Fatigue Properties of Welded Joints Related to Specified Quality Levels in Shop Fabrication

64th Annual Assembly and International Conference of the International Institute of Welding 17-22 July 2011, Chennai India A. F. Hobbacher Jade Univ. of Appl. Sciences, Wilhelmshaven Germany

Why do we need weld quality ??

Big desaster from a small detail

Lack of fusion in important weld

(Thiruvalluvar)

Possible failure modes

A welded component can wrecked in multiple ways: 1. 2. 3. 4. 5. 6. 7. Plastic collapse due to overload Brittle fracture Elastic collapse (all types of buckling) Creep due to high temperatures Wear due to friction Corrosion Fatigue

Besides corrosion, about 75% of all failures are caused by fatigue. So, a weld quality code should primarily consider the effects of weld imperfections on fatigue.

Codes for weld quality assurance

Old German DIN 8563: Code for understanding between welders in shop and inspection personnel. Five levels: A, B, C, D, E Basis of ISO 5817: Now for quality assurance. Quality Groups B, C, D Collection of experimental data and fracture mechanics calculations. Compiled in BS PD 6493 later BS 7910 IIW Fatigue Recommendations widely based on BS 7910 Application codes for different areas of industry

Fatigue classes FAT for design

Example 1: Angular misalignment

Example 2: Porosity

Example 3: Slag inclusions

Fatigue properties of slag inclusions up to 10 mm long

Evaluation of porosity and slag inclusions

Evaluation of undercut

Matching imperfections and fatigue

Example for matching ISO 5817 quality groups and fatigue class FAT for 10 mm wallthickness and 5 mm fillet weld throats

Quality groups and fatigue class 1

Quality groups and fatigue class 2

Poposal for ISO 5817

The proposal for the future is that each quality group correspond to the same fatigue resistance Example: quality group B >> at least FAT 90, which is a good butt weld quality group C >> at least FAT 63, which is the toe of a fillet weld quality group D >> at least FAT 40, wich is the root of a fillet weld

Quality groups and fatigue - butt welds

19 types of imperfections in group B result in fatigue classFAT 90 only 8 types need a modification to result in fatigue class FAT 90 1. 2. 3. 4. 5. 6. 7. 8. Continuous undercut Single pore Clustered porosity Slag inclusions Metallic inclusions Linear misalignment of circumferential welds Multiple imperfections in longitudinal direction Angular misalignment (not in actual version of ISO 5817

Quality groups and fatigue - fillet welds

17 types of imperfections in group D result in fatigue class FAT 63 for weld toe failure and FAT 40 for weld root failure. Only 5 types need a modification to result in the proposed fatigue class. 1. 2. 3. 4. 5. Clustered porosity Slag inclusions Lack of fusion Lack of penetration Multiple imperfections in logitudinal direction

End