Abstract
Undercut, as a typical surface imperfection at the weld toe, significantly impacts the weld fatigue life. Neither the ISO5817 standard for imperfection level definition nor the traditional fatigue life prediction methods for welds can accurately identify the undercut effect on weld fatigue life. To solve this problem, a new stress concept and life prediction method are proposed, which can predict the fatigue life of undercut welds in both linear elastic and elastic–plastic conditions. Its prediction accuracy is verified by test data and engineering examples.
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