Article
Nanoscience & Nanotechnology
Sumit Choudhary, Vidit Gaur
Summary: AA5086-H116 plates were welded with and without copper (Cu)-reinforcement using friction stir welding. Single-pass and double-pass processes were applied to develop a localized composite (AA5086/Cu). The addition of Cu-reinforcement improved the microhardness, weld joint efficiency, and fatigue strength of the welded joints.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2023)
Article
Engineering, Mechanical
Rajneesh Jaisawal, Vidit Gaur, Shahnawaz Ahmed
Summary: This study aimed to investigate the fatigue properties of AA5086-H321 and its weld joints. The weld joints showed similar hardness and ultimate tensile strength as the base alloy, but with slightly reduced elongation. The endurance limits of the weld joints were either higher or the same as compared to that of the base alloy. The fatigue lives of weld joints were increased due to crack growth retardation during intergranular fatigue crack propagation.
INTERNATIONAL JOURNAL OF FATIGUE
(2023)
Article
Engineering, Mechanical
Chao Jiang, Wen Xiong, C. S. Cai, Linyun Zhou, Yichen Zhu
Summary: Field inspection reveals that corrosion and fatigue loading can simultaneously affect the fillet weld in steel bridge towers. This study investigates the corrosion effects on the fatigue life of the weld to ensure structural safety during its service life. A prediction procedure based on fracture mechanics is proposed and validated by test results. Different corrosion effects and levels are considered, and a finite element model incorporating a local shell model is used to analyze stress variation. The results show a significant reduction in fatigue life due to corrosion pits and the interaction between corrosion and fatigue. However, the fatigue performance of the fillet weld, considering corrosion effects, still meets code specifications due to low tensile stress range in the steel bridge towers.
ENGINEERING FAILURE ANALYSIS
(2023)
Article
Engineering, Marine
Zhihao Chen, Banglong Yu, Ping Wang, Hongliang Qian
Summary: This study examined the fatigue behavior of fillet weld steel joints in marine structures (such as cruciform and T-welded joints) using experimental tests and finite element analysis. Ultrasonic phased array testing confirmed the fatigue failure of full-scale specimens in cyclic tensile loading, consistent with the failure mode of marine structures. The influence of incomplete penetration and weld profile on fatigue performance was analyzed using the traction structural stress method. The study proposed a unified master S-N curve that can evaluate the fatigue performance of fillet weld joints in different conditions.
Article
Engineering, Electrical & Electronic
Jiapeng Gao, Yuxiang Hong, Bo Hong, Xiangwen Li, Aiting Jia, Yuanyuan Qu
Summary: This article presents a highly robust weld feature extraction model based on a low-cost structured-light vision sensor, which can achieve seam tracking of variable gap fillet welds and still maintain good robustness under uneven and strong reflection conditions on workpiece surfaces.
IEEE SENSORS JOURNAL
(2021)
Article
Engineering, Marine
Shizhu Xing, Xianjun Pei, Jifa Mei, Pingsha Dong, Shaojuan Su, Chunbo Zhen
Summary: Two fatigue failure modes, weld toe cracking and weld root cracking, can occur in load-carrying fillet welded connections. The fatigue life associated with weld root cracking is typically lower and exhibits more variability, especially for welded aluminum alloys. This paper examines the transition behaviors of fatigue failure modes in load-carrying fillet welds made of aluminum, considering parameters such as plate thickness, weld penetration, joint misalignment, weld material, and ultrasound impact peening (UIP). Experimental and theoretical studies are used to propose a quantitative fillet weld sizing criterion for preventing weld root cracking in fillet-welded aluminum connections.
Article
Engineering, Civil
Mehran Ghafouri, Antti Ahola, Joseph Ahn, Timo Bjork
Summary: This study investigates the influence of welding sequences and external constraints on angular distortion and residual stresses in short fillet welds made of high strength steel. The findings show that external constraint has a larger impact than welding sequence on the development of angular distortion and peak residual stresses. Furthermore, the results demonstrate that short fillet welds have larger peak magnitudes of localized transverse residual stress fields compared to continuous fillet welds. The stiffness of external constraint has a greater influence on preventing angular distortion in continuous fillet welds than in short fillet welds.
ENGINEERING STRUCTURES
(2022)
Article
Engineering, Mechanical
Sang Woo Han, Geonho Lee, Hansol Kim, Min Soo Kim, Young Rae Jo, Jungho Cho
Summary: This study investigated the effects of different weld geometries on the fatigue performance of T-fillet joint aluminum arc welding. The results showed that the area of the welded part and weld reinforcement were the primary factors affecting fatigue performance, with full penetration and larger weld reinforcement leading to improved fatigue performance. Surprisingly, optimal size and higher quantity of porosities were found to increase fatigue performance.
JOURNAL OF MECHANICAL SCIENCE AND TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Lixia Zhu, Jinheng Luo, Haidong Jia, Lifeng Li, Wenchang Yu, Yongnan Chen
Summary: Tensile tests were conducted on X80 steel girth welds with different parameters to investigate the strain distribution behavior, strain hardening law, and the effect of welding parameter deviation on mechanical properties. The results showed that inadequate welding layers led to strain localization at the maximum thickness of the filler layer, while inadequate preheating and interpass temperatures resulted in strain localization at the interface of the weld filler layer. Deviation of welding parameters significantly reduced the strength of the girth weld, with the lowest yield strength and tensile strength observed when the interpass temperature was inadequate. Fracture patterns varied depending on the welding parameters, with ductile fracture observed in the absence of deviation and a mixed fracture of toughness and brittleness observed when the parameters deviated.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Engineering, Mechanical
Hamidreza Rohani Raftar, Edris Dabiri, Antti Ahola, Timo Bjork
Summary: This paper presents a fatigue analysis of load-carrying fillet welded joints using literature data and focuses on the application of the 4R method for a thorough re-evaluation. The results show that the 4R method can improve the accuracy of fatigue evaluation for weld root failure in such joints.
INTERNATIONAL JOURNAL OF FATIGUE
(2022)
Article
Computer Science, Interdisciplinary Applications
Shengfeng Chen, Jian Liu, Bing Chen, Xinyu Suo
Summary: Welding is widely used due to its economical materials and adaptability to various shapes. Robot-based intelligent welding is gaining popularity as a safe alternative to manual welding. This study proposes a universal method using structured light for recognizing and positioning fillet weld joints, which is robust, versatile, and accurate.
ROBOTICS AND COMPUTER-INTEGRATED MANUFACTURING
(2022)
Article
Energy & Fuels
T. V. B. Babu, M. Amala Justus Selvam, L. Natrayan
Summary: By introducing wheat husk biosilica into the weld pool of different materials, it was found that a biosilica content of about 1.0wt% had the highest tensile and fatigue strength. By optimizing the microstructure and improving the properties of the heat-affected zone and thermo-mechanically affected zone, the potential for enhancing mechanical and fatigue strength was provided.
BIOMASS CONVERSION AND BIOREFINERY
(2022)
Article
Optics
Wei Xu, Shanglu Yang, Wu Tao, Guotao Zhang, Haiwen Luo, Shuoshuo Li
Summary: In this study, the laser beam oscillation welding approach was used to weld the Al-Si coated 22MnB5 steel, and the process parameters were optimized to improve the joint strength. The experimental results showed that the laser power had the largest effect on the tensile strength of the welded joint.
OPTICS AND LASER TECHNOLOGY
(2022)
Article
Computer Science, Interdisciplinary Applications
Liang Tian, Yu Luo
Summary: Through numerical simulation analysis, it is found that the longitudinal and transverse inherent deformations decrease with the increase of welding speed and plate thickness, whereas as the nominal heat input increases, the inherent deformations increase significantly. The plastic strains in the cross section of the T-joint also vary greatly because of the process parameters and plate thickness, but the maximum value always appears near the location of the welding toe.
ENGINEERING COMPUTATIONS
(2021)
Article
Engineering, Mechanical
Lise Sandnes, Torgeir Welo, Oystein Grong, Filippo Berto
Summary: This study investigates the high-cycle axial fatigue behavior of a third generation Al-steel butt weld made by Hybrid Metal Extrusion & Bonding (HYB). The microstructure in this specific weld provides high intrinsic resistance against interfacial cracking during high-cycle fatigue testing. Fatigue fracture typically initiates at the weld toe on the aluminum side due to a geometrical stress riser localized inside the soft heat-affected zone, rather than being limited by interfacial bond strength.
INTERNATIONAL JOURNAL OF FATIGUE
(2022)
Article
Mechanics
M. Oberreiter, R. Aigner, S. Pomberger, M. Leitner, M. Stoschka
Summary: This study focuses on the technological size effect of cast aluminium alloy EN-AC 46200 and statistically analyzes the microstructural properties. The results show that microstructure has an impact on crack propagation, but the initial crack threshold is independent of microstructural properties.
ENGINEERING FRACTURE MECHANICS
(2021)
Article
Engineering, Manufacturing
W. Schneller, M. Leitner, S. Leuders, J. M. Sprauel, F. Grun, T. Pfeifer, O. Jantschner
Summary: The research aims to contribute to the fatigue strength assessment of selectively laser melted metallic structures by deriving a methodology based on experimental data and focusing on residual stresses and material properties. By considering the effects of thermal gradients and residual stresses, the study introduces a correction factor to established designing concepts to estimate fatigue strength within a conservative region.
ADDITIVE MANUFACTURING
(2021)
Article
Materials Science, Multidisciplinary
Martin Leitner, Wolfgang Schneller, Sebastian Springer, Florian Grun
Summary: The study revealed that the surface layer has a significant impact on the fatigue strength of selectively laser melted 17-4 PH stainless steel flat specimens, particularly in the high-cycle fatigue region. Machining process can greatly increase the fatigue strength. Therefore, considering surface layer properties is crucial for fatigue design of additively manufactured 17-4 PH steel structures.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2021)
Article
Engineering, Civil
M. J. Ottersboeck, M. Leitner, M. Stoschka
Summary: Automated welding processes produce high-quality welds with smooth and regular global geometry, but the local geometry variations due to dynamic effects impact fatigue behavior; Estimation of stress concentration in welds based on characteristic parameters is common, but underestimation occurs at locations with distinct undercuts; An improved approach is presented to consider the stress concentrating effect of local undercuts at the weld toe.
ENGINEERING STRUCTURES
(2021)
Article
Engineering, Mechanical
Andreas Trausmuth, Michael Stoschka, Florian Grun
Summary: FZG tests are widely used to determine fatigue lifetime and operational parameters in gear applications. The transferability of results between FZG and twin disc tests has been assessed in this study, providing insights for future test configurations.
Article
Materials Science, Multidisciplinary
Matthias Oberreiter, Stefan Fladischer, Michael Stoschka, Martin Leitner
Summary: This study focuses on the local microstructure and fatigue performance evaluation in the advanced lightweight design of cast aluminium alloys, highlighting the influence of local stress conditions under different microstructural properties.
Article
Materials Science, Multidisciplinary
Sebastian Springer, Martin Leitner, Thomas Gruber, Bernd Oberwinkler, Michael Lasnik, Florian Grun
Summary: This research investigates the fatigue strength of wire arc additive manufactured structures, considering the influence of imperfections such as gas pores. The study utilizes a stress intensity equivalent transformation approach to assess fatigue strength, showing that modifying data leads to better results with a slight underestimation compared to unmodified data.
Article
Chemistry, Multidisciplinary
Yusuf O. Busari, Yupiter H. P. Manurung, Martin Leitner, Yusuf L. Shuaib-Babata, Muhd F. Mat, Hassan K. Ibrahim, David Simunek, Mohd Shahar Sulaiman
Summary: This research numerically evaluates fatigue crack growth of structural steels S355 and S960 using Paris' law parameters determined experimentally. The crack propagation is modeled using 3D FEM with adaptive remeshing, showing acceptable agreement with experimental investigation.
APPLIED SCIENCES-BASEL
(2022)
Article
Engineering, Mechanical
Michael Horvath, Michael Stoschka, Stefan Fladischer
Summary: This study applies Taylor's Theory of Critical Distances to assess the fatigue strength of defect-afflicted cast steel components and presents a new methodology for fatigue assessment based on the projected planar defect shape. The results show good agreement with experimental data and the method does not require extensive numerical simulations.
INTERNATIONAL JOURNAL OF FATIGUE
(2022)
Article
Materials Science, Multidisciplinary
Murat Tiryakioglu, Anders E. W. Jarfors, Martin Leitner
Summary: There is a trend for automotive producers to require increased usage of secondary aluminum alloy ingots in order to reduce car production's CO2 footprint. This study investigates the merits of this trend and finds that simultaneously reducing elongation requirements for aluminum alloy die castings while increasing the use of secondary ingots is counterproductive, as it fails to take advantage of weight reduction possibilities and actually increases the car's CO2 footprint over its useful life. The study recommends that foundries improve their melt handling capabilities to minimize damage to the melt in the melting and casting process chain, and that automobile producers reduce weight by increasing elongation requirements to achieve a reduced CO2 footprint in car designs, material usage, and life-cycle.
Editorial Material
Materials Science, Multidisciplinary
Martin Leitner
Article
Chemistry, Multidisciplinary
Michael Horvath, Matthias Oberreiter, Michael Stoschka
Summary: This study applies the linear-elastic strain energy density concept to evaluate the fatigue behavior of defect-afflicted cast steel components made of high-strength alloy G12MnMo7-4+QT. An energy-based design limit curve is derived through analytical calculations, which combines experimental results of notched and unnotched small-scale specimens. The stress ratio dependency is also investigated. Additionally, a numerical methodology is introduced for the energy-based fatigue assessment of complex spatial imperfections using radiographs. The established framework is validated through experimental results of defect-afflicted large-scale specimens, showing a close agreement between numerically and experimentally derived fatigue strength values with an average deviation of only eight percent.
APPLIED SCIENCES-BASEL
(2023)
Article
Chemistry, Multidisciplinary
Michael Stoschka, Michael Horvath, Stefan Fladischer, Matthias Oberreiter
Summary: This study presents feasible engineering methods to assess the fatigue strength of irregularly shaped planar imperfections and pore networks using linear-elastic numerical analysis. It introduces advanced concepts such as the Theory of Critical Distances, Notch Stress Intensity Factors, and Elastic Strain Energy Density methods to provide additional insight into the local fatigue strength distribution. The study also presents two numerical strategies to efficiently evaluate the fatigue strength by optimizing load case count and stress field evaluation data points.
APPLIED SCIENCES-BASEL
(2023)
