Influence of Residual Stresses on Fatigue Response of Welded Tubular K-Joints

Seeking light and transparent bridge designs, engineers and architects have found an efficient and artistic way to fulfill their requirements: steel tubular bridges. In these modern tubular truss bridges, welded K-joints have been shown to be critically susceptible to fatigue failure induced by repeated traffic loads. Despite the research devoted to the study of fatigue during the last 35 years, especially in the offshore oil industry, estimating their fatigue resistance of tubular truss bridges is difficult and solutions are approximate. This is due to the complexity of the parameters influencing bridge fatigue strength, including: 1) complex loadings, 2) applied stress concentrations in joints, 3) welding imperfections, 4) welding residual stresses, and 5) size effects. Some design rules and studies are available to estimate these effects; however, residual stresses in tubular K-joints remain unknown as well as their influence on fatigue crack propagation. Residual stresses are well known to have detrimental influence on fatigue crack propagation in other metallic structures, and further study is a necessary for improving the understanding of K-joint fatigue behaviour. To address this problem, the main objective of this research is to assess, experimentally and numerically, welding residual stresses and their influence on the fatigue response of K-joints. In this thesis, experimental measurements of the residual stress fields were investigated through neutron-diffraction, hole-drilling and X-ray methods. Results have shown that, principal residual stresses are oriented transversely, i.e. perpendicularly to the weld direction, both at and near the surface. Residual stresses can reach the S355 steel yield strength at the weld toe. This orientation is particularly detrimental for fatigue because it is also the orientation of the principal applied stresses, and as a consequence high residual and applied stresses superimpose. Moreover, it is proved that a restraining effect occurs in the gap region in-between the braces remaining the critical residual stresses high in the gap region. Two large scale tubular truss beams were subjected to high-cycle fatigue in order to assess the effect of residual stresses on fatigue response of welded tubular K-joints. These tests revealed that tensile residual stresses do not affect the fatigue crack growth in details loaded in tension (hot-spot 1), whereas they play a significant role in details loaded in compression (hot-spot 1c). Tensile residual stresses enable crack opening, making the fatigue cycle partly or entirely effective to crack propagation. Based on these tests and previous tests from the ICOM test database, it is recommended to design all (tension or compression) K-joints using a strength curve Srhs Srhs – Nf category 100 (for T = 16 mm). A thermo-mechanical finite element model was also developed to numerically reproduce the residual stress creation (using ABAQUS and MORFEO codes). Once the numerical results were validated by comparison with experimental results, the finite element model was used to model other K-joint geometries. A geometrical parametric study was performed to identify the most influential parameters affecting the residual stress distribution (technological size effect). It is found that a raise of the wall chord thickness T (proportional scaling) or of the wall thickness τ = t/T (non-proportional scaling) strongly increases the magnitude of tensile transverse residual stresses. Based on this parametric study, residual stress distributions with depth for transverse, longitudinal and radial directions are proposed. Finally, an extended finite element method (X-FEM) model was used to propagate a fatigue crack under residual and applied stresses. An analytical model based on the effective stress intensity factor range ΔKeff (fracture mechanics) and combined with the proposed distribution for residual stresses was also established to predict fatigue crack propagation in joints loaded in tension and in compression.

Size effects in the fatigue behaviour of tubular bridge joints

Luís Costa Borges

A critical aspect in the design of tubular bridges is the fatigue performance of the structural joints. Economic viability depends on it. Lower fatigue strength for joints with thicker failing members was observed in welded joints typical to the bridge application. Different approaches to this phenomenon, called size effect, have been suggested, all based on the thickness correction for welded plate joints first proposed by Gurney. For the welded tubular joints, few studies on the size effects have been carried out; most of the existing investigations refer to geometries typical to petroleum industry offshore structures. In contrast to offshore structures, bridge structures have different absolute sizes and different member proportions (in particular lower chord radius to thickness ratios, γ). Tubular joints are far more complex than welded plate joints, multiple parameters are needed to describe the geometry (α, β, γ, τ, ζ) and there are several load scenarios. For these reasons, the fatigue behaviour analysis of such joints is a complex task. Current design recommendations combine the use of the structural (hot-spot) stress at the weld toe with a correction factor to take into account the wall thickness of the failing member. This approach oversimplifies the problem and can be very penalising, in particular for joints composed of thicker tubes, as is commonly the case for bridges. Furthermore, the truss member sizes that result from static design are likely to fall out of the validity range of current recommendations. This thesis focuses on a case of commonly used tubular joints: welded steel K-joint made out of circular hollow section (CHS). The main goals of this research are to understand the fatigue behaviour of as-welded CHS K-joints and to clarify the influences/effects of the different geometric parameters on their fatigue strength. In order to carry out a thorough study on the geometric size effects in CHS K-joints for bridges, fatigue tests were conducted for large-scale specimens with crack depth measurements and an advanced 3-D crack propagation model was developed. The first chapters of this thesis provide an introduction and a brief review of the main concepts in tubular joint fatigue and size effects on fatigue behaviour. The experimental tests of two tubular trusses under fatigue loading are then outlined. Crack growth in selected truss joints is monitored using the Alternating Current Potential Drop (ACPD) system. An advanced 3-D modelling of welded K-joint with surface crack is implemented using the boundary element method (BEM). A crack propagation model, based on Linear Elastic Fracture Mechanics (LEFM), is then developed using a step-wise incremental crack growth strategy. This model allows for fatigue strength and life estimations. Furthermore, it considers the influence of all geometric parameters that define CHS K-joints in a realistic way. The validation of the crack propagation model is made by comparisons with experimental data at different levels (i.e. member and joint strains and stresses, ACPD crack growth data). A parametric study is then carried out on joint geometries typical for a bridge application (low chord radius to thickness ratio) considering three basic load cases. Examples of results are shown and analysed on a "geometry cause"/"effect over the stress intensity factor and fatigue strength" basis. Parametric study results are then analysed, highlighting the case where the joint is proportionally scaled. The geometry correction factor, Y, is introduced as a function of the relative crack depth that is common to homothetic joints. The influence of the absolute size of the joint, also known as thickness effect, is determined for the three basic load cases. Parametric results are finally explored bringing to light the effect of non-proportional scaling. It is shown that size correction factors for fatigue strength can be expressed as a function of the non-dimensional geometrical parameters β, γ and τ, chord thickness, T, and different load cases. A new fatigue design method is proposed for welded (CHS) K-joints, based on LEFM and accounting for geometric size effects.

EPFL2008

Influence of welding residual stresses on stable crack growth in tubular K-joints under compressive fatigue loadings

Claire Acevedo, Alain Nussbaumer

Tubular bridge design has to deal with fatigue issues. The fatigue susceptibility of these bridges, composed of circular hollow section profiles welded together in K-joints, is mainly due to stress concentrations, to welding imperfections and to tensile residual stresses induced by the welding process. Since these residual stresses are unknown for K-joints, measurements were carried out in vicinity of weld toes using the incremental hole-drilling method, X-ray diffraction and neutron diffraction in particular. Re-sults from these techniques show that on the first millimeters from the surface, the most important tensile re-sidual stresses are oriented perpendicular to the weld and reach the yield strength. According to experimental investigations on two large scale specimens, it is established that tensile residual stresses have a strong influ-ence down to a depth of 2-3 mm from the surface, allowing cracks to propagate in compressive joints. Prelim-inary Finite Element Analyses are presented in this paper.

CRC Press/Balkema, Taylor & Francis group2010

Residual stress effects in tubular K-joints crack growth

Claire Acevedo, Alain Nussbaumer

Seeking light and transparent bridge designs, engineers and architects have found an efficient and artistic way to fulfill their requirements: steel tubular bridges. Like any other welded structure, the joints of this kind of bridge suffer from high tensile weld residual stresses. Combined with high stress concentrations, tensile residual stress is a relevant factor in fatigue crack development. Therefore, an experimental study has been carried out on tubular joints in order to characterize the 3D residual stress field, using mainly the Neutron Diffraction method. On the other side, two large-scale welded tubular truss beams were tested under constant amplitude fatigue loading. It is revealed that the peak tensile residual stress, exceeding the yield stress of the material, is localized at ~2 mm under the surface and allows cracks to develop in compressive joints. The influence of residual stresses on stable crack propagation is analyzed based on fracture mechanics theory.

EPFL2010

Size effects in the fatigue behaviour of tubular bridge joints

Luís Costa Borges

EPFL2008