PSI - Issue 75

Kevin Mouradian et al. / Procedia Structural Integrity 75 (2025) 616–624 Kevin Mouradian et al. / Structural Integrity Procedia (2025)

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plate thickness of 15 mm, as illustrated Fig. 1. The joint preparation was a single-V configuration with a 60° bevel angle and a 1 mm gap between the plates. The welding process was completed in four passes.

Fig. 1. Geometry of specimens (dimensions in mm)

A certified welder performed the semi-automatic metal active gas (MAG) welding process 135 in the flat position (PA). The base metal employed in the fabrication of the specimens was S355 J2, in accordance with the specifications set out in EN 10025 ‑ 2 (CEN 2019). The filler metal utilized to connect the plates was a solid wire G42 (G 42 4 M21 3Si1 – G 42 3 C1 3Si1), in compliance with ISO 14341 (CEN 2020). The mechanical properties of the base and weld metals are presented in Table 1. The selection of both materials was made on the basis of their matching properties and widespread use in steel structure fabrication.

Table 1. Mechanical properties of base and weld metals

Material S355 J2

f y [MPa]

f u [MPa]

A [%]

363 420

518

29 20

G42

500-640

3. Non-destructive testing 3.1. Overview

Non-destructive tests were conducted at Centre Technique des Industries Mécaniques (CETIM 2024) to evaluate the distribution and dimensions of imperfections within the welds. Table 2 presents the quality level tolerances for weld imperfections analyzed in this study according to ISO 5817 (CEN 2023a) – tolerances applicable to fatigue loaded welds are provided in red.

Table 2. Imperfections tolerances according to quality levels outlined in ISO 5817

Limits for imperfections for quality levels

Imperfection

Schema

D

C / C 63

B / B 90

Undercut (5011)

und a but max. 0.5 mm 0.1 h t  0.15 b + 1mm but max. 7 mm

und a but max. 0.5 mm 0.05 h t 

und  but max. 1 mm 0.2 h t

w h  but max. 10 mm 0.25 b + 1mm

0.1 b + 1mm but max. 5 mm

Excess weld metal (502) Incorrect weld toe angle (505)

w h 

w h 

a

a

90  

110   a

150   a

Lack of fusion (401)

Short imperfections 0.4 h t  but max. 4 mm

Not permitted a

Not permitted a

Incorrect weld toe radius (5052)

-

- b

1mm r 

Angular misalignment (508)

ali 2   

ali 1   

-

a Same values are applicable for static and fatigue loading

Not specified

b