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The results of axial-stress and repeated-bending loading tests on welded thin-gage alloys
indicate joint geometry has the greatest effect on fatigue strength
6Y N. L PERSON
ABSTRACT. A study of aluminum alloy road cars, military vehicles and high- which were 12 in. long. All welds
butt, lap and tee welded joints under way trailers. were allowed to age at room tempera-
axial-stress loading and of butt welds The fatigue strength of an alumi- ture for at least 30 days before being
under repeated-bending loading (all of num plate material with welds is gen- tested.
thin-gage plate materials) revealed that erally lower than that of the base
their fatigue strengths were affected fore- metal. Such factors as stress concen- Butt Joints
most by the geometric characteristics of All the butt joints were of the
the joints. The degree of stress concen- trations and variations in physical and
mechanical properties in the weld area single-vee-groove design (60 to 70
tration and of symmetry with respect to
the load axis both contribute to the fol- contribute to that difference. Although deg) with l / 1 ( to V 4 in. lands, ex-
lowing order of decreasing axial-stress fatigue must be considered in the de- cept for the 3 / 1 6 in. 5052 sheet welds
fatigue strength for the joints investi- sign of many structures, the literature which were square-butt design. Only
gated: contains little fatigue data for the butt joints for the repeated-
weldments in the newer alloys. This bending tests had a root opening
1. Butt, bead on. ( V 1 6 in.). The butt joints for the
paper partially fills that void by
2. Butt, bead off. repeated-bending tests were welded
3. Tee, double fillet. presenting fatigue data for butt, lap
4. Lap, double fillet. and tee-welded joints. Several base with two superimposed passes on the
5. Lap, single fillet. and filler metals alloys were included face side and one pass on the back
6. Tee, single fillet. in the study. side (total of three weld passes); the
7039-T61 (5039) joints were an ex-
Only small differences were found be- ception in that these were welded with
tween the last three joints listed, all of Materials
only one pass on each side. The
which had substantially lower fatigue All base and filler metals used to
strengths than the three joints rated 7039-T61 (5039) butt joints were
prepare the welded joints were regular prepared with very low weld-bead
above them. The base metal and filler production materials. Table 1 gives
metal alloys apparently had less effect on profiles (bead height about 13% of
fatigue strength than the geometric fac- the chemical compositions of the base base metal thickness). One face pass
tors. and filler metals. and one back pass were also used for
For any given type joint (butt, lap or Generally, the weld joints were the butt joints for axial-stress testing.
tee), the weld size and shape were prime made with plate of nominal 3 / 8 in. The root pass was back chipped be-
factors affecting their fatigue strengths thickness. Alloys 5052 and 6061 were fore the back pass, except for the
(except bead-off butt welds). The high- used in 3 / 1 0 and V 4 in. thicknesses, 3
/ 1 6 in. 5052 welds. Alloy 5083-to-
est fatigue strength for bead-on butt respectively, because a specific ap- 6161 dissimilar joints (both base met-
joints was obtained from welds with plication required data from material als were 3 / s in. thick) were in-
low-profile reinforcements and high ten- of those thicknesses. Table 2 lists the luded.
sile strength. Fillet welds with a convex tensile properties of the unwelded
shape produced lower fatigue strengths plates. The butt welds were radiographed
for both lap and tee joints. Tee joints to determine their soundness (welds in
with fillet welds substantially oversize lap and tee joints were not radio-
and with the welds blending smoothly Welding Procedures
graphed). Only those butt welds with
into base metals had the highest fatigue The following three types of welded a porosity rating of 2 or better ac-
strength for that type joint. joints (Fig. 1) were evaluated: cording to the porosity standards
1. Butt, weld bead-on and bead-off shown in Fig. 2 were tested. The
Introduction (axial-stress and repeated-bending fa- maximum amount of porosity (in size
In the past couple of decades, a tigue tests). and number) permitted by the ASME
number of weldable high-strength 2. Lap, single and double-fillet Boiler and Pressure Vessel Code cor-
aluminum alloys have been developed. joints (axial-stress tests only). responds approximately to rating no.
Alloys that have received wide ac- 3. Tee, single and double-fillet joints 5 and 6 in Fig. 2.
ceptance include 5083, 5086, 5456 (axial-stress tests only).
and 7039. These alloys have been used All welding was done in the flat Lap Joints )
for many applications, such as pres- position using the gas metal-arc proc- As shown in Fig. 1, lap joints were
sure vessels, ship superstructures, rail- ess. Table 3 gives specific details of prepared with one or two fillet welds.
welding conditions. Generally, the Each fillet was made in one pass. The
N. L. PERSON is Senior Research Engi- weldment measured 24 in. along the overlap of the base plates was 1V 2
neer, Kaiser Aluminum & Chemical Corp.,
Pleasanton, Calif. weld axis; except for the tee joints, in. for the single-fillet joint and 1 in.
for the double-fillet joint. sheet was the load-carrying member. tests conducted with V 2 in. wide
Two types of dissimilar alloy joints Table 4 gives the results of tensile specimens of each type joint. Only the
were prepared. One was 3 / 1 6 in. 5052 tensile strength is reported for the lap
welded to 1/i in. 6061 and the other
was V 4 in. 6061 to 3 / s in. 5083 (for
s and tee joints. For the dissimilar-alloy
lap joints, the tensile strength was
dissimilar joints, the thinner of the BEAD OFF based on the cross-sectional area in
two base materials will be mentioned
3x:
a. BUTT JOINTS the thinner of the two base metals.
first). As expected, the butt welds with
SINGLE FILLET the weld reinforcement (bead-on) had
Tee Joints higher tensile strengths than the bead-
Single-fillet and double-fillet joints DOUBLE FILLET off welds. Also the double-fillet lap
were welded (Fig. 1). Dissimilar-alloy and tee joints had substantially higher
joints were prepared with the same tensile strengths than the correspond-
alloys*, used in making the lap joints. ing single-fillet joints. For the single-
For the 5052-to-6061 joints, the thin- fillet lap joints the highest tensile
ner 5052 sheet was the load-carrying WELD SIZE strengths were obtained when the two
member (in subsequent tensile and base metals had unequal thicknesses
fatigue tests), as shown in Fig. 1. In c. TEE JOINTS and the fillet weld was on the edge of
the 6061 to 5083 joints, the 6061 Fig. 1Configuration of welded joints the thinner of the two plates.
78-s | F E B R U A R Y 1971
Table 3Typical Welding Conditions 6
Base metal Filler metal
Thickness, Diameter,
ftlloy(s) in. Alloy in. Amperes Arc volts Travel, ipm
Butt joints:
5052-H32 He 5356 0.045 190 23 42
5083-H113 Vs 5183 He 230 25 15
5083-H113 Vs 5356 %2 300, 250 25, 24 16, 24
5083-H113 to 6061-T6 Vs 5356 %2 300 25 17
5086-H32 Vs 5356 He 295, 270" 23 14
5456-H321 Vs 5556 He 250 25 18
7039-T61 Vs 5183 He 250 23 22
7039-T61 Vs 5039 He 235, 225" 25, 26 b 23, 17b
7039-T6 Vs 5039 %2 300 23 18
Lap joints:
5052-H32 He 5356 0.045 200, 180b 24 34
5052-H32 He
to 6061-T6 M 5356 0.045 180 22 24
5083-H113 Vs 5356 %2 270 24 24
5083-H113 Vs
to 6061-T6 5356 He 270, 260" 25, 22= 34, 16=
7039-T61 u
Vs 5039 He 230 24 18
Tee joints:
5052-H32 He 5356 Vei 170 20 20
5052-H32 He
to 6061-T6 H 5356 Ve* 170 20 20
5083-H113 Vs 5356 %% 270 24 24
5083-H321d Vs 5356 Vl2 325 24 12
5083-H113 Vs
to 6061-T6 H 5356 He 235 22 20
7039-T61 Vs 5039 He 275 24 14
5083 plate.
r all welds.
Test Procedures the length of the specimen. Prior to axial-stress tests. The butt and lap-
The axial-stress and repeated- start of the fatigue tests, the sharp joint specimens were loaded axially
bending test specimens are shown in corners of the specimen tests sections using pin-type grips. Figure 4 shows
Fig. 3. Bead-off butt weld specimens were rounded slightly with 3 / 0 emery how the tee-joint specimens were
were prepared by machining off the paper. loaded in these test machines. The test
weld reinforcements and about 0.005 Two MTS Systems Corporation frequencies ranged from about 2 to 60
in. from the surface of the base metal. electrohydraulic test systems (10 and Hz. Krouse plate-bending fatigue ma-
The machining marks ran parallel to 50 kip capacities) were used for the chines were used for the repeated-
r
<7 |
*
J \ v.
4- *
** *
80-s | F E B R U A R Y 1971
30 11| m 9i^: 1 1f i l l r-rr rmi I I I .
tin A
J,- - O 5 0 5 2 - H 32(5356)
'' tA : 0 5083-HII3(5l83)
.-A
^ 2.
w
to
CO
E rz: *,
2|L. 55 00 88 33 -- HH II II 33 ( TO
5356)
606I-T6 (5356
Ld & )
a: 20
b,N, i *>-}(> * B- 4 9 -
--5Wk
(O
J lk L-s\
b; ">.- a?2-" ^ 2V
T n - 11X
3 %7
i > L ( *- .
'-* 5086-H32(53e S>
_ n * \\-lS
\\> I
X -a 7 0 3 9 - T 6 I (5183) Br?5 "'*.*E
< : 7 0 3 9 - T 6 I (5039) " "
"a 2 TO 3 WELD WARP/iuc
"D BASEi PL AT c o Q r r oi h1 11 2 5 To Or 1 H l it /111
i i i in
ftNtoo
i MI ! 1 1
10' 10" IO 5 IO 6 IO7 10*
NUMBER OF CYCLES
Fig. 5Axial-stress fatigue data for bead-on butt joints, R = 0
Fig. -Method of loading tee joints in
axia stress
_30
to
ments had a lower profile than welds
in the other alloys. (On the other to"
hand, the 7039 (5039) bead-on welds O 5 0 5 2 - H 3 2 (5356)
co20 ;o 5083-HII3(5l83)
might have had an even higher tensile
strength if the reinforcements had an : 5083-HII3 (5356)
been larger.) The reinforcement :A 5083-HII3 TO 606I-T6(5356)
<n > 5086-H32 (5356)
profile influences the fatigue strength,
because the stress concentration at the iio :D
:
7039-T6I (5183)
7039-T61 (5039)
toe of the weld bead changes as the LARGE PORE ON FRACTURE SURFACE
profile changes. x INITIATED AT DROSS BELOW SURFACE:
A number of investigators have < INITIATED AT PORE BELOW SURFACE
studied relationships between fatigue in
strength of bead-on butt welds and the I0 a 10* I0 : 106 10' 10'
stress concentration at the toe of the
NUMBER OF CYCLES
weld reinforcement.1"4* 6 _ s Often they
used photoelastic models to deter- Fig. 6Axial-stress fatigue data for bead-off butt joints, R = 0
mine elastic stress concentration fac-
tors. * 2* 6 Probably one of the most weld toe: where 1 is the width of the weld bead,
comprehensive studies of that type r is the radius of the weld toe, and the
was reported by Trufyakov et al. 6 I +r other coefficients are dependent on
That work used the following equa- K, =1 + Rlog ratios of the joint dimensions (not
TTA
tion, which relates the stress concen- specifically defined by Trufyakov et
tration factor to the height and width al). 6 The equation was originally pro-
- Ro + n - rSR* + To posed by Navrotskii. 9
of the weld bead and the radius of the
Table 5Axial-Stress Fatigue Strength s of Welded Butt Joints (Stressed Tranvserse to Weld Axis)
Fatigue s t r e n g t h , k s i ,
Thickness, - a t i ndicated n u m ber of cycles -
Alloy(s) in. Fil er metal /? IO4 IO 5 IO 6 10'
Bead-on:
5052-H32 Vie 5356 0 22.5 15.5 10.5 8
5083- H113 Vs 5183 0 27 17 13.5 11
5356 0 27 17.5 10.5 9
5083-H113 to 6061-T6 Vs 5356 0 26.5 16 9.5 7.5
0.5 27.5 18.5 15.5
5086- H32 Vs 5356 0 30 22 12 10
7039-T61 Vs 5183 0 32 22 15.5 10.5
5039 0 33 22.5 17.5 14
Bead-off:
5052-H32 He 5356 0 28.5 17 15
5083-H113 Vs 5183 0 28.5 19 15
5356 0 27.5 18 14
5083-H113 to 6061-T6 Vs 5356 0 27 20 15
0.5 26.5 21
5086-H 32 Vs 5356 0 27 18.5 14
7039-T61 Vs 5183 0 30 20 15
5039 0 30.5 21.5 17
R = _Sli. Smin = 0.2 ksi for all tests; therefore, R va lues are a pproximate.
*> m a x
*: 1 i 1 I . I .
z 10 2030 40 50
TENSILE STRENGTH
IN KILO-POUNDS PER SQUARE INCH
10 20 30 40
Fig. 8Butt weld (bead on) fatigue strength vs. tensile
TANGENT ANGLE IN DEGREES strength (axial stress, R=0)
Fig. 7Butt weld (bead on) fatigue strength vs. tangent
angle at toe of weld bead (axial stress, R = 0 )
A simpler measure of the stress pears in Fig. 9. It is reasonable to included in Figs. 5 and 6. The other
concentration due to the bead was expect the weld strength to be influ- alloys are expected to have S-N curves
used by other workers. 3* 4* 7* 8 The enced to some extent by the angle. for i?=0.5 similar to those shown in
angle between the tangent to the weld The resulting plot shows the data in these figures.
bead and the plate surface was meas- two groupsthe high tensile strength Several bead-on weldments had
ured at the toe of the bead. welds and the relatively low strength conditions that proved detrimental to
A general trend of increasing fa- welds. Neither group shows any tend- their fatigue strength. First, one 5083
tigue strength with decreasing tangent ency for the tensile strength to de- (5356) weldment had the base metals
angle was observed for aluminum al- crease with an increasing tangent an- offset by nearly 2 5 % of the base
loy and steel weldments. Figure 7 gle. The two groups should be consid- metal thickness. Offset causes bending
shows the results of a similar analysis ered separately, because 5052 and stresses when the joint is loaded axial-
for the welds in this study. The angles 5083-6061 welds have inherently low- ly, which superimpose on the load/-
were measured from photographs of er strengths than the others. Even if area stress. In Fig. 5, the test points
cross sections of the welds. The curves they had a tangent angle equal to, or for specimens from that weldment are
indicate a trend similar to that found less than, those of the high strength noted. The offset produced a reduc-
in the earlier workthat of increasing welds, their strength level would be tion in fatigue strength of approx-
fatigue strength with decreasing tan- lower. imately 2 5 % . Another weldment had
gent angle. The effect is more promi- Figures 10 and 11 compare the warpage of 2 to 3 deg between the
nent for IO4 and IO5 stress cycles axial-stress fatigue results for R=0 planes of the two base metals. This
than at the longer fatigue lives. Since and 0.5 (5083-to-6061 butt welds condition, as in the case of offset,
the bead size is primarily affected by only). The data for R=0 were also introduces bending stresses under ax-
the arc travel speed, the bead size
varied, because different welders used
different speeds. 60
The trend of increasing fatigue 7039 7039
strength with decreasing tangent angle I (5039) (5|83)
shown in Fig. 7 is probably affected to o
some extent by the tensile strength of z
the welds. Figure 8 shows a plot of _ UJ 50
5086 5083 5083
fatigue strength vs. weld tensile F oc f(5l83) (5356)
strength for the same welds. A gener- fc
2 <3 TANGENT
al increase in fatigue strength with in- zUJ COa ANGLE
increasing tensile strength is evident in <r
the graph. The rate of increase (slope 1- <.
CO UJ
40
of the lines) decreases somewhat as
a. 5083
the fatigue lives become longer, just UJ .
5052
as the curves in Fig. 7. Apparently the -i TO
tangent angle and tensile strength each az
to 6061
Z => il
have an effect on bead-on weld fatigue UJ O
strength, with both effects showing up
30
I- a.
in both Figs. 7 and 8. Which effect is
o
greater is unknown. Tomlinson and _i
Wood 5 reported, however, that the x.
long-life fatigue strength of bead-on
welds is affected little by static z 20
strength. 10 20 30 40
A plot similar to Fig. 7, but TANGENT ANGLE IN DEGREES
showing the relationship between weld Fig. 9Butt weld (bead on) tensile strength vs. tangent angle at toe of
tensile strength and tangent angle, ap- weld bead (axial stress. R=0)
82-s | F E B R U A R Y 1971
10 IO* IO5 IO6 IO7 IO8
NUMBER OF CYCLES NUMBER OF CYCLES
Fig. 10Axial-stress fatigue S-N curves for 5083 to 6061 butt Fig. 11Axial-stress fatigue SN curves for 5083 to 6061 butt
joints, bead on joints, bead off
ial loads. The warped specimens had a they are more apt to affect the fatigue ently, if the p o r e had not reduced the
fatigue strength about 1.5 ksi lower strength of bead-off welds than those net area, fatigue crack growth would
than "straight" specimens (Fig. 5 ) . of welds with the reinforcement in- have continued giving longer total
Neither offset nor warpage would be tact. This is because the defects are life. The fatigue life of the specimen
expected to have as large an effect on often exposed on the surface. Even with the large pore was less than
fatigue strength under repeated- when a defect is not exposed on the V 10 th that of the second specimen
bending fatigue loading. surface, it can cause a significant re- tested at the same stress (Fig. 6 ) .
Figure 12 shows the two fracture duction in fatigue strength, as illus-
trated by Fig. 13. The fatigue strength Lap Joints in Axial Stress
surfaces of a butt-joint specimen
where weld spatter fell on the toe of of that specimen was 2 ksi below the Double-fillet lap joints had substan-
the weld. The fracture surfaces re- band of data for that alloy (Fig. 6 ) . tially higher tensile strengths than sin-
vealed that fatigue initiated at that The effect of dross below the surface gle-filler joints. However, there was
spatter. However, the test point for is similar. In that case, the fatigue generally little difference in fatigue
the specimen fell in line with those of strength was lowered about 3 ksi strength between the two joint de-
unspattered welds, suggesting that (Fig. 6 ) . signs (Table 6 ) . The main difference
spatter had little effect. Internal de- Figure 14 shows another case noted was at the short fatigue lives
fects, such as porosity and dross, ap- where a large solitary pore apparently where the fatigue strength of double-
parently had little effect on the fatigue had a more indirect effect. Since the fillet joints was somewhat higher due
strength of the bead-on welds. Fatigue pore was far from the surface, initia- to their higher tensile strength. The
initiation always occurred at the toe tion was not associated with it. The highest fatigue strength was obtained
of the welds. Conceivably, the defects pore did, of course, reduce the net from dissimilar single-fillet joints of
could have had an effect, if they had area of the specimen at the cross V 4 in. 6061 and 3 / 8 in. 5083 plate,
occurred close to the weld toe. Of section, thus increasing the stress but only when the fillet weld was
course, if the defects were so large somewhat (less than 1%). Apparent- placed on the edge of the thinner
that cross-sectional area was reduced ly, the pore had its greatest effect 6061 plate (Fig. 15). When the welds
significantly an effect would be seen. after fatigue initiated at the surface. were on the edge of the 5083 plate
Although the tensile strengths of The area of fatigue on the fracture (requiring larger welds), lower fa-
the bead-off welds varied considerably surface shown in Fig. 14 is less than tigue strengths resulted (apparently
for the various alloys, their fatigue half the area on another specimen due to the lower tensile strength for
strengths were fairly equal (Table 5 ) . tested at the same stress level. Appar- that condition). In both cases the
The main exception was for alloy
7039 welded with 5039 filler metal.
SHADOW PORE
Those welds had, by far, the highest
bead-off tensile strength and the
highest axial-stress fatigue strength.
If internal defects exist in a weld,
Fatigue s t r e n g t h
Thickness, Filler at ir d i c a t e d n u m b e r of c ,
Alloy(s) in. metal 3 X 10' 104 10s 10s 10'
Single fillet:
5052-H32 He 5356 10 7.5 4.5 3 2
5052-H32 He
to 6061-T6 H 5356* 10 8 5 3.5 2
5083-H113 Vs 5356 10 8 4.5 3 2
6061-T6 H
to 5083- H113 Vs 5356' 11.5 8 5 3.5 2
5356h 11.5 7 5 3.5
7039-T61 Vs 5039 10 7.5 5 3 1
Double fillet:
5052-H32 He 5356 9.5 5.5 2.5 2
5052-H 32 He
to 6061-T6 H 5356 9 4.5 3.5 2
5083-H113 Vs 5356 9 4.5 2.5 2
6061-T6 H
to 5083-H113 Vs 5356 11 7.5 4.5 2.5
7093-T61 Vs 5039 9 5 2.5 1
IO 3
IO 4
IO IO 5 6
IO 7
IO 8 The range of data obtained from
tee joints is shown in Figs. 18 and 19.
NUMBER OF CYCLES Both the tensile strength and fatigue
Fig. 15Axial-stress fatigue data for single-fillet-welded lap joints, R = 0 strength of double-fillet tee joints were
very substantially higher than those of
stress reported is that in the 6061 single-fillet joints (Table 7 ) . Usually
plate. The smaller welds (weld on the difference between the two joints
x edge of 6061) probably caused less was more than the factor of two that
stress concentration than when larger might be expected by increasing the
fillets were required. number of welds from one to two.
Figure 16 shows a double-fillet The main reason double welds gave
Fig. 16Dissimilar lap joint of 3/16 in.
5052-H32 and 1/4 in. 6061-T6 5052-to-6061 joint with one excessive- more than twice the strength is that
single-fillet joints are nonsymmetric
with respect to the line of axial load-
i i
| ing, resulting in large bending stresses.
The highest fatigue strengths for
CO '
5
tHH^
Mil me A - *
larger than normal, respectively (Fig.
20). Another factor that favored the
5083-H321 double-fillet joints was that
X -o-JU Y'M.
- 5- ! ay u
m*-~a1
f:
T -gss
i the surface of the fillet welds blended
<
S
rt
IO 3
IO 4
IO IO 5 4 6
IO 7
IO 8
very gently into the base plates. This
low angle reduced the severity of the
NUMBER OF CYCLES stress concentration at the weld toe.
Fig. 17Axial-stress fatigue data for double-fillet-welded lap joints, R = 0 Contrasted with that, the alloy 7039
84-s [ F E B R U A R Y 1971
joints had fillet welds with somewhat
convex surfaces (Fig. 21) which in- O5052-H32(5356)
creased the stress concentration. The CO 5052-H32 TO 606I-T6 (5356)
A 5 0 8 3 - H I I 3 ( 5 3 5 6 , U N D E R SIZE WELDS)
7039 joints had the lowest fatigue * 5 0 8 3 - H 3 2 l ( 5 3 5 6 , 0 V E R SIZE WELDS)
strength at long lives along with the co*20 6 0 6 1 - T 6 TO 5083-H32l(5356,0VER SIZE WELDS)
5083-H113 joints (Table 7 ) . The lat- co 7039-T6I (5039)
UJ
ter joints had undersize welds and <r
low tensile strengths. h-
co
Weld porosity of moderate size and
amount had no apparent effect on the 2 10
fatigue strength of either the single or
double-fillet tee joints. When porosity
occurred, it was usually seen at the <
root of the welds after fracture (Fig. 2 0
21). Fatigue usually initiated at the 10 10 I0 5 IO6 10' 10'
root in the single-fillet joint. On the NUMBER OF CYCLES
other hand, the double-fillet joints
Fig. 18Axial-stress f a t i g u e data for single-fillet-welded tee j o i n t s , R=0
failed from the root of the welds only
in the case of the undersize
5083-H113 welds. The interface be- 30r 1 1 111II 1 1 1m ~ - r i rr
CO o 5052-H32(5356) -
tween the two base metals made such
a sharp notch at the root of the weld * 5052-H32 TO 606I-T6 (5356)
5083-HII3 (5356,UNDER SIZE WELDS)
that the incidence of porosity proba- CO* A 5CS3-H32I(5356 OVER SIZE WELDS) :.
CO
bly added little to the stress concen- UJ 2 0 !
tration at the root. The porosity at the
root of the welds may have acted to 11
CO
blunt the sharp interface notch. Sever- s s &m-t HE - 4 - _. s -_
al cases were found where double-
fillet joints had porosity at only one of ^I0
yi * i - f l 1^
- - = i te-
2
* *
Fig. 20Alloy 5083-H321 tee joint with oversize fillet welds Fig. 21Alloy 7039-T50 tee joint with porosity and oversize
fillet welds
Table 8Repeated-bending Fatigue Strengths of Welded Butt Joints (Stressed Transverse to Weld Axis)
Fatigue strength, ksi
at indicated number of cycles
Base metal a Filler IO1 IO 5
IO6 10; IO8
Bead-on:
5083- H113 5183 26 18 11.5 8 7
5456-H321 5556 28 16.5 9.5 7.5 7
7039-T61 (low-profile beads) 5039 25 16 10.5 10
7039 (T6 type temper) 5039 >35 19 11.5 8 7
Bead-off:
5083-H113 5183 30.5 24.5 16 10.5 10
5456-H 321 5556 33 25 15.5 13 11.5
7039-T61 5039 28 17.5 12 10.5
8B-s I F E B R U A R Y 1971
tration and decreasing symetry), the in a tee connection is to replace the
fatigue strength decreases. Thus, the welded joint with a tee-shaped ex-
joints are ranked in order of decreas- trusion and to then butt weld the
ing fatigue strength as follows: connecting plates to the extrusion.
1. Butt, bead off.
2. Butt, bead on. References
3. Tee, double fillet. 1. Frost, N. E., and Denton K., "The
4. Lap, double fillet. Fatigue Strength ot Butt Welded Joints
5. Lap, single fillet. in Low-Alloy Structural Steels," British
Welding Journal, Vol 14, April 1967, pp
6. Tee, single fillet. 157-162.
2. Koziarski, J., "Fatigue Aspects in Air-
The differences in fatigue strength craft Welding Design," WELDING JOURNAL,
between the last three designs listed 34 (5), 446 to 458. (1955).
were only slight. 3. Newman, R. P., "Fatigue Strength ol
Butt Welds in Mild Steel," British Weld-
The highest fatigue strength for ing Journal, Vol 7, March 1960, pp 169-178.
welded tee joints was achieved by 4. Sanders, W. W., Jr., Derecho, A. T.,
and Munse, W. H., "Effect ol External
using oversize fillet welds (double Geometry on Fatigue Behavior of Welded
fillet) that blends smoothly into the Joints," WELDING JOURNAL, 34(2), Research
Suppl. 49-s to 55-s (1965).
base plates. A similar effect could 5. Tomlinson, J. E., and Wood, J. L.,
probably be attained by beveling the "Factors Influencing the Fatigue Behavior
Fig. 24Alloy 7039 (5039) butt welds of Welded Aluminum," British Welding
butting member of the joint before with low and high-profile reinforcements Journal, Vol. 7, April 1960, pp 250-264.
welding to give deeper weld penetra- tested in repeated bending. A (top) 6. Trufyakov, V. I., Asaulenko, L. L.,
tion (with smoothly blending welds, and Koryagin, Yu A., "Stress Concentra-
7039T61 (5039) weld; B (bottom)7039- tion in Butt Joints," Avto. Svarka, No. 10,
also). Large fillet welds with a convex T6 (5039) weld pp 19-21 (Translation published by British
shape lower the fatigue strength of Welding Research Association).
7. Wilson, W. M., et al, "Engineering
both lap and double-fillet tee joints. (offset in butt joints and warpage in Experiment Station Bulletin No. 327, Uni-
Other physical conditions that have all joints superimpose bending versity of Illinois, 1941.
8. Wood, J. L., "The Flexural Fatigue
significant effects on fatigue strength stresses). The proven practice of plac- Strength of Butt Welds in NP.5/6 Type
include surface and internal defects ing welds away from stress concentra- Aluminum Alloy." British Welding Journ-
(which give added stress concentra- tions gives added assurance of good al, Vol 7, May 1960, pp 365-380.
9. Navrotskii, D. I., "The Strength of
tions) and alignment of base metals fatigue resistance. An example of this Welded Joints," Mashgiz, Kiev, 1961.