Calibration of welding simulation parameters of fillet welding joints used in an orthotropic steel deck

Abstract

ABSTRACTA common problem of orthotropic steel decks is fatigue failure under cyclic loading. The fillet welded connection between the deck and longitudinal stiffeners is a position where cracks are generally found. Residual stresses induced by welding influence fatigue crack initiation and propagation. An effective way of predicting the stress distribution in complicated 3D welded joints is via three‐dimensional subsequent thermo‐mechanical finite element analyses. The methodology of numerical modelling of the welding procedure in order to predict the induced residual stresses is presented in the paper. Predicted results are verified by temperature and distortion measurements derived during a small‐scale welding experiment. In the case of the thermal analysis, a double ellipsoid heat source model is used to simulate the heat input. Convection and radiation heat loss coefficients used in FEA are calibrated by the experimental results. The validated numerical procedure is then applied to a typical orthotropic steel deck joint to predict the residual stress distribution.