Influence of deep rolling on surface layer condition and fatigue life of steel welded joints

Dänekas, Christian; Heikebrügge, Steffen; Schubnell, Jan; Schaumann, Peter; Breidenstein, Bernd; Bergmann, Benjamin

doi:10.1016/j.ijfatigue.2022.106994

Cited by 14 publications

(9 citation statements)

References 32 publications

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“…The process was applied at a conventional CNC milling machine with the rolling direction parallel to the welding direction. The stepover distance was increased from a = 0.1 to a = 0.5 mm in contrast to the previous investigations regarding the post treatment of welded joints by deep rolling [24,25]. This was motivated by the relatively large area which was to be treated compared to the previous studies.…”

Section: Post Weld Treatmentmentioning

confidence: 99%

“…The successful application of deep rolling for fatigue life improvement of Alalloys was documented for 5000-, 6000-, and 7000-aluminum alloys [13][14][15][16]. First studies show also a high potential for the post weld treatment of welded joints for fatigue life improvement [23][24][25][26]. However, it seems that the contact force needs to be adapted to the local weld toe geometry to reach optimum results [25].…”

Section: Introductionmentioning

confidence: 99%

“…First studies show also a high potential for the post weld treatment of welded joints for fatigue life improvement [23][24][25][26]. However, it seems that the contact force needs to be adapted to the local weld toe geometry to reach optimum results [25]. For this reason, FSW joints with no weld bead seem to have a high potential for the application of the deep rolling process.…”

Section: Introductionmentioning

confidence: 99%

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Fatigue life improvement of similar and dissimilar aluminum friction stir welds by deep rolling

Schubnell

Müller

Boywitt³

et al. 2023

Weld World

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At the moment, high production costs prevent the friction stir welding (FSW) process from further industrial applications even if comparable high fatigue strength of the joints can be reached. Higher welding speed may reduce the production costs but decrease the fatigue strength of the manufactured FSW joints. A potential solution is a mechanical post weld treatment directly after welding to increase the fatigue strength of the FSW joint again. In this study, hydrostatic deep rolling was applied for fatigue strength improvement of similar and dissimilar FSW joints made of EN AW 5083 and EN AW 6082 alloys manufactured with different welding speed. Additionally, the fatigue strength was directly compared to conventional joints manufactured by metal inert gas (MIG) welding and to base material specimen made of EN AW 5083. The surface state in as-welded condition was characterized by surface roughness and residual stress measurements. Fatigue tests were performed to quantify the fatigue strength of the FSW joints. Similar compressive residual stresses were determined after deep rolling for similar and dissimilar joints. No fatigue life improvement was determined for deep-rolled similar joints made of EN AW 5083. However, in this condition, the fatigue life of the specimen was within the range of the base material. Thus, significant lower fatigue life and a high fatigue life improvement by deep rolling were reached for dissimilar joints. An increase of the welding speed from 300 to 800 mm/min strongly decreased the fatigue strength of dissimilar welded joints in the investigated case.

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Section: Post Weld Treatmentmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Fatigue life improvement of similar and dissimilar aluminum friction stir welds by deep rolling

Schubnell

Müller

Boywitt³

et al. 2023

Weld World

View full text Add to dashboard Cite

show abstract

“…The geometrical parameters and fatigue test results taken from previous studies [30][31][32][33][34][35][36] and other unpublished investigations are summarized in Table 1. These data contain 390 single fatigue tests with four different types of welded joints: single V-butt joints, double V-butt joints, cruciform joints, and T-joints.…”

Section: Materials and Specimensmentioning

confidence: 99%

Approach for the probabilistic fatigue assessment of welded joints based on the local geometry of the weld seam

Schubnell,

Konidena,

Jung

et al. 2023

Fatigue Fract Eng Mat Struct

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Welded joints show large variation of the weld toe geometry along the weld seam, which is one important reason for the comparably large scatter in fatigue life. Therefore, it is crucial to take the local geometry at the weld toe into account, to reduce the conservatism in fatigue assessment of welded joints. This study is based on the IBESS procedure for the calculation of the fatigue strength, whereby the evaluation of local geometrical parameters is carried out by means of 3D surface scans. The approach is validated against 26 fatigue test series. The fatigue life is in general overpredicted, whereas good agreement is achieved for high stress ratio ( ). A sensitivity analysis conducted with IBESS shows that weld toe radii ρ < 2 mm and flank angle α < 30° have a significant influence on the calculated fatigue strength. In contrast to this, no strong correlation between and the fatigue strength was determined experimentally in this study.

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“…Aufgrund der weitgehend automatisierten Fertigung der Monopiles stellt eine automatisierte Schweißnahtnachbehandlung eine sinnvolle Anwendung dar, um den Einsatz hochfester Stähle zu ermöglichen. Hier bietet sowohl eine Automatisierung der bereits etablierten Hämmerverfahren [8] wie auch die mechanische Bearbeitung durch den Festwalzprozess [9] eine Möglichkeit zur Verbesserung der Ermüdungsfestigkeit von Schweißverbindungen.…”

Section: Introductionunclassified

Automatisierte Schweißnahtnachbehandlung für Offshore‐Windenergieanlagen

et al. 2022

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Für die Umsetzung der klimapolitischen Ziele ist eine wirtschaftliche und ressourcenschonende Bauweise von Offshore‐Windenergieanlagen (OWEA) dringend erforderlich. Die Erhöhung der anzusetzenden Ermüdungsfestigkeit durch den Einsatz hochfester Stähle und durch die Anwendung von Schweißnahtnachbehandlungsmethoden bietet großes Potenzial zur Senkung des Materialeinsatzes und der Kosten bei Monopiles. Speziell in der automatisierten Fertigungskette der OWEA bieten sich automatisierte Prozesse wie das Festwalzen an. Festwalzen ist ein im Maschinenbau etabliertes mechanisches Bearbeitungsverfahren zur Erhöhung der Verschleiß‐ und Ermüdungsfestigkeit von metallischen Komponenten. Der vorliegende Aufsatz stellt Ergebnisse des Festwalzens als neuartige Nachbehandlungsmethode zur Erhöhung der Ermüdungsfestigkeit von Schweißnähten dar. Es werden die Oberflächen‐ und Randzoneneigenschaften UP‐geschweißter Stumpfnahtstöße aus einem Baustahl der Güte S355MLO vor und nach dem Festwalzen gezeigt. Um den Einfluss des Festwalzens auf die Nahtgeometrie zu quantifizieren, werden zusätzlich Ergebnisse von Messungen mit einem Laserliniensensor dargestellt. Abschließend werden die Ergebnisse der Ermüdungsversuche diskutiert, die das große Potenzial des Festwalzprozesses als Schweißnahtnachbehandlungsmethode aufzeigen.

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Influence of deep rolling on surface layer condition and fatigue life of steel welded joints

Cited by 14 publications

References 32 publications

Fatigue life improvement of similar and dissimilar aluminum friction stir welds by deep rolling

Fatigue life improvement of similar and dissimilar aluminum friction stir welds by deep rolling

Approach for the probabilistic fatigue assessment of welded joints based on the local geometry of the weld seam

Automatisierte Schweißnahtnachbehandlung für Offshore‐Windenergieanlagen

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