Experimental study on the fatigue crack growth rates of welded ultra-high strength steel plates

The assessment of the fatigue crack growth rate behavior of welded structural components made of ultra-high strength steels (UHHS) is very important to gain a comprehensive understanding of these materials under high-cycle fatigue loadings and to enhance their applications in the construction industry. The literature on the fatigue crack growth rates of welded ultra-high strength steel plates with nominal yield strengths higher than 690 MPa is very scarce and only very limited research has been done thus far to provide the Paris’ Law fatigue material constants for welded UHSS components in terms of the base metal (BM), the weld metal (WM), and the heat-affected zone (HAZ) regions, which are essential for fatigue life prediction. Hence, the fatigue crack growth rates of butt-welded UHSS plates with three grades (S700, S960, and S1100) are experimentally investigated in this study using Paris’ Law for these three different regions of the welded components. Gas metal arc welding (GMAW) and laser welding (LW) methods are adopted to analyze the influence of welding methods on each steel grade with respect to their static and fatigue strength, microstructural changes, and hardness. In the fatigue crack growth rate test, it was observed that the S700 base material shows the lowest fatigue crack propagation resistance amongst these three grades. In welded components, laser welding outperforms gas welding in terms of the fatigue crack growth resistance. Comparisons of fatigue crack growth behaviors are made among all three tested UHSSs as well as with those from the literature.