Low-cycle fatigue in ultra-high-strength steel welded joints in the as-welded and post-weld-treated conditions

This study investigates four different joints under fluctuating tension cycles in the low-cycle fatigue (LCF) regime. The selected material was S960 ultra-high-strength steel, manufactured via the direct-quenching manufacturing route. Based on typical engineering solutions, the following joints were chosen to be investigated in the experimental tests: metal active gas and laser welded butt joints, fillet-welded load-carrying cruciform joints, and non-load-carrying double-sided transverse attachment joints. To evaluate the improvement gained by the post-weld treatment, both as-welded condition and high-frequency mechanical impact treated joints from all joint types were tested. In addition to the experimental tests, some of the joints were analyzed using finite element (FE) models, with the aim of comparing the accuracy of the different fatigue assessment methods and the effect of the toe radius on the computational fatigue lives. The results obtained from the experimental tests and FE analyses were compared with each other and with IIW recommendations using the nominal stress, structural hot-spot (HS) stress, effective notch stress (ENS) and 4R methods. Based on the results, the structural HS and 4R methods are very suitable for the fatigue strength assessment in the LCF regime. With the nominal stress method, the computational fatigue lives remained uniformly conservative, while with the ENS method, the results varied depending on the calculation method. Using the value r = 1 mm as the weld toe rounding is justified in the FE analysis.