Damage tolerance reliability analysis of automotive spot-welded joints

Reliability Engineering and System Safety

Volumn 81, Issue 1, 2003, Pages 9-21

  Mahadevan, Sankaran ^a   Ni, Kan ^a  

^a VANDERBILT UNIVERSITY   (United States)

Author keywords

Crack growth; Fatigue; Finite element modeling; Fracture; Multi axial loading; Probabilistic analysis; Spot weld joint; Strain life; Variable amplitude loading

Indexed keywords

COMPUTER SOFTWARE; CRACK INITIATION; CRACK PROPAGATION; FATIGUE OF MATERIALS; FINITE ELEMENT METHOD; FRACTURE; PROBABILITY; SPOT WELDING; STRAIN; STRESS ANALYSIS; WELDS;

MULTIAXIAL LOADING;

RELIABILITY THEORY;

EID: 0037506161     PISSN: 09518320     EISSN: None     Source Type: Journal    
DOI: 10.1016/S0951-8320(03)00057-7     Document Type: Article

References (61)

1. Provan J.W. Probabilistic fracture mechanics and reliability. 1987;Martinus Nijhoff.
2. Atluri S.N. Structural integrity and durability. 1997;Tech Science Press.
3. Goranson U.G. Fatigue issues in aircraft maintenance and repair. Int J Fatigue. 20:(6):1997;413-431.
4. Shi P., Mahadevan S. Damage tolerance approach for probabilistic pitting corrosion fatigue life prediction. Engng Fract Mech. 68:2001;1493-1507.
5. Lassen T., Sorensen J.D. A probabilistic damage tolerance concept for welded joints. Part 1: data base and stochastic modeling. Marine Struct. 15:2002;599-613.
6. Proppe C., Schueller G.I., Hartl J., Kargl H. Probabilistic design of mechanical components. Struct Safety. 24:2002;363-376.
7. Conle F.A., Chu C.-C. Fatigue analysis and the local stress-strain approach in complex vehicular structures. Int J Fatigue. 19:1997;S317-S323.
8. Fermer M., Svensson H. Industrial experience of FE-based fatigue life prediction of welded automotive structures. Fatigue Fract Engng Mater. 24:2001;489-500.
9. Kuo EY, Jayasuriya MM, Wung P. The effect of high mileage spot weld degradation on vehicle body joint stiffness. SAE paper 2001-01-0426.
10. Lee Y.-L., Raymond M.N., Villaire M.A. Durability design process of a vehicle suspension component. J Test Eval. 23:(5):1995;354-363.
11. Chu C.-C. Multiaxial fatigue life prediction method in the ground vehicle industry. Int J Fatigue. 19:1997;S325-S330.
12. Linder J., Melander A., Larsson M., Bergenren Y. Fatigue design of spot-welded austenitic and duplex stainless sheet steels. Fatigue Fract Engng Mater Struct. 21:1998;673-686.
13. Henrysson H.-F. Fatigue life predictions of spot welds using coarse FE meshes. Fatigue Fract Engng Mater Struct. 23:2000;737-746.
14. Henrysson H-F. Fatigue of spot welded joints: experiment and life prediction. PhD Thesis. Chalmers University of Technology, Sweden; 2001.
15. Newman J.A., Dowling N.E. A crack growth approach to life prediction of spot-welded lap joints. Fatigue Fract Engng Mater. 21:1998;1123-1132.
16. Radaj D. Review of fatigue strength assessment of non-welded and welded structures based on local parameters. Int J Fatigue. 18:(3):1996;153-170.
17. Pan N., Sheppard S.D. Spot welds fatigue life prediction with cyclic strain range. Int J Fatigue. 24:2002;519-528.
18. Pan N. Fatigue life study of spot welds. PhD Thesis. Stanford, CA: Stanford University; 2000.
19. Sheppard S.D., Strange M. Fatigue life estimation in resistance spot welds: initiation and early growth phase. Fatigue Fract Engng Mater Struct. 15:(6):1992;531-549.
20. Zhang Y., Taylor D. Sheet thickness effect of spot welds based on crack propagation. Engng Fract Mech. 67:2000;55-63.
21. Kan Y. Fatigue resistance of spotwelds - an analytical study. Met Eng Quart. 16:(4):1976;26-36.
22. Oh H.L. Fatigue-life prediction for spotweld using Neubers rule. Design of fatigue and fracture resistance structures. Philadelphia, ASTM. 1982;296-309.
23. Pook L.P. Fracture mechanics analysis of the fatigue behavior of spot welds. Int J Fract. 11:1975;173-176.
24. Zhang S. Stress intensity at spot welds. Int J Fract. 88:1997;167-185.
25. Cooper J.F., Smith R.A. The measurement of fatigue cracks at spot-welds. Int J Fatigue. 3:1985;140-143.
26. Paris P.C., Erdogan F. A critical analysis of crack propagation laws. Trans ASME J Basic Eng. 84:(4):1963;528.
27. Walker K. The effect of stress ratio during crack propagation and fatigue life for 2024-T3 and 7075-T6 aluminum. ASTM STP 462: 1-14.
28. Chang B., Shi Y., Dong S. Comparative studies on stress in weld-bonded, spot-welded and adhesive-bonded joints. J Mater Process Technol. 87:1999;230-236.
29. Deng X., Chen W., Shi G. Three-dimensional finite element analysis of the mechanical behavior of spot welds. Finite Elements Anal Des. 35:2000;17-39.
30. Kang H., Barkey M.E., Lee Y. Evaluation of multiaxial spot weld fatigue parameters for proportional loading. Int J Fatigue. 22:2000;691-702.
31. Barkey M.E., Kang H., Lee Y. Failure modes of single resistance spot welded joints subjected to combined fatigue loading. Int J Mater Prod Technol. 16:(6/7):2001;510-527.
32. Lin S.-H., Pan J., Wu S.-R., et al. Failure Loads of spot welds under combined opening and shear static loading conditions. Int J Solid Struct. 39:2002;19-39.
33. Lee Y-L. Fatigue reliability analysis of resistance spot welds. SAE Paper, 94RM-040.
34. Amzallg C., Gerey J.P., Robert J.L., Bahuad J. Standardization of the rainflow counting method for fatigue analysis. Int J Fatigue. 16:(4):1994;287-293.
35. Manson S.S. Behavior of materials under conditions of thermal stress. Heat Transfer Symp Univ Mechigan Engng Res Insti. 1953;9-75.
36. Coffin L.F. A study of the effects of cyclic thermal stresses on a ductile metal. Trans ASME. 76:1954;931-950.
37. Morrow J.D. Fatigue design handbook. Dearborn (MI), SAE. 4:1968;21-29.
38. Neuber H. Theory of stress concentration for shear-strained prismatic bodies with arbitrary nonlinear stress-strain law. J Appl Mech, ASME. 1961;544-550.
39. Dupart D., Davy A., Boetsch R., Boudet R. Fatigue damage calculation in stress concentration fields under variable uniaxial stress. Int J Fatigue. 18:(4):1996;245-253.
40. Wu W.F., Liou H.Y., Tse H.C. Estimation of fatigue damage and fatigue life of components under random loading. Int J Pres Ves Piping. 72:1997;243-249.
41. Kandarpa S., Spencer B.F. Jr, Kirkner D.J. Reliability analysis of structural components utilizing the strain-life method. Engng Fract Mechanic. 53:(5):1996;761-774.
42. Zhao J., Tang J., Wu H.C. A generalized random variable approach for strain-based fatigue reliability analysis. J Pressure Vessel Technol, ASME. 122:2000;156-161.
43. Miner M.A. Cumulative damage in fatigue. J Appl Mech. 12:1945;A159-A164.
44. Shimokawa T., Tanake S. A statistical consideration of Miner's rule. Int J Fatigue. 2:(4):1980;165-170.
45. Ni K. Two-dimensional probabilistic Miner's rule and its application in structural fatigue reliability. PhD Dissertation, Department of Flight Vehicle Design and Applied Mechanics, Beijing University of Aeronautics and Astronautics; 1994 (in Chinese).
46. Ni K, Zhang SK. Two-dimensional probabilistic Miner's rule in fatigue reliability. ICOSSAR'01, Proceedings of the 8th International Conference on Structural Safety and Reliability, Newport Beach, California, USA, June 17-22; 2001.
47. Manson S.S., Halford G.R. Re-examination of cumulative fatigue damage analysis - an engineering perspective. Engng Fract Mech. 25:(5):1986;539-571.
48. Weibull W. Fatigue testing and analysis of results. 1961;The Macmillan Company, New York.
49. Todinov M.T. Necessary and sufficient condition for additivity in the sense of the Palmgren-Miner rule. Comput Mater Sci. 21:2001;101-110.
50. Ni K., Zhang S.K. Fatigue 99, Proceedings of the Seventh International Fatigue Congress, Beijing, China, Jun 8-12. Fatigue 99, Proceedings of the Seventh International Fatigue Congress, Beijing, China, Jun 8-12. Vol. 4/4:1999;. p. 2705-10.
51. Ni K., Zhang S.K. Fatigue reliability analysis under two-stage loading. Reliab Engng Syst Safety. 68:(2):2000;153-158.
52. Ni K., Zhang S.K. Reliability analysis of fatigue damage accumulation under variable amplitude loading. Int J Offshore Polar Engng. 10:(2):2000;131-136.
53. Sobczyk K., Spencer B.F. Jr. Random fatigue: from data to theory. 1992;Academic Press INC. p. 213.
54. Virkler D.A., Hillberry B.M., Goel P.K. The statistical nature of fatigue crack propagation. J Engng Mater Technol. 101:1979;148-153.
55. Ortiz K., Kiremidjian A.S. Stochastic modeling of fatigue crack growth. Engng Fract Mech. 29:(3):1988;317-334.
56. Bogdanoff J.L. A new cumulative damage model. J Appl Mech. 45:1978;246-250.
57. Tang J., Spencer B.F. Jr. Reliability solution for the stochastic fatigue crack growth problem. Engng Fract Mech. 34:(2):1989;419-433.
58. Gao Z. Handbook of fatigue behavior of aeronautical metallic materials. 1981;Beijing Research Institute of Aeronautical Materials, Beijing, China. in Chinese.
59. Hollander JB. Probabilistic analysis of automotive spot-weld joint stiffness degradation under high mileage. Master Thesis, Vanderbilt University; 2002.
60. MSC NASTRAN. Version 70.7. MacNeal-Schwendler Corporation, Los Angeles, CA; 1999.
61. MSC FATIGUE. Version 2000. MacNeal-Schwendler Corporation, Los Angeles, CA; 2000.