Fatigue analysis and design of arc-welded and laser-welded lap joints

Abstract

Fatigue might be the governing limit state in marine structures mainly induced by the waves and wind. Therefore, using a lap joint for the shell plating to replicate the appearance of a riveted joint for a retro yacht is critical due to the limited fatigue resistance. For this joint type cracks initiated at the root, which should always be avoided due to hard detectability, might appear. Arc- and laser-welded lap joints are researched to estimate fatigue resistance and reduce the risk of root failure.
The hot spot peak stress of weld toe and weld root notches is insufficient to reflect the fatigue strength, explaining why an effective notch stress parameter is used, able to deal with both weld toe and weld root notch induced fatigue. Semi-analytical weld notch stress formulations are established in order to avoid solid finite element modelling to capture the effective notch stress. Particular attention is paid to the lap joint characteristic extreme weld notch load carrying level. A second-order weld load carrying stress formulation is introduced. Since the (laser) weld is typically small in comparison to the plate thickness, a dedicated way of weld modelling is proposed, assuming a shell finite element type of formulation, allowing to capture the far field stress for both the weld toe and weld root notch accurately.
Fatigue tests are performed to obtain the laser-welded lap joint mid-cycle fatigue resistance information, including the material characteristic length as effective notch stress coefficient. Particular attention is paid to mean (residual) stress effects in comparison to the arc-welded joint equivalent to explain the fatigue performance.
Comparing the lap joint fatigue resistance in arc-welded and laser-welded configurations to the resistance of other joint types, the results turned out to be aligned. Investigating different material characteristic parameters, either an effective point or an effective line is used. A line based parameter shows a better performance. The main reason is that the actual notch stress gradient is explicitly considered. The mean (residual) stress seems to be larger for arc-welded joints. Furthermore, the mean (residual) stress correction seems at the same time to be one reason for toe induced- rather than expected root induced failure. For arc-welded joints, the change in failure location induced by stress level dependent secondary bending moments is another reason. The fatigue resistance parameter confidence for laser-weld weld joints is relatively low in comparison to the confidence for arc-welded ones, as a result of data size: respectively ≈190 and ≈3000.
When not considering the change in secondary bending moments in the fit of a Se-N curve, the overall fit parameters and quality do not change significantly for arc-welded lap joints. However, the influence on the effective stress range is substantial and changed the value on average by 4.7 % and up to 14.7 %.
Considering only the mid-cycle fatigue resistance, laser welding is superior to arc welding when exposed to low load and response ratios resulting from the lower residual stress level. The FAT class design curve of arc-welded joints for the hot spot structural stress concept with a load and response ratio of 0.5 can be used with a mean stress correction to estimate the fatigue resistance of laser welds.