Sequence effects on the life estimation of welded tubular structures made of S355J2H under uniaxial fatigue loading

• Published in: Welding in the world 2024-05, Vol.68 (5), p.1103-1141
• Main Authors: Neuhäusler, Josef, Roth, Jakob, Oswald, Markus, Dürr, André, Rother, Klemens
• Format: Article
• Language: English
• Subjects: Agricultural equipment; Chemistry and Materials Science; Commercial vehicles; Cranes; Damage accumulation; Fatigue life; Finite element method; Frame structures; Hollow sections; Lightweight; Low carbon steels; Materials Science; Metal fatigue; Metallic Materials; Overloading; Research Paper; Service life; Shape effects; Solid Mechanics; Spectra; Steel; Steel bridges; Stress concentration; Theoretical and Applied Mechanics; Tubes; Weight reduction
• ISSN: 0043-2288; 1878-6669
• DOI: 10.1007/s40194-023-01605-4

The use of hollow sections to form lightweight structures is widespread in common steel processing industries such as crane, commercial vehicle, steel bridge and agricultural machinery construction. The hollow sections are mainly designed as truss or frame structures, in some cases using high-strength and higher-strength steels in order to achieve optimum utilization of the component and material. A new collection of fatigue life data covering sequence effects and the accuracy of the linear damage accumulation is presented. Effects of the shape of the applied load spectra and sequence effects of different amplitudes have been investigated. This document covers tubes of 4 to 8 mm thickness made by low-carbon or mild steel S355J2H. In general, it was found that the spectrum shape and the loading sequence have an influence on the service life. Depending on the shape of the spectrum, random tests tended to lead to shorter service lives than tests with block-loading sequences. An influence of overloads was also found for the tests with interspersed overloads. Typical maximum linear damage sums taken from recommendations and codes of 0.2 or sometimes 0.5 are exceeded for all spectra investigated and in some of the cases even significantly above 1.0. Transferability of the recommendations to component-type structures like tubular joints needs revision to lift its lightweight potential. Using stress concentration factors (SCF) from finite element analysis, typical strength values for the structural and effective notch stress concepts are checked. All joints investigated show a significantly higher strength compared to the IIW recommendations using the structural stress approach or compared to the DVS 0905 with the effective notch stress approach.