Numerical determination of stress concentrations in laser hybrid welded butt joints with severe imperfections using 3D scanning and reverse engineering

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Kurzfassung

Fatigue failure under cyclic loading conditions often tends to initiate at welded joints due to the high stress concentrations developed by the local weld geometry. The presence of various weld imperfections can significantly influence the development of stress concentrations on the weld surface. Therefore, assessing the quality of welds is crucial for the safety evaluation of the welded structures. One of the most effective methods to assess weld quality is using 3D laser scanning technology to gather detailed information about the weld profile, which can be used to inspect different weld imperfections and determine critical locations with high stress concentrations for predicting areas of fatigue failure on the weld surface. However, the complexity of weld geometry makes it challenging to develop numerical models for calculating stress concentrations from the 3D scans. In this paper, we propose a method to assess the weld quality and numerically determine stress concentrations in laser-hybrid-welded butt joints with severe imperfections using 3D scans. For this purpose, a total of 76 specimens were scanned using a high-resolution 3D laser scanner to precisely capture the weld geometry. The scan results are then used to assess the weld quality following the standards and to develop numerical models for 3D finite element (FE) analysis. The scan results are converted into numerical models using the reverse engineering method. Additionally, fatigue tests were performed to observe the failure location for each specimen and compare it with the predicted failure location from the FE analysis. The results indicate the high potential of this method for identifying weld imperfections, numerically determining stress concentrations on the weld surface, and predicting fatigue failure locations using 3D scans. However, it is observed that the presence of various weld imperfections greatly influences the prediction accuracy of the FE analysis.

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• Numerical determination of stress concentrations in laser hybrid welded butt joints with severe imperfections using 3D scanning and reverse engineering. (deposited 10 Jan 2025 08:33) [Gegenwärtig angezeigt]