Fatigue life prediction of friction-stir-welded aluminum bridge decks – Experimental tests and numerical framework

Mahmoud Trimech; Charles Darwin Annan; Scott Walbridge; Johan Maljaars

doi:10.1016/j.engstruct.2024.118559

Fatigue life prediction of friction-stir-welded aluminum bridge decks – Experimental tests and numerical framework

Mahmoud Trimech (Corresponding author)
, Charles Darwin Annan
, Scott Walbridge
, Johan Maljaars

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

5 Citations (Scopus)

147 Downloads (Pure)

Abstract

This paper presents the results of experimental tests and proposes a numerical framework for the prediction of the fatigue behaviour of friction stir welded (FSW) butt-lap joints of aluminium bridge deck extrusions. Fatigue test specimens made of welded real roadway bridge deck extrusions were subjected to cyclic bending under different loading conditions. The fatigue failure modes were thoroughly analyzed. A numerical framework incorporating a 2D finite element (FE) model based on the theory of critical distances (TCD) and a simplified linear elastic fracture mechanics (LEFM) model was developed to predict the fatigue failure initiation location and the fatigue life of the specimens under the test conditions. The location of the failure initiation played a key role in the choice of the numerical approach adopted in the prediction of fatigue life. For fatigue failures initiating from the base metal, the framework utilizes the TCD formulations while for failures in the weld joint, the LEFM model was applied. The proposed numerical framework showed a good agreement with the experimental data.

Original language	English
Article number	118559
Number of pages	18
Journal	Engineering Structures
Volume	317
Early online date	27 Jul 2024
DOIs	https://doi.org/10.1016/j.engstruct.2024.118559
Publication status	Published - 15 Oct 2024

Funding

The authors acknowledge the financial support provided by the Fonds de recherche du Qu\u00E9bec: Nature et Technologie (FRQNT) and the Natural Sciences and Engineering Research Council of Canada (NSERC). The welding of the extrusions was carried out at the Aluminum Technology Center of the National Research Council of Canada (NRCC). The authors extend their thanks to Mr. Fran\u00E7ois Nadeau and Mr. Mario Party for their assistance. Furthermore, the authors appreciate the financial support and practical insights from Mr. Michel Toupin of Proco Inc. and Dr. Rachik Elmaraghy of SAFI Inc. The support of the Aluminum Research Center (REGAL), Qu\u00E9bec, is also gratefully acknowledged. The authors recognize the contributions of Professor Mario Fafard (AluQu\u00E9bec) and Dr. Sofiene Amira (CQRDA).

Keywords

Aluminium bridge deck extrusions
Friction stir welding
Butt-lap joints
Critical distance
Fracture mechanics
Numerical predictions
Aluminum bridge deck extrusions

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10.1016/j.engstruct.2024.118559

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title = "Fatigue life prediction of friction-stir-welded aluminum bridge decks {\textendash} Experimental tests and numerical framework",

abstract = "This paper presents the results of experimental tests and proposes a numerical framework for the prediction of the fatigue behaviour of friction stir welded (FSW) butt-lap joints of aluminium bridge deck extrusions. Fatigue test specimens made of welded real roadway bridge deck extrusions were subjected to cyclic bending under different loading conditions. The fatigue failure modes were thoroughly analyzed. A numerical framework incorporating a 2D finite element (FE) model based on the theory of critical distances (TCD) and a simplified linear elastic fracture mechanics (LEFM) model was developed to predict the fatigue failure initiation location and the fatigue life of the specimens under the test conditions. The location of the failure initiation played a key role in the choice of the numerical approach adopted in the prediction of fatigue life. For fatigue failures initiating from the base metal, the framework utilizes the TCD formulations while for failures in the weld joint, the LEFM model was applied. The proposed numerical framework showed a good agreement with the experimental data.",

keywords = "Aluminium bridge deck extrusions, Friction stir welding, Butt-lap joints, Critical distance, Fracture mechanics, Numerical predictions, Aluminum bridge deck extrusions",

author = "Mahmoud Trimech and Annan, \{Charles Darwin\} and Scott Walbridge and Johan Maljaars",

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AU - Trimech, Mahmoud

AU - Annan, Charles Darwin

AU - Walbridge, Scott

AU - Maljaars, Johan

PY - 2024/10/15

Y1 - 2024/10/15

N2 - This paper presents the results of experimental tests and proposes a numerical framework for the prediction of the fatigue behaviour of friction stir welded (FSW) butt-lap joints of aluminium bridge deck extrusions. Fatigue test specimens made of welded real roadway bridge deck extrusions were subjected to cyclic bending under different loading conditions. The fatigue failure modes were thoroughly analyzed. A numerical framework incorporating a 2D finite element (FE) model based on the theory of critical distances (TCD) and a simplified linear elastic fracture mechanics (LEFM) model was developed to predict the fatigue failure initiation location and the fatigue life of the specimens under the test conditions. The location of the failure initiation played a key role in the choice of the numerical approach adopted in the prediction of fatigue life. For fatigue failures initiating from the base metal, the framework utilizes the TCD formulations while for failures in the weld joint, the LEFM model was applied. The proposed numerical framework showed a good agreement with the experimental data.

AB - This paper presents the results of experimental tests and proposes a numerical framework for the prediction of the fatigue behaviour of friction stir welded (FSW) butt-lap joints of aluminium bridge deck extrusions. Fatigue test specimens made of welded real roadway bridge deck extrusions were subjected to cyclic bending under different loading conditions. The fatigue failure modes were thoroughly analyzed. A numerical framework incorporating a 2D finite element (FE) model based on the theory of critical distances (TCD) and a simplified linear elastic fracture mechanics (LEFM) model was developed to predict the fatigue failure initiation location and the fatigue life of the specimens under the test conditions. The location of the failure initiation played a key role in the choice of the numerical approach adopted in the prediction of fatigue life. For fatigue failures initiating from the base metal, the framework utilizes the TCD formulations while for failures in the weld joint, the LEFM model was applied. The proposed numerical framework showed a good agreement with the experimental data.

KW - Aluminium bridge deck extrusions

KW - Friction stir welding

KW - Butt-lap joints

KW - Critical distance

KW - Fracture mechanics

KW - Numerical predictions

KW - Aluminum bridge deck extrusions

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JO - Engineering Structures

JF - Engineering Structures

M1 - 118559

ER -

Fatigue life prediction of friction-stir-welded aluminum bridge decks – Experimental tests and numerical framework

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