PSI - Issue 75

Xiru Wang et al. / Procedia Structural Integrity 75 (2025) 85–93 Author name / Structural Integrity Procedia 00 (2019) 000 – 000 7 with a slope of =3 , to a difference in life of approximately 3. This finding suggests that the weld start-stop position is associated with a lower fatigue life. However, when considering the highly stressed weld length 90 (approximately 90 =6 mm ) (Baumgartner, Bruder and Hanselka, 2012; Fricke, Gao and Paetzold, 2017) compared to the total weld length of tot = 100 mm – while neglecting 10 mm of weld length due to global 3D-effects at coordinates 0 – 10 and 110 – 120) – a factor of (100/6) 0.12 =1.4 is derived. With a slope of =3 , this also results in a difference in cycles by a factor of 2, which subsequently reduces the previously mentioned difference in calculated fatigue life between welds with and without distinct start-stop positions. Although the approach using the highly stressed weld length has not yet been validated for evaluating scanned welds, the results indicate a promising direction. 6. Conclusion The aim of this study is to further investigate the relation of weld quality and fatigue life based on further investigations by Wang et al. (2025) of welded joints with start-stop positions. Fatigue tests show minimal differences among specimens related to different quality levels according to ISO 5817:2023 Annex B (Ref. 505 and 5052 ‘incorrect weld toe’). To cover the effect of the variation of the local weld geometry, a reverse engineering approach is used to translate 3D-scans into 2D- and 3D-Finite Element models for assessment of local stress-trough thickness profiles. For fatigue life analysis, a combination of critical distance and linear elastic fracture mechanic approach is used. Following conclusions can be made: • The parameter and are analyzed based on 3D-scans. Specimens contain start-stop positions are referred to the quality levels C or

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