure

The influence of welder


technique on the risk of slag
inclusions when welding with a
basic MMA (7018) electrode
Inhomogeneous
microstructure

6
Material inhomogeneity

Figure according to T oyoda, 1998 7


Fracture mechanics of weldments: Specific aspects

Crack along the coarse grain


structure in the HAZ

8
Strength mismatch

9
Strength mismatch

10
Welding residual stresses

11
Welding residual stresses

12
Welding residual stresses

Residual stress profiles


1. Individual determination
2. Compendia (upper bound curves to literature data) to
literature data)
3. Membrane stress (as-welded: max. value: yield strength)
4. Post weld treatment: σ+σ≥σ
Membrane stress
(yield strength at annealing temperature + correction
for ratio of E modules at room & annealing temperatures
5. Mechanical post weld treatment

13
Welding residual stresses
Types of misalignment:
(a)Axial misalignment between flat plates
(b)Angular misalignment between flat plates
(b)Angular misalignment between flat plates
(c)Angular misalignment in a fillet welded joint
Consequence:
Notch effect/local bending stress
 Strong effect of fatigue life and shallow crack
propagation
 Effect on long crack fatigue propagation and
(sometimes)on failure load

14
Fracture toughness determination
Modifications compared to testing of non-welded
material

 Specimen geometries most appropriate for


weldments, e.g., shallow cracked bend specimens
 Weldment specific aspects of specimen
preparation such as the introduction of the notch,
minimization of residual stresses and
misalignment
 Generation of a straight crack front
 Validity criteria
 Required number of test specimens
 Strength mismatch effects for testing in the net
section yielding range

15
Fracture toughness determination: Scheme

16
Fracture toughness determination

17
Fracture toughness determination

18
Fracture toughness determination

19
Fracture toughness determination

20
Fracture toughness determination

21
Fracture toughness determination

22
Specific features because of strength mismatch

23
Fracture toughness determination

24
Definition of weld width H for other than prismatic welds

25
Effect of strength mismatch on constraint and toughness

26
Effect of strength mismatch on toughness and crack path deviation

27
Stress-strain curves

Micro tensile tests


e.g., Kocak et al., 1998

28
Specific features because of residual stresses

29
Crack driving force and fracture assessment

30
Crack driving force: R6 type assessment

31
Mismatch corrected limit load FYM

32
Mismatch corrected limit load FYM

33
Primary and secondary stresses

34
Crack driving force due to primary
and secondary stresses

35
Interaction factor V

36
Determination of V

37
Fracture analyses including residual stresses

38
Fracture analyses including residual stresses

39
Fracture analyses including residual stresses

40
Fracture analyses including residual stresses

41
Initial defects in engineering alloys

42
Weld discontinuities and defects

43
Example: Weldment quality grades: VOLVO
Group Weld Quality Standard 181-0004, 2008

44
Contributions to fatigue life

45
Specific of mechanically short cracks

46
Literature

47

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