Fatigue and Fracture of Weldments: The IBESS Approach for the Determination of the Fatigue Life and Strength of Weldments by Fracture Mechanics Analysis

174 Pages·2019·11.57 MB·English

by  Uwe Zerbst

Uwe Zerbst · Mauro Madia · Benjamin Schork 
Jonas Hensel · Pawel Kucharczyk 
DesireTchoffo Ngoula · Didi Tchuindjang 
Julian Bernhard · Carla Beckmann
Fatigue and
Fracture of
Weldments
The IBESS Approach for the
Determination of the Fatigue Life and
Strength of Weldments by Fracture
Mechanics Analysis
Fatigue and Fracture of Weldments
Uwe Zerbst Mauro Madia
(cid:129)
Benjamin Schork Jonas Hensel
(cid:129)
Pawel Kucharczyk DesireTchoffo Ngoula
(cid:129)
Didi Tchuindjang Julian Bernhard
(cid:129)
Carla Beckmann
Fatigue and Fracture
of Weldments
The IBESS Approach for the Determination
of the Fatigue Life and Strength of Weldments
by Fracture Mechanics Analysis
123
UweZerbst DesireTchoffo Ngoula
Bundesanstalt für Materialforschung Materials MechanicsGroup
und-prüfung(BAM) Technische UniversitätDarmstadt
Berlin, Germany Darmstadt, Hessen,Germany
MauroMadia Didi Tchuindjang
Bundesanstalt für Materialforschung Saarbrücken, Saarland, Germany
und-prüfung(BAM)
Berlin, Germany and
Benjamin Schork HamburgUniversityofTechnology(TUHH)
Centerfor Engineering Materials—State Hamburg,Germany
Materials Testing Institute Darmstadt
(MPA),Institute for Materials Julian Bernhard
Technology(IfW) SAM,LBFDarmstadt
Technische UniversitätDarmstadt Technische UniversitätDarmstadt
Darmstadt, Hessen,Germany Darmstadt, Hessen,Germany
Jonas Hensel CarlaBeckmann
Institute of Joining andWelding IFS Fraunhofer-Institut für Werkstoffmechanik
Braunschweig University ofTechnology Freiburgim Breisgau, Baden-Württemberg,
Braunschweig, Niedersachsen, Germany Germany
Pawel Kucharczyk
IWT SolutionsAG
Aachen, Nordrhein-Westfalen, Germany
ISBN978-3-030-04072-7 ISBN978-3-030-04073-4 (eBook)
https://doi.org/10.1007/978-3-030-04073-4
LibraryofCongressControlNumber:2018960756
©SpringerNatureSwitzerlandAG2019
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Foreword
Thisbookgivesacomprehensiveandthoroughguidetothereaderswhoarelostin
the forest offatigue of weld. It presents the clear fracture mechanics and material
background offatigue of weld by starting first from fatigue crack initiation, short
crack and next by discussing long cracks, crack closure, crack growth and
threshold, residual stress, stress concentration, stress intensity factor, J-integral,
multiplecracks,weldgeometriesanddefects,microstructuralparametersincluding
HAZ and cyclic stress–strain behavior. The authors have succeeded in treating all
these mutually interacting important parameters in a unique distinct way of anal-
ysis. The elaborate works performed by the deep scientific knowledge of the
authors should be admired.
This is the timely and excellent publication in the field of weld.
Fukuoka, Japan Yukitaka Murakami
Emeritus Professor
Kyushu University
v
Notice
While theauthorsbelievethat theinformation andguidance given inthis bookare
correct,allpartiesmakinguseofitmustrelyontheirownskillandjudgement.The
authors cannot assume any liability for loss or damage caused by any error or
omission in the application of the IBESS method. Any and all such liabilities are
disclaimed.
The authors do not give any warranty or guarantee whatsoever that the infor-
mationandguidancegiveninthisbookdonotinfringetherightsofanythirdparty
or can be used for any particular purpose at all. Any person intending to use the
same should satisfy himself as to accuracy and the suitability for the purpose for
which it is intended to be used.
vii
Contents
Fatigue and Fracture of Weldments. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Background Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Stages of Fatigue Crack Propagation and Lifetime . . . . . . . . . . . . 1
1.2 The Crack Closure Phenomenon . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Crack Arrest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Describing Fatigue Crack Propagation and Arrest. . . . . . . . . . . . . 8
1.5 Fatigue Life and Fracture Mechanics Triangle . . . . . . . . . . . . . . . 16
1.6 Initial Crack Size for Fracture Mechanics Analysis. . . . . . . . . . . . 19
1.7 Multiple Crack Propagation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.8 The Need of Probabilistic Assessment . . . . . . . . . . . . . . . . . . . . . 21
1.9 Factors Affecting Monotonic Fracture and Fatigue Crack
Propagation of Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2 The IBESS Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.1 Basic Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2 Cyclic Elastic-Plastic Crack Driving Force. . . . . . . . . . . . . . . . . . 43
2.3 IBESS Input Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.4 Determination of the Fatigue Strength and Life . . . . . . . . . . . . . . 96
2.5 Preliminary Recommendations for Considering Welding
Residual Stresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.6 Misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.7 Application and Validation of the Approach. . . . . . . . . . . . . . . . . 113
3 Summary and Future Perspective. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Annexes.. .... .... .... .... ..... .... .... .... .... .... ..... .... 131
Annex A: Master Curve Analyses for the Statistical Determination
of Monotonic Fracture Resistance of Welds.. .... ..... .... 133
Annex B: Strength Mis-match η Factors for J-Integral
p
Determination. .... ..... .... .... .... .... .... ..... .... 137
ix
x Contents
Annex C: Determination of the Monotonic Elastic-Plastic Crack
Driving Force Including Strength Mis-match
and Secondary Stresses .. .... .... .... .... .... ..... .... 139
Annex D: Roughness Determination Close to the Weld Toe
for Specifying the Secondary Notch Depth k. .... ..... .... 147
Literature .... .... .... .... ..... .... .... .... .... .... ..... .... 149
Contributors
J. Baumgartner Fraunhofer Institute for Structural Durability and System
Reliability LBF, Darmstadt, Germany
H. Th. Beier Materials Mechanics Group, Technische Universität Darmstadt,
Darmstadt, Germany
W. Fricke Hamburg University of Technology (TUHH), Hamburg, Germany
J. Hohe Fraunhofer-Institut für Werkstoffmechanik, Freiburg, Germany
M. Kaffenberger Center for Engineering Materials—State Materials Testing
Institute Darmstadt (MPA), Institute for Materials Technology (IfW), Technische
Universität Darmstadt, Darmstadt, Germany
S. Münstermann RWTH Aachen University, Aachen, Germany
T. Nitschke-Pagel Institute of Joining and Welding IFS, Technical University
Braunschweig, Braunschweig, Germany
M. Vormwald Materials Mechanics Group, Technische Universität Darmstadt,
Darmstadt, Germany
xi
Abbreviations
ASTM American Society for Testing and Materials
bcc Body-centered cubic (lattice)
BM Base metal
BS The British Standards Institution
CDF Crack driving force
CG Coarse grain (HAZ)
COV Coefficient of variation (ratio of standard deviation r and mean or
expected value l of a statistical distribution)
CP Cap position at a weld (Fig. 23)
CPCA Compression pre-cracking constant amplitude
CPLR Compression pre-cracking load reduction
C(T) Compact tension specimen (fracture mechanics testing)
cyc Cyclic
FAD Failure assessment diagram
FAT FAT class, stress range referring to 2 (cid:1) 106 loading cycles
fcc Face-centered cubic (lattice)
FCP Fatigue crack propagation
FG Fine grain (HAZ)
HAZ Heat-affected zone
IIW International Institute of Welding
ISO International Organization for Standardization
L Longitudinal
LC Long crack
MAG Metal active gas (welding)
NASGRO Computerprogramfor fatigue crack propagation,providedbyNASA
OM Strength overmatching (r > r )
YW YB
p Plasticity-corrected
p Primary
PWHT Post-weld heat treatment
R-curve Crack resistance curve (monotonic and cyclic version)
xiii