Fatigue design of lightweight welded vehicle structures: influence of material and production procedures

Structural details and components in many types of products are continuously subjected to variable amplitude loading during operation. Fatigue loading and fatigue damage is thus the most common failure mode for the mentioned equipment in operation. The influence of the material grade, weld quality and fabrication procedure have a major impact on the structural durability of welded vehicle structures. The comprehensive research work within the Nordic research and development community have contained development of finite element modelling of complex structures, including crack growth in two-and three-dimensional fatigue testing of welded small-scale specimen and full-scale components, investigations of weld defects and flaws (e. g. cold laps) and weld roots. An important part of these projects is related to simulation and measurements of formation and relaxation of residual stresses. Within these projects three new quality systems, for welded and cast components and for cut edges, have been developed based on a scientific ground and a fitness for purpose design philosophy. Volvos new weld class system, which is an open standard, is now a base for the revision of the international weld quality system ISO 5817. In this article the major findings in these research activities are briefly presented and discussed.