Development of residual stresses in fatigue-stressed joints subjected to four-point bending

The residual stresses introduced into a component as a result of the mechanical processes necessary for its manufacture significantly influence the fatigue behaviour. The application of loads themselves can, however, alter the initial residual stress distribution, so it is feasible to believe that the residual stress field of a fatigue-stressed structure develops over its entire lifespan. The aim of this article is to analyse the development that the residual stresses initially present in a welded butt joint undergo following the application of an external cyclic load. Comparisons between two residual stress measurements, conducted on the same joint before and after the application of fatigue cycles, have made it possible to obtain interesting information regarding the development of residual stresses in components subjected to fatigue. In particular, it has been found that unlike what is commonly reported, there are particular conditions where the application of a cyclic load results in an increase in the residual stresses initially present, rather than their relaxation. This phenomenon should be taken into consideration in order to avoid unexpected failure in components subjected to fatigue. © 2012 Copyright Taylor and Francis Group, LLC.