A fatigue crack tip field model considering residual stress and plasticity-induced closure for welded structures

In order to more accurately understand and predict the fatigue crack growth behavior in welded structures, a fatigue crack tip field model considering residual stress and plasticity-induced closure (RSPC model) is presented in this paper. Building upon the existing CJP model, which adequately explains plasticity-induced crack closure, the RSPC model further considers the influence of tensile residual stress induced by welding. The model, through a detailed derivation and analysis of the residual stress function, establishes the theoretical stress and displacement fields at the crack tip of the butt-welded joint. Integrating these fields with the CJP model, the theoretical framework of the RSPC model is formulated. Subsequently, through fatigue crack growth experiments and digital image correlation analysis, a comparison and validation of the predictive performance of the CJP and RSPC models are conducted. It is observed that the latter aligns more closely with experimental results in calculating plastic zone area, with a maximum error of only 10%. In comparison to the CJP model, the average error decreases by 19.143%, indicating higher predictive accuracy. Furthermore, the study focuses on the contribution of tensile residual stress in butt welded joints to the growth of the plastic zone at the fatigue crack tip and the underlying reasons for its variations. Finally, the research investigates the constrained relationship between plastic zone size and fatigue crack growth rate. Corresponding relationship functions are fitted, providing more accurate guidance for crack control and material design.