This study explores the morphological changes and interaction mechanisms of multiple crack propagations in steel bridge joints. Fatigue testing was conducted to determine the locations at which multiple cracks initiated and to obtain fatigue fracture surfaces with easily discernible crack propagation traces. Based on the theory of fracture mechanics, the propagation behavior of coplanar and out-of-plane cracks in joints was simulated using ABAQUS and FRANC3D joint simulation technology. The characteristics of the morphological changes were analyzed, and the interaction mechanism between different crack spacings was investigated to quantitatively characterize the relative positions at which cracks were enhanced or suppressed. The results showed that coplanar cracks exhibited different morphological trends and propagation rates in different stages of propagation. The shape of the crack front continuously changed, and the merging point that appeared during fusion rapidly expanded and evolved into a semi-elliptical crack. The fatigue life was more sensitive to the relative position of multiple cracks. In particular, the fusion of coplanar cracks significantly reduced the fatigue life, and the mutual suppression effect between heterogeneous cracks increased the fatigue life. When the ratio of coplanar crack spacing to crack length (s/2c) was less than 0.2, the crack fusion process significantly accelerated. In addition, when the a2/a1 ratio of the crack propagation depth dropped below 0.5, the suppression effect was significant. Finally, by determining the spacing between multiple cracks, the method established this study can provide a reference for the design of fatigue resistance and joint optimization.
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