This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Development of Fatigue Evaluation Procedure for Weld-Bonded Joints Using the Battelle Structural Stress Method
Technical Paper
2012-01-0477
ISSN: 0148-7191, e-ISSN: 2688-3627
Annotation ability available
Sector:
Language:
English
Abstract
In this paper, the Battelle structural stress method for evaluating the fatigue life of welded joints is applied to weld-bonded joints. In order to overcome the complexity of modeling and analyzing both crack paths in weld-bonded joints, a superposition approach is proposed as a reasonable and effective alternative for fatigue design purpose.
The superposition approach for evaluating the fatigue life of weld-bonded joints uses two simplified finite element (FE) models: a spot weld model and an adhesive bond model. Each simplified FE model is required to represent the fatigue behavior properly and to minimize the modeling effort without sacrificing the accuracy of the results. The superposition concept can be used in practice if the life evaluation results using the superposition are comparable with the experiments. For the spot welds, the recently developed simplified procedure and master fatigue S-N curve is employed [1]. The spot-weld master fatigue S-N curve is applicable to a wide range of spot-weld diameters, sheet thicknesses, and loading directions. For adhesive bonded joints, a new procedure that combines shell and solid elements is developed and a corresponding master fatigue S-N curve is constructed.
Recently, Auto/Steel Partnership (A/SP) has undertaken an investigation of the fatigue performance of advanced high strength steel spot welds [2]. The proposed superposition approach was validated using A/SP's fatigue test results from adhesive bonded and weld-bonded joints of HSLA340 steel and DP600 steel. A comparison of the observed fatigue lives with those predicted using the superposition procedure that was based on the Battelle structural stress method demonstrated the effectiveness of the proposed tool for fatigue design assessment and optimization purposes.
The key contribution of the development of this procedure is that a consistent approach using the Battelle structural stress method based on nodal forces/moments, now can be applied to adhesive joints and to weld-bonded joints, and as has already been established, can be applied successfully to spot-welded joints and fusion-welded joints.
Recommended Content
Authors
Citation
Hong, J. and Forte, T., "Development of Fatigue Evaluation Procedure for Weld-Bonded Joints Using the Battelle Structural Stress Method," SAE Technical Paper 2012-01-0477, 2012, https://doi.org/10.4271/2012-01-0477.Also In
References
- Hong, J. “The Development of a Simplified Spot Weld Model for Battelle Structural Stress Calculation,” SAE Int. J. Mater. Manuf. 4 1 602 612 2011 10.4271/2011-01-0479
- Bonnen, J. Agrawal, H. Amaya, M. Iyengar, R. et al. “Fatigue of Advanced High Strength Steel Spot-Welds,” SAE Technical Paper 2006-01-0978 2006 10.4271/2006-01-0978
- Dong, P. Hong, J.K. Cao, Z. “A Mesh-Insensitive Structural Stress Procedure for Fatigue Evaluation of Welded Structures, IIW Doc. XIII-1902-01/XV-1089-01 2001
- Dong, P. Hong, J. K. De Jesus, A. M. P. “Analysis of Recent Fatigue Data Using the Structural Stress Procedure in ASME Div 2 Rewrite,” Transactions of ASME, Journal of Pressure Vessel Technology 139 3 355 362 2007
- Dong, P. Hong, J. K. “The Master S-N Curve Approach to Fatigue Evaluation of Offshore and Marine Structures,” Proceedings of the OMAE 2004 2 2004
- Dong, P. Hong, J. K. Osage, D.A. Dewees, D.J. Prager, M. “The Master S-N Curve Method An Implementation for Fatigue Evaluation of Welded Components in the ASME B&PV Code, Section VIII, Division 2 and API 579-1/ASME FF-1 ,” Welding Research Council Bulletin 523 Welding Research Council 2010
- 2007 ASME Boiler and Pressure Vessel Code, Section VIII, Div.2 ASME 2007
- API Standard 579-1/ASME FFS-1 Fitness for Service API 2007
- Dong, P. Hong, J. “CAE Weld Durability Prediction: A Robust Single Damage Parameter Approach,” SAE Technical Paper 2002-01-0151 2002 10.4271/2002-01-0151
- Potukutchi, R. Agrawal, H. Perumalswami, P. Dong, P. “Fatigue Analysis of Steel MIG Welds in Automotive Structures,” SAE Technical Paper 2004-01-0627 2004 10.4271/2004-01-0627
- Dong, P. Hong, J.K. Potukuchi, R. Agrawal, H. “Master S-N Curve Development an d Validations for Aluminum MIG and Laser Welds,” IIW Doc. XIII-2035-04/XV-1172-04 2004
- Kang, H. T. Dong, P. Hong, J. K. “Fatigue Analysis of Spot Welds Using a Mesh-Insensitive Structural Stress Approach,” International Journal of Fatigue 29 1546 1553 2007
- Rahman, M.M. Bakar, R. A. Noor, M. M. Rejab, M. R. M. Sani, M. S. M. “Fatigue Life Prediction of Spot-Welded Structures: A Finite Element Analysis Approach,” European Journal of Scientific Research 22 444 456 2008
- Castagnetti, D. Dragoni, E. “Standard Finite Element Techniques for Efficient Stress Analysis of Adhesive Joints,” International Journal of Adhesion & Adhesives 29 125 135 2009
- Auto Steel Partnership http://www.a-sp.org
- Andruet, R. H. Dillard, D. A. Holzer, S. M. “Two- and Three- Dimensional Geometrical Nonlinear Finite Elements for Analysis of Adhesive Joints,” International Journal of Adhesion & Adhesives 21 17 34 2001
- Gonçalves, J.P.M. de Moura, M.F.S.F. Magalhães de Castro, P.M.S.T. “Application of Interface Finite Elements to Three-Dimensional Progressive Failure Analysis of Adhesive Joints,” Fatigue & Fracture of Engineering Materials & Structures 26 479 486 2003
- He, X. “A Review of Finite Elements Analysis of Adhesively Bonded Joints,” International Journal of Adhesion & Adhesives 31 248 264 2011
- Xia, Y. Zhou, Q. Wang, P.C. Johnson, N.L. Gayden, X.Q. Fickes, J.D. “Development of High-Efficiency Modeling Technique for Weld-Bonded Steel Joints in Vehicle Structures - Part I: Static Experiments and Simulations,” International Journal of Adhesion & Adhesives 20 414 426 2009
- Chang, B.H. Shi, Y. W. Dong, S.J. “A Study on the Role of Adhesives in Weld-Bonded Joints,” Welding Journal Research Supplement 78 275-s 279-s 1999
- Chang, B. Shi, Y. Lu, L. “Studies on The Stress Distribution and Fatigue Behavior of Weld-Bonded Lap Shear Joints,” Journal of Materials Processing Technology 108 307 313 2001
- Melander, A. Linder, J. Stensio, H. Larsson, M. Gustavsson, A. “How Defects in an Adhesive Layer Influence the Fatigue Strength of Bonded Steel-Sheet Speciemens,” Fatigue and Fracture Engineering and Material Structures 22 421 426 1999
- Melander, A. Larsson, M. Stensiö, H. Gustavsson, A. Linder, J. “Fatigue Performance of Weldbonded High Strength Sheet Steels Tested in Arctic, Room Temperature and Tropical Environments,” International Journal of Adhesion & Adhesives 20 415 425 2000
- Dong, P. Hong, J. K. Cao, Z. “Stresses and Stress Intensities at Notches: “Anomalous Crack Growth” Revisited,” International Journal of Fatigue 25 811 825 2003
- Wang, P.C. Chisholm, S.K. Banas, G. Lawrence, F. V. Jr. “The Role of Failure Model, Resistance Spot Weld and Adhesive on the Fatigue Behavior of Weld-Bonded Aluminum,” Welding Journal Research Supplement 74 41-s 47-s 1995
- Sam, S. Shome, M. “Static and Fatigue Performance of Weld Bonded Dual Phase Steel Sheets,” Science and Technology of Welding and Joining 15 242 247 2010
- Long, X. Khanna, S. K. “Fatigue Performance of Spot Welded and Weld Bonded Advanced High Strength Steel Sheets,” Science and Technology of Welding and Joining 13 241 247 2008