Proceedings of the ASME 2010 Pressure Vessels & Piping Division / K-PVP Conference
PVP2010
DRAFT
INFLUENCE OF STRENGTH MISMACHT AND WELD RESIDUAL STRESS ON
FATIGUE CRACK GROWTH BEHAVIOR FOR PIPELINE STEEL INCLUDING
CLOSURE EFFECTS
Diego Felipe Sarzosa Burgos
Department of Naval Architecture and Ocean
Engineering, University of São Paulo, São Paulo,
SP 05508−900, Brazil
Email:dsarzosa@gmail.com
ABSTRACT
The integrity of mechanical components, particularly when
they undergo significant fatigue damage for the duration of
operating life, can be strongly influenced by the presence of
residual stress fields and mechanical heterogeneity. Premature
closure of crack flanks greatly influences fatigue crack growth
rate. To estimate the crack closure in any welded structure, the
residual stresses and strength mismatch in the vicinity of the
crack tip should be considered. Extensive elastic-plastic finite
element analyses have been carried out to investigate detailed
crack closure behavior in heterogeneous compact tension (CT)
specimens with three levels of weld strength mismatch and
imposed uniform tensile residual stress field. The restriction on
uncraked ligament imposed by E-647 is rather unconservative
because it does not ensure linear elastic behavior at the crack
tip. A relationship between the crack opening loads, the
mismatch level and maximum applied stress intensity factor
was obtained for small scale yielding (SSY) condition. This
equation shall be used for fast estimations of closure effects for
welding joints. A homogeneous, soft material has the largest
crack opening loads, while a heterogeneous material with 50%
overmatch conditions has the smallest opening load under SSY
condition. Residual tensile stresses have detrimental effects on
the fatigue resistance of the material. On average, residual
tensile stresses, with magnitude equal to 0.5σy of the base
metal, increase the Fatigue Crack Growth Rate (FCGR) by
40% when compared to the case without residual stress under
SSY condition. Moreover, overmatch conditions in welded
July 18-22, 2010, Bellevue, Washington, USA
PVP2010-25169
Claudio Ruggieri
Department of Naval Architecture and Ocean
Engineering, University of São Paulo, São Paulo,
SP 05508−900, Brazil
Email:claudio.ruggieri@usp.br
joints have detrimental effects on fatigue crack propagation
rate. The fatigue life can be reduced by more than 70% for a
condition of 50% overmatch when compared with the
evenmatch condition.
1. INTRODUCTION
Fatigue assessments of steel weldments remain a key
issue in design, fabrication and safe operation of critical
engineering structures including pressure vessels, storage tanks
and piping systems among others. Typical welding processes
(e.g., hot or cold cracking, lack of penetration, undercut) almost
invariably introduce crack-like defects in the welded region,
most often in the form of planar flaws, which substantially
reduce the fatigue strength of the welded joint.
Current design and in-service fatigue assessments for
welded components in pressure vessels and piping systems,
including the previsions given in the ASME code [1], employ
conventional procedures adopting stress-life approaches in
which fatigue life predictions are made based upon an implicit
crack initiation criterion and the simple knowledge of nominal
stresses acting on the weldment. While used effectively in
many structural applications, it is now generally recognized
that crack propagation from pre-existing defects dominates the
fatigue life of welded joints. Moreover, there is a complex
interplay of key factors affecting fatigue crack growth rates in
welds, such as weld geometry, strength mismatch and weld
1 Copyright © 2010 by ASME
residual stresses, which is not explicitly taken into account in
conventional stress-life methodologies. Consequently,
advanced procedures for fatigue assessments of critical
weldments must include the effects of crack extension under
cyclic loading on fatigue life predictions for pressurized
components. Moreover, accurate estimates of the effective
crack-tip driving force (here characterized by the stress
intensity factor (SIF) range, as measured by ∆K ) with crack
extension become central in robust correlations of fatigue
behavior between these conventional test specimens and
structures.
Since the seminal work of Elber [2, 3] on the closure
mechanism, a considerable amount of investigation has been
focused on incorporating the effects of crack closure on fatigue
assessment procedures. Most of the recent research specifically
addresses numerical models to simulate plasticity-induced
fatigue crack closure, most of them based on a 2D framework
(either plane-strain or plane-stress conditions). While these
previous research initiatives represent major advancements in
describing the crack closure mechanism for fatigue life
evaluation scheme, full understanding of fatigue crack
propagation to support development of robust fatigue
assessment procedures is still lacking. In particular, rather little
further effort has been expended in the systematic investigation
of the potential strong effects of weld strength mismatch and
residual stresses on the crack closure behavior and their
interconnection with fatigue life predictions.
As a step in this direction, this work provides an
investigation of the coupled effects of strength mismatch and
weld residual stresses on Fatigue Crack Growth Rate (FCGR)
behavior for pipeline steel weldments. One purpose of this
study is to develop a framework while, at the same time,
gaining additional understanding of key factors affecting the
fatigue life of structural welds. Another purpose is to assess the
potential strong effects of plasticity-induced crack closure on
fatigue crack extension of weldments. Very detailed non-linear
finite element analyses using plane-strain models of compact
tension (CT) fracture specimens with center cracked, square
groove welds provide the evolution of crack growth with cyclic
stress intensity factor which is required for the estimation of the
closure forces. This exploratory investigation provides further
understanding on the effects of crack closure of fatigue
propagation behavior for mismatched welds.
2. FATIGUE CRACK GROWTH MODELING
The finite element method has been increasingly used as a
very effective tool to model fatigue crack growth aiming at
estimating the number of cycles for a crack to grow from a
certain initial length to a maximum tolerable (critical) crack
size. Thus, a safe inspection interval for a specific structure,
such as a high pressure pipeline or vessel, can be planned based
on the knowledge of the fatigue damage evolution
Evaluation of the safe service life for structures containing
cracks undergoing cyclic loading has been usually conducted
based on semi-empirical relationships connecting key
parameters characterized by the crack growth rate da/dN, stress
intensity factor range ∆K and R-ratio, in addition to some
material properties whose values are commonly determined by
experimental measurements. The standard approach to predict
fatigue crack growth adopts the Paris law [4] to assess the
crack growth rate per cycle of load (da/dN). The rate of crack
growth is assumed to be a function of the effective stress
intensity factor ( ∆K eff ) which is defined as the difference
between the maximum stress intensity factor, K max and the
opening stress intensity factor, K op . Another more refined
approach that successfully models the R dependence is the
Walker model [4]. Both approaches will be used to estimate the
fatigue crack growth rate.
Regarding the treatment of the influence of residual
stresses in the calculation of FCGR there are two typical
methodologies applied to model the effects of residual stress
fields on fatigue crack growth. The first one employs the
principle of superposition. The stress intensity factor associated
with the residual stress ( K res ) is added to the stress intensity
factor due to the applied external cyclic load ( K L ). Thus, a
resultant stress intensity factor is obtained for the maximum
and minimum loads. This procedure will result in a range of
stress intensity factor SIF, ∆K , unaffected by the residual
stress. However, the R-ratio will change as the crack
propagates through the residual field. This will affect the mean
stress thereby resulting in an effective stress ratio ( R e ff ). The
second approach employs the effective stress intensity factor
range, ∆K eff = K max − K op , where K op is the crack opening
stress intensity factor. This procedure is known as the crack
closure approach.
Both methods have been successfully applied to predict
fatigue crack growth rates through uniform tensile and
compressive residual stresses fields [8]. The equivalence of
both methods is due to the fact that the behavior of the crack tip
opening stress is distinctively controlled by R e ff for a specified
K max , and constant tensile and compressive residual stress
fields [7]. Many other researchers have applied both methods
successfully in the linear elastic regime [[6, [8, [9].
An important issue related to fatigue crack propagation
through residual stress fields is the redistribution and possible
relaxation of stresses. In the low-cycle fatigue regime the high
level of plastic deformation achieved at the crack tip causes the
relaxation of the initial residual stresses such that they are
2 Copyright © 2010 by ASME
virtually equal to zero. In the medium-cycle to high-cycle
fatigue regime, which does not involve excessive cyclic plastic
deformation at the crack tip, the relaxation almost does not
exist. Thus, a high residual stress is usually said to be stable for
low applied fatigue loads. However, as the crack tip advances
the initial residual stresses get redistributed by the presence of a
new surface. Here, this redistribution will be neglected as a first
approximation of this phenomenon. How this redistribution
affects the fatigue crack propagation is an open issue and
subject of continuous research [9].
Several researchers have done important studies about
plasticity-induced crack closure phenomena using finite
element method [12, [14, [15]. The basic algorithm involves
building a refined enough mesh for the loads to be applied; it
means enough elements on the crack tip in order to simulate the
effects of forward and reverse plastic zone. Remote loads are
applied cyclically, this is time-dependent, and the crack tip is
released at an arbitrary point on the cycle, either during the
loading or unloading portion. This is repeated for each applied
cycle.
The growing crack creates a plastic wake which is
responsible for the premature contact of the faces of the crack,
even for loads greater than zero as shown in Fig. 1. The process
is repeated until stable values of K op are obtained.
In this study a constant cyclic loading was imposed on the
model under load control conditions. The cyclic loading
consisted of repeatedly increasing the values of applied load
from zero to the maximum load and then decreasing back to
zero as shown in Fig. 2. The crack propagates uniformly by an
amount equal to ∆a =0.02mm in each cycle. This is achieved
by releasing all (current) crack front nodes after the maximum
load is applied. Here the amount of crack growth was set equal
to the size of plastic zone, rp , for a plane strain condition
calculated as a second order estimation using Irwin’s approach.
Figure 1. Ilustration of plastic wake left by fatigue crack
growing
There are two common criteria used to define the opening
and closure of the crack. The first criterion is based on node
contact and assumes that the crack opens when its free surface
loses contact as described by the nodal displacement value:
positive nodal displacements indicate opening of the crack
whereas negative nodal displacements indicates closure of the
crack. Another criterion which is adopted in the present work
establishes that the crack opens when the (opening) stress state
ahead of crack tip, which is compression in the previous cycle,
changes from a state of compression to tension. Similarly, crack
closure is defined when the crack tip opening stress changes
from tension to compression. Such criterion appears more
realistic because the first one is strongly dependent on the mesh
size, since the node behind the advancing crack tip can
experience a positive (negative) displacement but the crack tip
node would still carry compressive (tensile) stresses [14].
1400
Nodal
1200 release
1000 Relaxation of nodal forces
Remote Load P [ N ] Accurate
800 determination
of opening load
600
400
200
Crack face contact
0
0 10 20 30 40 50 60 70 80 90
# Steps
Figure 2. Variable incremental load applied by each cycle.
In the present analysis the contact between crack flanks was
modeled using a rigid surface at the crack symmetry plane in
order to prevent crack surface penetration during unloading.
The contact between a soft surface (crack flanks) with a rigid
surface (symmetry plane) was considered. For more detailed
information on the numerical modeling of crack closure used
here the reader is remitted to [10].
2.1.Incorporation of residual stress field.
Residual stresses fields have been handled quantitatively
with crack closure models or by applying the principle of
superposition. Both methods are described in the following
sections itens.
2.1.1 Effective stress ratio approach
It is known that residual tensile stresses increase the mean
stress and reduce the weldment fatigue strength. Compressive
residual stresses have an opposite effect, that is, they reduce the
3 Copyright © 2010 by ASME
mean stress and increase the weldment fatigue strength. A
quantitative assessment of the influence of residual stresses can
be made by the principle of superposition:
K T = K L + K res (1)
where K L corresponds to the SIF due the applied remote cyclic
load and K res is the SIF due to residual stress. The SIF for the
residual stress is usually obtained by means of weight function
solution by applying the residual stress field on the uncracked
component. The weight function, m(x, a), depends only on the
geometry of the component. The relationship to obtain the K res
using m(x,a) is:
a metal – is different as can be seen in Figure 4. Symmetry
K res = ∫ σres (x) × m(x, a)dx ( 2)
0 with appropriate constraints imposed on the remaining ligament
Here, a is the crack size. The weight function employed here
was taken from [5]. The integration was made in two domains:
first in [0, 0.95a] employing a trapezoidal rule and second in
[0.95a, a] using a Gauss’s rule with three points. The
incorporation of residual stresses using the effective stress
approach only changes the local stress ratio ( Reff ). This ratio
will change continuously with the increasing of crack length as
shown below:
KT K L + K res
R e ff = Tmin = Lmin ( 3)
K max K max + K res
element analyses were performed on plane-strain models. The
research code WARP3D [13] was employed. WARP3D only
supports 3D solid elements, so the plane strain condition is
simulated by restraining the displacement of all nodes in the
thickness direction (w=0). Figure 3 shows the coordinated
system employed, the geometry and specimen dimensions for
the analyzed crack configurations.
Two types of mesh were employed to investigate the
effects of the mesh refinement on the values of the opening
loads. The level of refinement at the crack tip is the same for
both models but the mesh at the interface – base metal-weld
conditions permit modeling of only one-half of the specimen
v=0). Thus, the number of nodal degree of freedom is reduced
and consequently the computational time is decreased. One
layer was used to define the thickness of the specimens. A
sequence of small and identical elements ahead of crack front
permits an equal amount of crack growth, as shown in Figure 4.
A typical half-symmetric model has 1930 8-node, 3-D
elements (4178 nodes). The element material properties around
the loading point are defined as an elastic material to enhance
numerical converge.

This effect will cause a mean stress modification at the crack

tip.
2.1.2. Effective stress intensity factor range approach
The residual near-tip strains associated with the cyclic
loading form a plastic wake which is responsible for the
premature closure of the crack over some distance. This
phenomenon was first discovered by Elber [2] and may
strongly affect the effective load increment and reduce the
crack growth rate. The crack will be able to propagate only if
the residual stresses are overcoming to a degree that the crack
tip is opened again [9]. When the closure phenomena are taken
into consideration the driving force is reduced and effective
stress intensity factor range is defined as:
∆K eff = ( K max + K res ) − ( K OP + K res ) = K max − K OP
where K op is the crack opening stress intensity factor of the
structure affected by a residual stress field.
3. NUMERICAL PROCEDURE
3.1. Finite element models
Numerical models for a conventional compact tension (CT)
1T fracture specimen have been developed. Detailed finite
y y
BM
WM
x
BM
z
Figure 3: Schematic view of (CT) specimen geometry
employed in the analyses.
3.2. Computational procedures
(4)
The finite element code WARP3D provides the numerical
solution for the plane-strain analyses reported here. The code
incorporates Mises (J2) constitutive model in both small-strain
and finite-strain framework. The global solution procedure uses
an implicit, incremental–iterative strategy with Newton
iterations to achieved equilibrium at each load increment. Key
features of the code employed of the code in this work include:
(1) node release scheme, (2) contact procedure, and (3)
automatic nodal release forces. Each load cycle was set with 50
variable loads increments.

4 Copyright © 2010 by ASME

3.3. Material constitutive model 1.5, respectively, where the mismatch level is defined by
M y = σ WM
ys σ BM
ys with superscripts WM and BM denoting weld
The analyses use an incremental, isotropic hardening metal and base metal). The adopted yield stress and hardening
constitutive model to describe the cyclic, elastic-plastic properties of the baseplate material are the same in all analyses
response of the material in small geometry change setting. The
numerical solutions employ a simple power-hardening model to and assigned the following properties: n=12.4 and σ ys = 483
characterize the uniaxial true stress-logarithmic strain in the MPa.
form: 800
n
ε σ ε ⎛σ ⎞ 700
= ε ≤ εy ; =⎜ ⎟ ε > ε y (5)
εy σy ε y ⎜⎝ σ y ⎟⎠ 600

where σy and εy are the yield stress and strain, and n is the 500

σ [MPa]
True stress-strain
strain hardening exponent. The finite element analyses consider 400 Ramberg - Osgood
Engineering stress-strain
material flow properties of typical pipeline steel API 5L grade
300
X60 (20º C). The stress-strain response for this material is API 5L - X60 (20º C)
shown in Fig. 5. σy=483 MPa
200
E=206 GPa
n=0.3
100

0
0 0,05 0,1 0,15 0,2
ε
Mesh 1
Figure 5. Stress-strain response for a steel API 5L- X60 [14].

Base Metal Table 1 provides the material properties utilized in the

numerical analyses of these fracture specimens with square
groove welds which also consider E=206 GPa and ν = 0.3.
Y
h=7 mm

Weld Metal The strain hardening parameters for the weld metal are
Z X
estimated from a simple correlation between the yield stress
and hardening exponent applicable for typical structural steels:
n=5 and E / σ y = 800 (high hardening material), n=10 and
E / σ y = 500 (moderate hardening material), n=20 and
Mesh 2 E / σ y = 300 (low hardening material). These ranges of
properties also reflect the upward trend in yield stress with the
increase in strain hardening exponent characteristic of ferritic
materials, including pipeline steels.
Y
h=7 mm

Table 1: Material properties adopted in the analyses

Z X

Figure 4. Details of the mesh used in the analysis.The crack tip

area has been enlarged to ilustrate the mesh around the crack
tip
The finite element analyses consider material flow
properties covering a wide range of moderate-to-high strength
mismatch: evenmatch, 20% and 50% overmatch ( M y =1.2 and
4. RESULTS AND DISCUSSION
4.1 Mesh refinement effects
The crack opening values for the condition of 20%
overmatch, K max =25 MPa m and ratio a/W=0.635, are shown

5 Copyright © 2010 by ASME

in Figure 6. These values are presented as a function of the value of the applied force to open crack flanks. The general
normalized crack length normalized by the radius of the plastic trend of lower K op values with increasing constraint should be
zone. The plot indicates that there is no significant difference noted. Relative “steady” values can be selected when the crack
between the two mesh refinements. This result suggests that a
has grown one size of the plastic zone rp . On the other hand,
correct modeling of the crack tip region is sufficient for
estimating reliable values of K op . Therefore, the Mesh 1 was for a/W=0.5 the evenmatch condition has the lowest values of
K op and the highest values correspond to the condition of 50%
selected to perform all analyses in this study.
0,50 of overmatch. The situation of 20% overmatch is again in the
mesh2 middle of the two previous conditions. This behavior is in
mesh 1 contrast to that observed previously for a/W=0.25. This
0,40
behavior can be explained by the loss of elastic constraint at the
crack tip. The size requirements, ( W − a ) ≥ 2.5 ( K I × σ −y1 ) ,
2
0,30
Kop / Kmax

Kmax [MPa-m^0,5] = 25
CTspecime
according to ASTM to ensure that the nominal behavior is
0,20 a/W= 0.635 W=50.8 mm linear elastic and the SIF at the crack tip, K, characterizing the
R=0.0 ; rp=0.27 mm
2h= 14 mm
crack tip conditions were calculated and for the case a/W=0.5,
0,10 20% Overmatch it was determined that these conditions were not satisfied.
0,50

0,00 0,45
0% 50% 100% 150% 200% 250% 300% 0,40
(ai-ao)/rp [mm/mm]
0,35
Figure 6. Crack opening loads for the two types of mesh
0,30
Kop / Kmax
refinement adopted in the analyses.
0,25
Pmax [N] = 1230
The effect of weld width (2h) was analyzed. Two values of 0,20 CT Specimen EvenMatch
the width, 2h=7.5mm and 2h=14mm, were considered. 0,15 Plane Strain
20% OverMatch
a/W= 0.25 W=50.8 mm
Basically, both specimens display essentially similar values of 50% OverMatch
0,10 R=0
K op / K max with a little difference when the crack has grown to 2h= 14 mm
0,05
1.25rp. As expected the opening behavior only depends of the 0,00
crack wake left by the growing crack. The weld width does not 0% 20% 40% 60% 80% 100% 120%
affect the values of Kop, under SSY conditions. (ai-ao)/r p [mm/mm]

0,50
The first effort in this study was to understand the crack
0,45
closure behavior for welded specimens with three levels of
0,40
strength mismatch. Three models were employed in the
0,35
analyses: one model with evenmatch condition, and the
0,30
Kop / Kmax

remaining two models with 20% and 50% overmatch levels.

0,25 Pmax [N] = 1230
The loading corresponded to R=0 and maximum load, CT Specimen
Pmax =1230 N. The results of the two extreme conditions were 0,20 EvenMatch
Plane Strain
0,15 a/W= 0.5 W=50.8 mm 20% OverMatch
analyzed. The corresponding crack lengths, in terms of the R=0 50% OverMatch
0,10
ratio,a/W , were equal to 0.25 and 0.5, respectively. The 2h= 14 mm
loading configuration satisfied the requirement of ASTM E-647 0,05

for the uncraked ligament of a compact specimen, given by 0,00

0% 20% 40% 60% 80% 100% 120%
(W − a) ≥ 4× π −1
(K I ×σ Y )
−1 2
. Theoretically, this condition (ai-ao)/r p [mm/mm]

guarantees elastic behavior of the specimen. The evolution of Figure 7: Values of K op / K max for two cracks lengths and three
crack opening loads with the amount of crack growth is shown
levels of strength mismatch.
in Figure 7.
Figure 8 provides further support to the above argument.
For a/W=0.25 the evenmatch condition has the highest
The plastic zones for the evenmatch and 50% overmatch
values of K op and the lowest values correspond to the 50% conditions are shown in the figure. The plastic zones shown
overmatch condition. The K op values for 20% of mismatch are correspond to the minimum load of the applied cyclic loading.
closest to evenmatch configuration. As expected: the greater the
levels of plastic deformation at the crack tip the greater the

6 Copyright © 2010 by ASME

 Only under overmatch conditions the crack tip has enough obtained using such an equation will be conservative and useful
elastic constraint to close the crack flanks. Therefore, it can be for fatigue life assessments for design/maintenance.
concluded that the restriction on uncraked ligament imposed by
E-647 is not conservative because it does not ensure linear 15 20 25 30 35 40
0,5 0,5
elastic behavior at the crack tip. Besides, plasticity-induced
0,45 0,45
crack closure becomes less significant as net section plasticity
increases and elastic constraint is lost. 0,4 0,4

0,35 0,35

In related article, Sarzosa and Ruggieri [10] verified that the 0,3 0,3

Kop/Kmax
values of K op are independent of defect size for constant value 0,25 0,25

of ∆K applied under SSY conditions, corresponding to a test 0,2 0,2

with a decreased applied cyclic load. In view of this, a high 0,15 0,15
constraint specimen, a/W>0.6, was employed to calculate the
0,1 50% OverMatch C(T)-1T Specimen 0,1
intermediary values of K op / K max for 0.25<a/W<0.5. This 20% OverMatch Plane Strain
0,05 EvenMatch R=0 2h= 14 mm 0,05
guaranteed SSY conditions and ensured that high plasticity at
0 0
the crack tip was avoided. 15 20 25 30 35 40
Kmax [MPa m^0.5]

Figure 9: Ratio K op / K max as function of maximum applied

stress intensity factor for R=0.

A non-linear regression was employed to obtain a

multidimensional fitting equation. The model employed uses a
second order equation on M y and K max . The final expression of
the equation is written as:
K op
= P1 + P2 M y + P3 M 2y (6)
K max
Where
(
P1 = 3.7655 − 0.213K max + 0.0032K 2max )
P2 = ( −7.2896 + 0.5006K max − 0.0081K 2
max )
P3 = ( 2.8456 − 0.2114Kmax + 0.0036K 2
max )
The previous equation is valid under SSY conditions.

3.4.Coupled effects of residual stress and strength

Figure 8: Plastic zones for two levels of strength mismatch,
a/W=0.5.
A curve for K op / K max versus K max , for the opening values
when the crack has grown to one rp size, is shown in Figure 9.
For low stress levels where the crack closure phenomena is
more important, a high degree of parallelism between all the
curves can be seen. This behavior should be further
investigated to estimate the opening loads for a given level of
strength mismatch with reference to the condition of evenmatch
for example. An equation for the ratio K op / K max as a function
of K max and the level of mismatch has been developed. As the
analyses were made for plane-strain situation the values
mismatch
For two levels of tensile residual stress (0.5 σ yBM and
1.0 σ yBM ), the effective stress ratio, Reff , was calculated and
determined to be equal to 0.1202 and 0.215, respectively. The
finite elements models were run using these values. The
evolution of opening loads for both cases is shown in Figure 10
for two crack lengths.
Analytical work made by Sehitoglu [16] and recently by
Codrington and Kotousov [19] showed increase in the values of
K op / K max with increase in the applied stress ratio R, for R>0. It
is expected that for high R values K op / K max , will be equal to
R, which implies that K op = K min and there are no closure

7 Copyright © 2010 by ASME

effects. As the level of mean stress has been increased the
relative separation of curves is reduced. This effect is more
pronounced for higher values of applied residual stress. For
a/W=0.5, the K op / K max ratio between evenmatch and 20%
overmatch and evenmatch and 50% overmatch differs by 3.7%
and 9.7%, respectively, for σ res =241 and 3.2% and 6.4% for
σ res =483 MPa, when the crack has grown one rp . For higher
residual tensile stresses it is expected that there will be no
difference between the levels of opening loads for all levels of
strength mismatch under SSY condition.
These values have been used to evaluate the FCGR using
the Paris law and ∆K eff as the driving force.
The variation of K op / K max with R eff is similar to that seen
in the previous case analyzed, with no residual stresses. For
a/W=0.25, the highest value of K op / K max corresponds to the
evenmatch condition and the lowest value to 50% overmatch.
In contrast the trend is reversed for a/W=0.5. The highest value
corresponds to the 50% overmatch condition and the lowest to
the evenmatch.

0,60 fillet_symbol: σres=241 MPa x [mm]

0 0,05 50%MS 0,1 0,15
unfillet_symbol: σres=483 MPa
4,0E-03 4,0E-03
0,50 + bottom
opening
3,5E-03 Kmax [MPa-m^0,5] = 52.7 3,5E-03
a/W= 0.5 top
Σ ai =0.185rp
0,40 3,0E-03 R=0.2146 (σres=412 Mpa) 3,0E-03
2h= 14 mm
Kop / Kmax

2,5E-03 2,5E-03
0,30

Evenmatch

50%MS
v [mm]
v [mm]
EvenMatch 2,0E-03 2,0E-03
Kmax [MPa-m^0,5] = 52.8
0,20 CT specimen 20% OverMatch
a/W= 0.5 W=50.8 mm 50% OverMatch 1,5E-03 1,5E-03
2h= 14 mm
0,10 1,0E-03 1,0E-03
Base Metal: n=12.4 ; σy=483MPa

5,0E-04 5,0E-04
0,00
0% 20% 40% 60% 80% 100% 120%
0,0E+00 0,0E+00
0 0,1 0,2 0,3
(ai-ao)/rp [mm/mm]
x [mm]
0,60 fillet_symbol: σres=241 MPa Evenmatch
unfillet_symbol: σres =483 MPa
Figure 11: Crack tip profiles when the crack has grown 0.18rp
0,50 for evenmatch (close symbols) and 50% overmatch (open
symbols).
0,40
Kop / Kmax

0,30 0,60
fillet_symbol: a/W=0.5
unfillet_symbol: a/W=0.25
Kmax [MPa-m^0,5] = 26.8 0,50
0,20 CT specimen EvenMatch
a/W= 0.25 W=50.8 mm 20% OverMatch
2h= 14 mm 50% OverMatch 0,40
0,10 Base Metal: n=12.4 ; σy =483MPa
Kop / Kmax

0,30
Pmax [N] = 1230
0,00 CT Specimen EvenMatch
0% 20% 40% 60% 80% 100% 120% 0,20 Plane Strain 20% OverMatch
(ai-ao)/r p [mm/mm] W=50.8 mm 50% OverMatch
Σai=rp 2h= 14 mm
0,10
Figure 10: Evolution of K op / K max as function of the crack
length for R=0.12 ( σ yBM =241MPa) and R=0.214 0,00
0,1 0,12 0,14 0,16 0,18 0,2 0,22 0,24
(σ BM
y =483MPa). Reffective

Figure 12: K op / K max as function of the effective R for two

Figure 11 shows the behavior of the crack profile during the crack lengths.
cyclic loading. Upon loading the crack opens from the crack-
mouth side to the tip continuously. There is no partial opening
behavior and the typical K op definition can be used to predict 3.4. Fatigue crack growth evaluation and fatigue life
predictions.
FCGR as propose in [7]. When the crack has grown one rp only
a “small” region next to the crack actual tip is closed. For the case R=0, the effective driving force and the rate
da/dN as a function of applied remote load is shown for each
Figure 12 displays the variation of the ratio K op / K max as a level of mismatch analyzed in Table 2.
function of the R eff .

8 Copyright © 2010 by ASME

Table 2: (a) Values of ∆K eff as a function of the ∆K , and (b) Table 3: values of ∆K eff as a function of the ∆K and da/dN for
da/dN as a function of ∆K . R=0.1202(a), and R=0.2146 (b)
(a) (a)
evenmatch 20%over 50%over R=0,12024
∆K ∆Keff ∆Keff = ∆Keff = Keff [MPa m^0,5]
K 0% 20% 50% Walker
20 13,44 14,92 17,00
27 17,03 17,82 20,90 Equation
25 14,50 15,81 18,19
53 36,20 35,31 33,90
27 15,19 15,99 18,41
da/dN
29 16,10 16,82 18,91 27 1,777E-05 2,036E-05 3,286E-05 8,473E-05
35 20,79 20,55 20,86 53 1,707E-04 1,585E-04 1,402E-04 6,422E-04
53 37,91 36,04 33,79
(b)
(b) R=0,2146
evenmatch 20%over 50%over ⎝ Keff [MPa m^0,5]
∆K da/dN da/dN da/dN ⎝K 0% 20% 50% Walker
20 8,73E-06 1,195E-05 1,769E-05 27 17,810 19,779 19,895 Equation
25 1,098E-05 1,423E-05 2,166E-05 53 35,603 34,595 33,587
27 1,261E-05 1,473E-05 2,247E-05 da/dN
29 1,5E-05 1,713E-05 2,434E-05 27 2,034E-05 2,785E-05 2,835E-05 6,99E-05
53 1,625E-04 1,491E-04 1,364E-04 5,299E-04
35 3,235E-05 3,122E-05 3,268E-05
53 1,961E-04 1,685E-04 1,389E-04
Fatigue life predictions (FLP) have been performed for a
For lower values of the applied load corresponding to range of applied cyclic loads. Since only two values of opening
situations where the closure phenomena is more relevant, loads, K max =26.8MPa m and K max =52.8 MPa m , for the
considerable reduction of the rate da/dN upto 102% for the condition including residual stress fields were calculated the
case of evenmatch when as compared to 50% of overmatch FLP were performed only for the condition of no residual stress
condition and 37% as compared to 20% of overmatch can be fields.
seen. The above values are for an applied ∆K =20MPa m .
As the level of the applied load increases, the differences in Since ∆K increases with crack length during constant
da/dN rates is reduced until a minimum value is reached at amplitude loading the growth rate is not constant so it is
necessary to use an integration procedure to obtain the life
∆K =35 MPa m , under similar driving forces for each case
required for crack growth. The procedure employed to perform
of mismatch. For higher applied loads the elastic constraint at
the integration of FCGR was taken from Dowling [4].
the crack tip is lost for the case of evenmatch and 20%
Basically, the life in cycles is determined by the integration of
overmatch resulting in higher ratios of da/dN than 50%
the inverse of FCGR from an initial size ai (taken in all cases as
overmatch where the level of triaxiality is preserved and the
1 mm) to a final size af (taken as the smallest value between a
closure behavior is controlled by the elastic elements
critical crack size that produce plastic collapse or brittle
surrounding the crack tip material.
fracture). The inverse of FCGR, dN/da, represents the rate of
accumulation of cycles per unit increase in crack length [4].
For the case with R=0.1202 and R=0.2146, the effective
driving force and the rate da/dN as a function of applied remote
The numerical results are compared with two theoretical
load are shown for each level of mismatch analyzed in Table 3.
solutions presented by Codrington and Kotousov [19] and
Newman [20], Model 1 and Model 2 respectively, which
The da/dN rate evaluated using the Walker’s model is
employed the strip yield model to calculate the opening loads.
presented below. As the Walker’s model does not take into
As these models do not include the mismatch effects only
account the level of heterogeneity, direct comparisons can be
comparison with the condition of evenmatch will be possible.
made only in evenmatch case. The effective stress intensity
Newman’s equation for calculation of opening loads has been
factor approach gives da/dN rates that are 70% lower,
employed extensively by industry and academia. Further,
approximately, than those provided by Walker’s model. On
Newman’s equation is implemented in FASTRAN software
average the residual tensile stress, for R=0.1202, increase the
principal numerical code used to predict fatigue life for
FCGR by 40% for all levels of strength mismatch as compared
constant and variable cyclic load so that the employed
to the case without residual stress for cases under SSY
methodology can be evaluated with direct comparison with this
condition. For the case R=0.2146, on average the FCGR is
theoretical solution.
increased by 58% as compared to the case without residual
stress (R=0).
Figure 15 shows dN/da and ΣN (accumulation of cycles
with crack growing) curves obtained by the finite element
method and the two theoretical solutions previously mentioned,

9 Copyright © 2010 by ASME

for a constant amplitude load ∆P =1000 N. For this level of and 2.41 for the FEA, Model 1 and Model 2, respectively, are
applied load the Finite Element Approximation (FEA) and obtained.
Newman’s model of the effective driving force resulted in FLP
nearly the same (difference less than 1%). Codrington and 1
Kutuzov’s model produces fatigue life estimation 15.3% higher 0,9
than FE model. The FCGR was expressed as a function of an

U= (Kmax-Kop)/(Kmax-Kmin)
0,8
K max − K op
effective stress intensity ratio ( U = ) as proposed 0,7
K max − K min 0,6
by Elber [2]. The variation between the FLP showed in Figure 0,5
13 lies in the different values of U estimated for each model.
0,4 FE
This can be shown in Figure 14. The finite element results of U C(T)-1T Specimen
0,3
Plane Strain Model 1
were fitting by a quadratic function. As the fatigue life is R=0 2h= 14 mm Model 2
Base Metal: n=12.4 ; σy=483MPa
mostly consumed during the initial crack growth, see the area 0,2
under dN/da curve in Figure 13, the values of U that has more 0,1
impact in the fatigue estimations correspond to low K max . A 0
balance between the higher values of U, for the FEA, at the 5 15 25 35 45 55 65 75 85 95
beginning of the applied cyclic load than the Newman’s model Kmax [MPa m^0.5]
and the lower values of U, for FEA after some crack growth Figure 14: Variation of the effective stress intensity ratio
( ∼ 7mm ), than the Newman’s model produces fatigue life with K max for a constant amplitude loading ∆P =1000kN.
estimation almost equal between these two models.

Finite element model Analytical Model 1 Analytical Model 2 Evenmatch

6,0E+05 2,5E+06 1,6
20% Overmatch
∆P=1000 N 50% Overmatch
5,5E+05 R=0 1,4 Without Closure
Analytical Model 1
5,0E+05 Analytical Model 2
2,0E+06 1,2
4,5E+05

4,0E+05
+ 1
∆P [kN]
dN/da [cyles/mm]

x 1,5E+06 0,8
Σ N [cycles]

3,5E+05

3,0E+05 O 0,6
Fatigue Crack Propagation Life
CT specimen
ai =1 mm
2,5E+05 1,0E+06 0,4 af=min(plastic collapse, brittle fracture)
2,0E+05
W=50.8 mm
0,2 2h= 14 mm ; R=0
1,5E+05 Base Metal: n=12.4 ; σy=483MPa
5,0E+05 0
1,0E+05 1E+05 1E+06 1E+07
5,0E+04 Nf [cycles]

0,0E+00 0,0E+00 Figure 15: Comparisons of fatigue life estimations for constant
1 6 11 16 21 26 31 36
aj [mm]
amplitude loading.
Figure 13: Comparison of curves dN/da (left ordinates) and Although the FLP for the conditions 20% and 50%
ΣN (right ordinates) vs. crack length for applied constant cycle overmatch have the same tendency as the case evenmatch,
load obtained by finite element method and two theoretical appreciable reduction in the life can be shown in Figure 15. In
solutions. average, for the range ∆P ≤ 1100 N , the decreases in FLP are
equal to 37% and 73% for the 20% overmatch and 50%
Figure 15 shows fatigue life estimations for several values
overmatch, respectively, when compared to evenmatch case.
of the applied cyclic constant load. Besides, the curve of
fatigue life without taking in consideration the closure effect
4. CONCLUSIONS
has been included as reference. A good agreement between the
finite element and theoretical results can be seen at the region
A methodology to evaluate the influence of strength
around 850N ≤ ∆P ≤ 1150N for the Model 2, and at the region
mismatch and residual stresses was described. Finite element
∆P ≥ 1150 N for the Model 1 with difference less than 10% in
analysis provides the necessary information to include the
both cases. From a structural point of view, the loads higher crack closure phenomena into the problem. The conclusions
than ∆P ≥ 1100 N produce plastic zones that violate the SSY drawn for this study are as follows:
condition for the initial crack size assumed here. When the FLP
are compared with those values that do not take in account the
closure effects, average Safety Factors (SF) equals to 2.3, 2.82

10 Copyright © 2010 by ASME

 • The results indicate that heterogeneity in mechanical
properties between the base plate and weld metal has a
great effect on crack opening behavior. The
homogeneous, soft, material has the largest crack
opening loads, while the 50% overmatch condition has
the smallest one under SSY condition.
• Under SSY, the trend in the values of K op / K max ,
condition, showed a high parallelism between each
level of mismatch, suggesting the possibility of
determination of an equation relating the opening
loads as a function of the level mismatch.
• Walker’s model provides a more pessimistic approach
than the effective stress range model.
• Residual tensile stresses have detrimental effects on
the fatigue resistance of the material.
• Overmatch conditions in welded joints have
detrimental effects on the fatigue crack propagation
life.
5. ACKNOWLEDGMENTS
This investigation is supported by Fundação de Amparo à
Pesquisa do Estado de São Paulo (FAPESP) through a
scholarship (08/54130-4) provided to the first author.
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