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TALAT Lecture 2406: Annex 1

CORE-Materials
CORE-Materials

Fatigue and Fracture in Aluminium Structures. Proposal for a National Application Document (Updated from the TAS project). Contains tables.

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TALAT Lecture 2406 Annex 1 An Update of TALAT Chapter 2400 Fatigue and Fracture in Aluminium Structures Proposal for a National Application Document (Updated from the TAS project) TAS alu Leonardo da Vinci program Training in Aluminium Alloy Structural Design 6 pages Prepared by Prof. Dimitris Kosteas, Technische Universit辰t M端nchen, Germany Contents Table 5.1.1* Detail Categories for Plain Material ........................................................................................................................................................................ 2 Table 5.1.2* Detail Categories for Members with Welded Attachments - Transverse Weld Toe................................................................................................. 3 Table 5.1.3* Detail Categories for Members with Welded Attachments - Longitudinal Welds..................................................................................................... 4 Table 5.1.4* Detail Categories for Welded Joints between Members ......................................................................................................................................... 5 Table 5.1.5* Detail Categories for Crossing Welds / Built-up Beams.......................................................................................................................................... 6 TALAT 2406 Annex 1 1
Table 5.1.1* Detail Categories for Plain Material 3 1 1 3 Ds 4 4 2 Ds 2 Product Forms Simple Extruded Rod and Bar, Sheet, Plate, Extrusions, Notches, Holes Castings Machined Parts Tubes, Forgings Initiation Site Reference No. 1, 2 1, 2 4 1 3 Location Small surface irregularity Cast material 1) Stress orientation (see 4.3.4) PARALLEL or NORMAL to rolling or extrusion direction - - Alloys 7020 As table 1.1.1 7020 As table 1.1.1 7020 As table 1.1.1 As Table 1.1.2 (except 7020) (except 7020) (except 7020) Particular Dimensional Surfaces free of sharp corners unless parallel to stress direction; Edges free of stress raisers Requirements No re-entrant corners in profile, - No contact with other parts Fabrication Machining only by high speed milling Hand grinding not permitted unless Holes drilled and reamed Casting as per Table 1.1.2 cutters parallel to stress direction Machining only by high speed milling cutters Inspection/Testing Visual Dye Penetrant Radiography see Chapter 6* Quality Standard Surface finish (Ra < 0.5mm) No score marks transverse to stress - see Chapter 6* direction Stress Analysis Stress parameter Principal structural stress at initiation site Account for stress concentration Principal structural stress at initiation site Annex A.4 Stress Surface texture Permitted internal concentrations porosity already allowed for Type Number 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2) Detail Category - m1 130 - 7 95 - 7 85 - 7 70 - 7 as Types 1.1 to 1.4 70 - 7 70 - 7 1) The manufacturer shall be consulted concerning the quality assurance in case of extrusions by port hole or bridge die 2) m1 = m2 , constant amplitude fatigue limit at 2 x 106 cycles TALAT 2406 Annex 1 2
Table 5.1.2* Detail Categories for Members with Welded Attachments - Transverse Weld Toe L R 1 6 5 Ds Ds 4 Ds 1 3 2 T Ds 2 stress gradient 6 R 6 Product Forms Rolled, extruded and forged products Initiation Site Reference No. 1 2 3 4 5 6 Location At transverse weld toe on stressed member At longitudinal weld At transverse weld toe on stressed end member On surface away from edge At corner On edge In ground weld toe On surface away from edge on edge Stress orientation (see 4.3.4) Normal to transverse weld toe Parallel to weld axis Normal to weld toe Alloys As table 1.1.1 Particular Dimensional Joint Geometry Attachment on member surface Attachment on member edge Attachment on member surface Requirements Weld on surface away from corner Welded round Weld on edge Weld on surface away from corner corner Length L (mm) L 20 L > 20 L and T as for No radius R 50 R 50 No radius Thickness T (mm) see table below Types 2.1 and 2.2 Fabrication Grind undercut smooth Grind radius parallel to stress direction 1) Inspection/Testing see chapter 6* Quality in acc. internal C to EN 30 042 geometrical C Stress Analysis Stress parameter Nominal stress at initiation site Stress concentrations Discontinuities permitted as given in EN 30042 already allowed for Stiffening effect of attachment Type Number 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Detail Category T4 31 25 As Types 2.1 to 4 < T 10 31 22 2.2, but reduced by 18 35 35 23 m1 = 3,4 , m2 = 5,4 for all Types 10 < T 15 31 20 12% Adjustment for stress gradient Where 1 and 2 are of opposite sign increase by 2 Categories where T 15 mm 1) Weld toe shall be fully ground out TALAT 2406 Annex 1 3
Table 5.1.3* Detail Categories for Members with Welded Attachments - Longitudinal Welds 2 2 Ds 3 3 1 1 Ds 4 R 5 L卒 G Ds Product Forms Rolled, extruded and forged products Initiation Site Reference No. 1 2 3 4 5 Location A weld discontinuity Weld toe or crater Stress orientation (see 4.3.4) Parallel to weld axis Alloys As Table 1.1.1 Particular Dimensional Full penetration butt weld Continuous fillet weld Intermittent fillet weld Cope hole centred on weld axis Requirements G 2.5L R 25mm Fabrication Continuous automatic welding 2) Weld caps ground flush in direction of Any backing bars (and attachment welds) to be continuous Inspection/Testing see Chapter 6* Quality in acc. internal B C C B C C C to EN 30 042 geometrical C C D C D D D 1) 3 add. requirements ) Stress Analysis Stress parameter Nominal stress at initiation site Stress concentrations already Weld discontinuities as permitted by EN 30 042 allowed for Presence of cope hole Type Number Detail Category - m1 (m2 = m1 + 2) 60 - 4,3 55 - 4,3 45 - 4,3 45 - 4,3 40 - 4,3 35 - 4,3 28 - 3,4 1) 2) 3 1 Ripple/imperfection no. 504/EN 30 042:B imperfection due to stop-start effect shall be checked ) Discontinuity in direction of longitudinal weld shall not be higher than /10 of plate thickness or exhibit slope steeper than 1:4 TALAT 2406 Annex 1 4
Table 5.1.4* Detail Categories for Welded Joints between Members 9 12 1 2 3 4 5 11 11 10 9 8 10 77 T Ds Ds 6 8 Product Forms Rolled, extruded and forged products Castings Initiation Site Reference No. 1 2 3, 4 5 6 7 8 9 10 11 12 Location weld, base material weld base material weld base material weld Stress orientation (see 4.3.4) Normal to weld axis Alloys As table 1.1.1 Particular Dimensional Joint type In-line-butt Cruciform or Tee Lap Requirements Weld type Butt Double fillet 1) One sided fillet Fillet Preparation Double sided Single sided edge preparation Penetration Full Partial Full Partial Transition Taper slope < 1:4 at width or thickness change Manufacturing Root Ground Backed Unbacked Ground Cap Ground flush Ends Extension plates used on ends, cut off and ground flush in direction of Inspection/Testing see Chapter 6* Quality in acc. internal B C B B C C C B C C D B C C C C C C to EN 30 042 geometrical B C C B C C C B C C C B C C C C C C 3 3 3 3 3 3 2) 3 2) 3 2) 3 3 2) 3 3 3 3 3 3 3 add. requirements ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) Stress Analysis Stress parameter net section net throat net section net throat net section net throat Stress concentrations already allowed for Stiffening effect of transverse element stress peaks at weld ends Type Number 4.1 4.1 4.2 4.2 4.3 4.3 4.4 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 fl op fl op fl op/ho fl op/ho Detail Category - m1 55-7 45-7 50-4,3 40-3,4 35-3,4 40-4,3 30-3,4 45-4,3 40-4,3 30-3,4 18-3,4 35-3,4 30- 25-3,4 12-3,4 23-3,4 18-3,4 14-3,4 3,4 1) 2) Round tubes one sided fillet Imperfection no. 402 / EN 30 042 not allowed fl: Flats, Solids / op: Open Shapes / ho: Hollow, Tubular 3 1 ) Discontinuity in direction of longitudinal weld shall not be higher than /10 of plate thickness or exhibit slope steeper than 1:4 TALAT 2406 Annex 1 5
Table 5.1.5* Detail Categories for Crossing Welds / Built-up Beams see Table 5.1.3* Ref. No. 3 Type No. 3.4 / 3.5 Product Forms Initiation Site Reference No. 1 2 3 4 5 6 7 8 9 Location Weld Base Material Weld On surface away from edge Stress orientation (see 4.3.4) Alloys Particular Dimensional Joint type In-line-butt Attachment Cruciform or tee Coverplate Requirements Weld type Butt Fillet Preparation Single sided Double sided Double sided Single sided Double sided Penetration Full Transition Taper slope < 1:4 at width or thickness change Manufacturing Root Ground flush Ground Cap Ground flush Ground 1) Ends ?? Inspection/Testing see Chapter 6* Quality in acc. internal B B B C C C C C C to EN 30 042 geometrical B B C C C C C C C add. requirements for web-to-flange fillet welds 2) Stress Analysis Stress parameter net section net throat net section Stress concentrations already allowed for Stiffening effects of attachment Type Number 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 Detail Category - m1 40-3,4 35-3,4 30-3,4 18-3,4 23-3,4 30-4,3 25-4,3 20-4,3 1) 2 Transverse web and flange butt joint before final assembly of beam with longitudinal welds ) see Table 5.1.3* Reference No. 3 / Type No. 3.4 or 3.5 TALAT 2406 Annex 1 6

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TALAT Lecture 2406: Annex 1

  • 1. TALAT Lecture 2406 Annex 1 An Update of TALAT Chapter 2400 Fatigue and Fracture in Aluminium Structures Proposal for a National Application Document (Updated from the TAS project) TAS alu Leonardo da Vinci program Training in Aluminium Alloy Structural Design 6 pages Prepared by Prof. Dimitris Kosteas, Technische Universit辰t M端nchen, Germany Contents Table 5.1.1* Detail Categories for Plain Material ........................................................................................................................................................................ 2 Table 5.1.2* Detail Categories for Members with Welded Attachments - Transverse Weld Toe................................................................................................. 3 Table 5.1.3* Detail Categories for Members with Welded Attachments - Longitudinal Welds..................................................................................................... 4 Table 5.1.4* Detail Categories for Welded Joints between Members ......................................................................................................................................... 5 Table 5.1.5* Detail Categories for Crossing Welds / Built-up Beams.......................................................................................................................................... 6 TALAT 2406 Annex 1 1
  • 2. Table 5.1.1* Detail Categories for Plain Material 3 1 1 3 Ds 4 4 2 Ds 2 Product Forms Simple Extruded Rod and Bar, Sheet, Plate, Extrusions, Notches, Holes Castings Machined Parts Tubes, Forgings Initiation Site Reference No. 1, 2 1, 2 4 1 3 Location Small surface irregularity Cast material 1) Stress orientation (see 4.3.4) PARALLEL or NORMAL to rolling or extrusion direction - - Alloys 7020 As table 1.1.1 7020 As table 1.1.1 7020 As table 1.1.1 As Table 1.1.2 (except 7020) (except 7020) (except 7020) Particular Dimensional Surfaces free of sharp corners unless parallel to stress direction; Edges free of stress raisers Requirements No re-entrant corners in profile, - No contact with other parts Fabrication Machining only by high speed milling Hand grinding not permitted unless Holes drilled and reamed Casting as per Table 1.1.2 cutters parallel to stress direction Machining only by high speed milling cutters Inspection/Testing Visual Dye Penetrant Radiography see Chapter 6* Quality Standard Surface finish (Ra < 0.5mm) No score marks transverse to stress - see Chapter 6* direction Stress Analysis Stress parameter Principal structural stress at initiation site Account for stress concentration Principal structural stress at initiation site Annex A.4 Stress Surface texture Permitted internal concentrations porosity already allowed for Type Number 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2) Detail Category - m1 130 - 7 95 - 7 85 - 7 70 - 7 as Types 1.1 to 1.4 70 - 7 70 - 7 1) The manufacturer shall be consulted concerning the quality assurance in case of extrusions by port hole or bridge die 2) m1 = m2 , constant amplitude fatigue limit at 2 x 106 cycles TALAT 2406 Annex 1 2
  • 3. Table 5.1.2* Detail Categories for Members with Welded Attachments - Transverse Weld Toe L R 1 6 5 Ds Ds 4 Ds 1 3 2 T Ds 2 stress gradient 6 R 6 Product Forms Rolled, extruded and forged products Initiation Site Reference No. 1 2 3 4 5 6 Location At transverse weld toe on stressed member At longitudinal weld At transverse weld toe on stressed end member On surface away from edge At corner On edge In ground weld toe On surface away from edge on edge Stress orientation (see 4.3.4) Normal to transverse weld toe Parallel to weld axis Normal to weld toe Alloys As table 1.1.1 Particular Dimensional Joint Geometry Attachment on member surface Attachment on member edge Attachment on member surface Requirements Weld on surface away from corner Welded round Weld on edge Weld on surface away from corner corner Length L (mm) L 20 L > 20 L and T as for No radius R 50 R 50 No radius Thickness T (mm) see table below Types 2.1 and 2.2 Fabrication Grind undercut smooth Grind radius parallel to stress direction 1) Inspection/Testing see chapter 6* Quality in acc. internal C to EN 30 042 geometrical C Stress Analysis Stress parameter Nominal stress at initiation site Stress concentrations Discontinuities permitted as given in EN 30042 already allowed for Stiffening effect of attachment Type Number 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Detail Category T4 31 25 As Types 2.1 to 4 < T 10 31 22 2.2, but reduced by 18 35 35 23 m1 = 3,4 , m2 = 5,4 for all Types 10 < T 15 31 20 12% Adjustment for stress gradient Where 1 and 2 are of opposite sign increase by 2 Categories where T 15 mm 1) Weld toe shall be fully ground out TALAT 2406 Annex 1 3
  • 4. Table 5.1.3* Detail Categories for Members with Welded Attachments - Longitudinal Welds 2 2 Ds 3 3 1 1 Ds 4 R 5 L卒 G Ds Product Forms Rolled, extruded and forged products Initiation Site Reference No. 1 2 3 4 5 Location A weld discontinuity Weld toe or crater Stress orientation (see 4.3.4) Parallel to weld axis Alloys As Table 1.1.1 Particular Dimensional Full penetration butt weld Continuous fillet weld Intermittent fillet weld Cope hole centred on weld axis Requirements G 2.5L R 25mm Fabrication Continuous automatic welding 2) Weld caps ground flush in direction of Any backing bars (and attachment welds) to be continuous Inspection/Testing see Chapter 6* Quality in acc. internal B C C B C C C to EN 30 042 geometrical C C D C D D D 1) 3 add. requirements ) Stress Analysis Stress parameter Nominal stress at initiation site Stress concentrations already Weld discontinuities as permitted by EN 30 042 allowed for Presence of cope hole Type Number Detail Category - m1 (m2 = m1 + 2) 60 - 4,3 55 - 4,3 45 - 4,3 45 - 4,3 40 - 4,3 35 - 4,3 28 - 3,4 1) 2) 3 1 Ripple/imperfection no. 504/EN 30 042:B imperfection due to stop-start effect shall be checked ) Discontinuity in direction of longitudinal weld shall not be higher than /10 of plate thickness or exhibit slope steeper than 1:4 TALAT 2406 Annex 1 4
  • 5. Table 5.1.4* Detail Categories for Welded Joints between Members 9 12 1 2 3 4 5 11 11 10 9 8 10 77 T Ds Ds 6 8 Product Forms Rolled, extruded and forged products Castings Initiation Site Reference No. 1 2 3, 4 5 6 7 8 9 10 11 12 Location weld, base material weld base material weld base material weld Stress orientation (see 4.3.4) Normal to weld axis Alloys As table 1.1.1 Particular Dimensional Joint type In-line-butt Cruciform or Tee Lap Requirements Weld type Butt Double fillet 1) One sided fillet Fillet Preparation Double sided Single sided edge preparation Penetration Full Partial Full Partial Transition Taper slope < 1:4 at width or thickness change Manufacturing Root Ground Backed Unbacked Ground Cap Ground flush Ends Extension plates used on ends, cut off and ground flush in direction of Inspection/Testing see Chapter 6* Quality in acc. internal B C B B C C C B C C D B C C C C C C to EN 30 042 geometrical B C C B C C C B C C C B C C C C C C 3 3 3 3 3 3 2) 3 2) 3 2) 3 3 2) 3 3 3 3 3 3 3 add. requirements ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) Stress Analysis Stress parameter net section net throat net section net throat net section net throat Stress concentrations already allowed for Stiffening effect of transverse element stress peaks at weld ends Type Number 4.1 4.1 4.2 4.2 4.3 4.3 4.4 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 fl op fl op fl op/ho fl op/ho Detail Category - m1 55-7 45-7 50-4,3 40-3,4 35-3,4 40-4,3 30-3,4 45-4,3 40-4,3 30-3,4 18-3,4 35-3,4 30- 25-3,4 12-3,4 23-3,4 18-3,4 14-3,4 3,4 1) 2) Round tubes one sided fillet Imperfection no. 402 / EN 30 042 not allowed fl: Flats, Solids / op: Open Shapes / ho: Hollow, Tubular 3 1 ) Discontinuity in direction of longitudinal weld shall not be higher than /10 of plate thickness or exhibit slope steeper than 1:4 TALAT 2406 Annex 1 5
  • 6. Table 5.1.5* Detail Categories for Crossing Welds / Built-up Beams see Table 5.1.3* Ref. No. 3 Type No. 3.4 / 3.5 Product Forms Initiation Site Reference No. 1 2 3 4 5 6 7 8 9 Location Weld Base Material Weld On surface away from edge Stress orientation (see 4.3.4) Alloys Particular Dimensional Joint type In-line-butt Attachment Cruciform or tee Coverplate Requirements Weld type Butt Fillet Preparation Single sided Double sided Double sided Single sided Double sided Penetration Full Transition Taper slope < 1:4 at width or thickness change Manufacturing Root Ground flush Ground Cap Ground flush Ground 1) Ends ?? Inspection/Testing see Chapter 6* Quality in acc. internal B B B C C C C C C to EN 30 042 geometrical B B C C C C C C C add. requirements for web-to-flange fillet welds 2) Stress Analysis Stress parameter net section net throat net section Stress concentrations already allowed for Stiffening effects of attachment Type Number 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 Detail Category - m1 40-3,4 35-3,4 30-3,4 18-3,4 23-3,4 30-4,3 25-4,3 20-4,3 1) 2 Transverse web and flange butt joint before final assembly of beam with longitudinal welds ) see Table 5.1.3* Reference No. 3 / Type No. 3.4 or 3.5 TALAT 2406 Annex 1 6