Comparative fatigue analysis of structural steels considering welding and surface effects

Yevgen Gorash; Tugrul Comlekci; Carl Walker; Athanasios Toumpis; James Kelly; Andrew England; Lewis Milne

doi:10.1111/str.70003

Comparative fatigue analysis of structural steels considering welding and surface effects

Yevgen Gorash^*, Tugrul Comlekci, Carl Walker, Athanasios Toumpis, James Kelly, Andrew England, Lewis Milne

^*Corresponding author for this work

Research output: Contribution to journal › Article › peer-review

Abstract

There are limited data on the very high-cycle fatigue for structural steel welds for over 10 million cycles. The purpose of this research is a fatigue performance comparison of the welds made of steels S355JR+AR and S275JR+AR. The goal of reaching the gigacycle fatigue domain is achieved using the ultrasonic fatigue testing at 20 kHz. Fatigue samples are prepared to investigate the influence of two surface conditions—polished and precorroded. Fatigue failures are driven primarily by welding porosity with the fatigue life duration dependent on the size and location of pores. Visual comparison of fatigue data for steels poses a challenge, because of the vast scatter of experimental data points. Therefore, a statistical approach is used with a fatigue performance parameter applied to the fatigue data for welded samples to quantify the quality of the structural materials.

Original language	English
Article number	e70003
Number of pages	20
Journal	Strain
Volume	61
Issue number	2
Early online date	13 Mar 2025
DOIs	https://doi.org/10.1111/str.70003
Publication status	Published - 1 Apr 2025
Event	18th International Conference on Advances in Experimental Mechanics - University of Liverpool, Liverpool, United Kingdom Duration: 2 Sept 2024 → 5 Sept 2024 https://www.bssm.org/events/conference/18th-conference-liverpool/

Funding

This research was funded by Weir Group project reference WARC/MIN/18/20. The authors greatly appreciate Weir Minerals Australia for the engineering advising and practical guidance and Shimadzu Europe & UK for the technical support over the course of this work. The authors would like also to acknowledge that CT scanning was carried out in the CMAC National Facility, housed within the University of Strathclyde’s Technology and Innovation Centre (TIC), and funded with a UKRPIF (UK Research Partnership Institute Fund) capital award, SFC ref. H13054, from the Higher Education Funding Council for England (HEFCE).

Keywords

structural steel
welds
very high cycle fatigue
ultrasonic testing
corrosion

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

10.1111/str.70003Licence: CC BY 4.0

Gorash-etal-Strain-2025-Comparative-fatigue-analysis-of-structural-steelsFinal published version, 18.9 MBLicence: CC BY 4.0

2 Paper
1 Article
1 Conference Contribution

Very high cycle fatigue of welds: a review
England, A., Toumpis, A. & Gorash, Y., 7 Nov 2023, In: Metals. 13, 11, 23 p., 1860.
Research output: Contribution to journal › Article › peer-review

Open Access
File
7 Citations (Scopus)

96 Downloads (Pure)
Ultrasonic fatigue testing of structural steel welded joints
England, A., Toumpis, A. & Gorash, Y., 1 Sept 2023. 2 p.
Research output: Contribution to conference › Paper › peer-review

Open Access
File
Frequency effects in ultrasonic fatigue testing (UFT) of Q355B structural steel
Milne, L. A., Gorash, Y., Comlekci, T. & MacKenzie, D., 3 Jan 2023, In: Procedia Structural Integrity. 42, p. 623-630 8 p.
Research output: Contribution to journal › Conference Contribution › peer-review

Open Access
File
8 Citations (Scopus)

54 Downloads (Pure)

Cite this

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title = "Comparative fatigue analysis of structural steels considering welding and surface effects",

abstract = "There are limited data on the very high-cycle fatigue for structural steel welds for over 10 million cycles. The purpose of this research is a fatigue performance comparison of the welds made of steels S355JR+AR and S275JR+AR. The goal of reaching the gigacycle fatigue domain is achieved using the ultrasonic fatigue testing at 20 kHz. Fatigue samples are prepared to investigate the influence of two surface conditions—polished and precorroded. Fatigue failures are driven primarily by welding porosity with the fatigue life duration dependent on the size and location of pores. Visual comparison of fatigue data for steels poses a challenge, because of the vast scatter of experimental data points. Therefore, a statistical approach is used with a fatigue performance parameter applied to the fatigue data for welded samples to quantify the quality of the structural materials.",

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author = "Yevgen Gorash and Tugrul Comlekci and Carl Walker and Athanasios Toumpis and James Kelly and Andrew England and Lewis Milne",

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note = "18th International Conference on Advances in Experimental Mechanics, BSSM 2024 ; Conference date: 02-09-2024 Through 05-09-2024",

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T1 - Comparative fatigue analysis of structural steels considering welding and surface effects

AU - Gorash, Yevgen

AU - Comlekci, Tugrul

AU - Walker, Carl

AU - Toumpis, Athanasios

AU - Kelly, James

AU - England, Andrew

AU - Milne, Lewis

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N2 - There are limited data on the very high-cycle fatigue for structural steel welds for over 10 million cycles. The purpose of this research is a fatigue performance comparison of the welds made of steels S355JR+AR and S275JR+AR. The goal of reaching the gigacycle fatigue domain is achieved using the ultrasonic fatigue testing at 20 kHz. Fatigue samples are prepared to investigate the influence of two surface conditions—polished and precorroded. Fatigue failures are driven primarily by welding porosity with the fatigue life duration dependent on the size and location of pores. Visual comparison of fatigue data for steels poses a challenge, because of the vast scatter of experimental data points. Therefore, a statistical approach is used with a fatigue performance parameter applied to the fatigue data for welded samples to quantify the quality of the structural materials.

AB - There are limited data on the very high-cycle fatigue for structural steel welds for over 10 million cycles. The purpose of this research is a fatigue performance comparison of the welds made of steels S355JR+AR and S275JR+AR. The goal of reaching the gigacycle fatigue domain is achieved using the ultrasonic fatigue testing at 20 kHz. Fatigue samples are prepared to investigate the influence of two surface conditions—polished and precorroded. Fatigue failures are driven primarily by welding porosity with the fatigue life duration dependent on the size and location of pores. Visual comparison of fatigue data for steels poses a challenge, because of the vast scatter of experimental data points. Therefore, a statistical approach is used with a fatigue performance parameter applied to the fatigue data for welded samples to quantify the quality of the structural materials.

KW - structural steel

KW - welds

KW - very high cycle fatigue

KW - ultrasonic testing

KW - corrosion

U2 - 10.1111/str.70003

DO - 10.1111/str.70003

M3 - Article

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T2 - 18th International Conference on Advances in Experimental Mechanics

Y2 - 2 September 2024 through 5 September 2024

ER -

Comparative fatigue analysis of structural steels considering welding and surface effects

Abstract

Funding

Keywords

UN SDGs

Access to Document

Fingerprint

Research output

Very high cycle fatigue of welds: a review

Ultrasonic fatigue testing of structural steel welded joints

Frequency effects in ultrasonic fatigue testing (UFT) of Q355B structural steel

Cite this