EUROCODES

Background and Applications EN 1999-1-3 Fatigue of aluminium structures

Brussels, 18-20 February 2008 – Dissemination of information workshop 1

Fatigue of aluminium structures

EN 1999-1-3
Eurocode 9: Design of aluminium structures

Prepared by:
Univ. Prof. Dr.-Ing. Dr.-Ing. habil. Dimitris Kosteas
Technische Universität München, Germany

Presentation by:
Johan Maljaars
Eindhoven University of Technology, The Netherlands
TNO, The Netherlands
EUROCODES
Background and Applications EN 1999-1-3 Fatigue of aluminium structures
Brussels, 18-20 February 2008 – Dissemination of information workshop 2

Contents
• Introduction
• Fatigue design procedures
– Safe life design (SN-curve)
– Damage tolerant design (fracture mechanics)
– Design assisted by testing
• Safety factors and reliability
• Fatigue design and execution
• Future developments
– Harmonisation for imperfections / classification
– Friction stir welding
• Conclusions
EUROCODES
Background and Applications Introduction
Brussels, 18-20 February 2008 – Dissemination of information workshop 3

Fatigue
Crack initiation and propagation due to repeated loading

Examples of repeated loading:

- Traffic loads
- Wave loads
- Wind loads
EUROCODES
Background and Applications Introduction
Brussels, 18-20 February 2008 – Dissemination of information workshop 4

Fatigue and aluminium

Important for aluminium structures, due to generally high ratio
between life load and dead load

Example of fatigue crack:

EUROCODES
Background and Applications Introduction
Brussels, 18-20 February 2008 – Dissemination of information workshop 5

Eurocodes
Loads Design Execution / Inspection

Eurocode 1 Eurocode 9 EN 1090-3

EN 1991 EN 1999 Execution
Quality /
1-1: General structural rules Quality control
Inspection /
1-2: Fire design Supervision

1-3: Fatigue design

1-4: Cold-formed sheets

1-5: Shells
EUROCODES
Background and Applications Introduction
Brussels, 18-20 February 2008 – Dissemination of information workshop 6

Background to EN 1999-1-3
• General format of code for steel structures, but with
specific issues for aluminium
• Based on a comprehensive and reliable data bank
– Small-size component tests (shown here)
– Full-size component tests

• Refined statistical evaluation of test results

EUROCODES
Background and Applications Fatigue design procedures
Brussels, 18-20 February 2008 – Dissemination of information workshop 7

Fatigue design procedures

Three methods in EN 1999-1-3

• Safe life design – S-N curve approach

• Damage tolerant design – Fracture mechanics approach

• Design assisted by testing

EUROCODES
Background and Applications Safe life design
Brussels, 18-20 February 2008 – Dissemination of information workshop 8

S-N curves
• S-N curve: Log-based relation between stress range and number
of cycles:
Stress range ∆σ

4 5 6

Number of cycles N
Number of cycles N
EUROCODES
Background and Applications Safe life design
Brussels, 18-20 February 2008 – Dissemination of information workshop 9

S-N curves for aluminium

• Characteristic values depending on detail
• 3 slopes in range N = 105 to 5.106:
– m1 = 7 for base metal
– m1 = 4.3 or 3.4 for welded details

• Influence of alloy on S-N curve: m1 = 7

Base material m1 = 4.3
m2 = 7
– Same S-N curve for all 5xxx and
6xxx alloys listed EN1999-1-1 m2 = 6.3
– Different (more favourable) curve m1 = 3.4
for alloy 7020 Influence of alloy on S-N curve:
m2 = 5.4
Welds
– Same S-N curve for all alloys
EUROCODES
Background and Applications Safe life design
Brussels, 18-20 February 2008 – Dissemination of information workshop 10

Mean stress effect

• Taken into account by bonus factor

∆σC(R) = f ∆σC

1.6
Bonus factor f [-]

Base material
1.3
connections,
σres = known

Normal case 2σ res − Δσ

1 Reff =
-1 -0.5 0 0.5 1 2σ res + Δσ
R [-]
EUROCODES
Background and Applications Safe life design
Brussels, 18-20 February 2008 – Dissemination of information workshop 11

Types of details distinguished (1)

• Parent metal
∆σc
70-100

• Welded attachments 18-36

• Longitudinal welds
28-63

• Butt welds
18-56
EUROCODES
Background and Applications Safe life design
Brussels, 18-20 February 2008 – Dissemination of information workshop 12

Types of details distinguished (2)

∆σc
• Fillet welds
12-28

• Crossing welds
in built-up beams 18-40

• Bolted joints 56

• Adhesive bonded
joints
EUROCODES
Background and Applications Safe life design
Brussels, 18-20 February 2008 – Dissemination of information workshop 13

Variable amplitude load

• Rainflow-counting method

• Spectrum
∆σ
∆σ1
• Palmgren-Miner damage ∆σ2
∆σ3
accumulation: ∆σ4
ni
D = Σi
Ni n1 n2 n3 n4
n

ni Number of cycles in spectrum with range Δσi (load)

Ni Number of cycles according to S-N curve with range Δσi (resistance)

D Accumulative damage (shall be ≤ 1.0)

EUROCODES
Background and Applications Safe life design
Brussels, 18-20 February 2008 – Dissemination of information workshop 14

Geometric stress analysis

• Local stress concentration factor (due to weld geometry) in
classification of detail
• Global stress concentration factor (due to overall joint
geometry) depends on geometry:

Simple geometry Complex geometry

Stress increase Stress increase

Brace wall
Flat plate

due to weld due to weld

Stress increase
due to overall joint
geometry

σnom σnom

Flat plate Chord wall

EUROCODES
Background and Applications Safe life design
Brussels, 18-20 February 2008 – Dissemination of information workshop 15

Hot spot stress method

Not applicable according to EN 1999-1-3, because:
• Variable stress-strain relationship in HAZ
• Finite element results depend on mesh density, type of
modelling and type of elements

σnom σhs

t 0.4t
EUROCODES
Background and Applications Safe life design
Brussels, 18-20 February 2008 – Dissemination of information workshop 16

Reference detail procedure

Method in EN 1993-1-1 to take into account the joint geometry:
• Select similar detail (reference detail) and its S-N curve from
EN 1999-1-2
• Identify type for stress of reference and assessed details
• Establish same FEM on both reference and assessed details
• Load both details with stress identified above
• Determine hot spot stress ranges (HS) for both details
• Assume for assessed detail the same slopes m1 and m2 as in
reference detail
• Estimate fatigue strength for assessed detail at 2 x 106 cycles:

σHS,ref
∆σC,assess = σ ∆σC,ref
HS,assess
EUROCODES
Background and Applications Safe life design
Brussels, 18-20 February 2008 – Dissemination of information workshop 17

Steel versus aluminium (1)

Fatigue design values at 2.106 cycles for various details
EUROCODES
Background and Applications Safe life design
Brussels, 18-20 February 2008 – Dissemination of information workshop 18

Steel versus aluminium (2)

Different designs

Steel bridge deck Aluminium bridge deck

Welded Extruded

dekplaat

dwarsdrager

trogstuiklas

trog
hoofdligger

dwarsdrager

kruising dwarsdragerlijf-trogbeen
EUROCODES
Background and Applications Damage tolerant design
Brussels, 18-20 February 2008 – Dissemination of information workshop 19

Damage tolerant design

EUROCODES
Background and Applications Damage tolerant design
Brussels, 18-20 February 2008 – Dissemination of information workshop 20

Explanation damage tolerant

design (1)
• Analytical background
• Starts with an initial defect
• Predicts crack growth

Crack growth due to one stress cycle related to joint geometry:

da / dN ÅÆ ∆K
a
EUROCODES
Background and Applications Damage tolerant design
Brussels, 18-20 February 2008 – Dissemination of information workshop 21

Explanation damage tolerant

design (2)
da / dN ÅÆ ∆K
σ
• Central through-crack
in infinitely large plate:

K=σ πa σ
• Other geometries:

K = Yσ π a
EUROCODES
Background and Applications Damage tolerant design
Brussels, 18-20 February 2008 – Dissemination of information workshop 22

Determination of Y
Y = geometry factor, to be determined with FEM

Model: TROG Def = .236E4

Z X
Y

Z X
EUROCODES
Background and Applications Damage tolerant design
Brussels, 18-20 February 2008 – Dissemination of information workshop 23

Crack propagation data

Available for parent metal, HAZ and weld metal for (welded)
aluminium alloys

da / dN R=0.1

∆K
EUROCODES
Background and Applications Design by testing
Brussels, 18-20 February 2008 – Dissemination of information workshop 24

Design by testing
EUROCODES
Background and Applications Design by testing
Brussels, 18-20 February 2008 – Dissemination of information workshop 25

Testing for fatigue design

Required in case:
• Applied load spectrum is not available
• Geometry of structure is too complex for practical calculations
• Different materials, dimensional details, or manufacturing
methods than those given in detail category tables
• Crack growth data are needed for damage tolerant design
EUROCODES
Background and Applications Design by testing
Brussels, 18-20 February 2008 – Dissemination of information workshop 26

Acceptance
For safe life design:
Tm
TL =
F
TL = Design life (in cycles)
Tm = Mean life to failure determined by tests (in cycles)
F = Fatigue test factor, depending on number of tests
EUROCODES
Background and Applications Design by testing
Brussels, 18-20 February 2008 – Dissemination of information workshop 27

Fatigue test factor

In agreement with EN 1990:
4

Fatigue test factor F [-]

3
independent
2

1 simultaneous

0
1 10 100
Sample size n [-]
EUROCODES
Background and Applications Safety factors and reliability
Brussels, 18-20 February 2008 – Dissemination of information workshop 28

Safety factors and reliability

EUROCODES
Background and Applications Safety factors and reliability
Brussels, 18-20 February 2008 – Dissemination of information workshop 29

Partial safety factors

• Partial safety factor on loading γFf = between 1.0 and 1.5
• Partial safety factor for fatigue strength γMf = 1.0 (excluding
adhesive bonded joints)

Log ∆σ
mR
Rk kRsR
Rk(1-1/γM) S-N Curve standard

Sk(γF-1)
Sk kSsS
Characteristic value load
ms

Log Ncrit Log N

EUROCODES
Background and Applications Safety factors and reliability
Brussels, 18-20 February 2008 – Dissemination of information workshop 30

Reliability index
μR - μS
β=
√σR2 - σS2
EUROCODES
Background and Applications Safety factors and reliability
Brussels, 18-20 February 2008 – Dissemination of information workshop 31

Example of reliability EN 1999-1-3

By Prof. Kosteas

kR = 2.0
kS = 1.0

sr = 0.03-0.18
ss = 0.03-0.15
EUROCODES
Background and Applications Safety factors and reliability
Brussels, 18-20 February 2008 – Dissemination of information workshop 32

Example of reliability EN 1999-1-3

EUROCODES
Background and Applications Safety factors and reliability
Brussels, 18-20 February 2008 – Dissemination of information workshop 33

Example of reliability EN 1999-1-3

• γM γF = 1.0 Æ β ≈ 2.2
• γM γF > 1.35 Æ β ≈ 3.5

• Recommended value: β ≈ 3.8

• This issue needs further elaboration

EUROCODES
Background and Applications Fatigue design and execution
Brussels, 18-20 February 2008 – Dissemination of information workshop 34

Fatigue design and execution

EUROCODES
Background and Applications Fatigue design and execution
Brussels, 18-20 February 2008 – Dissemination of information workshop 35

Relation Eurocodes
Consequence class CC (3) EN 1990

Execution class EXC (4) EN 1999-1-1

Execution requirements EN 1090-3

Acceptance criteria for welds in EN ISO 10042

EUROCODES
Background and Applications Fatigue design and execution
Brussels, 18-20 February 2008 – Dissemination of information workshop 36

Execution classes

Conseq. CC1 CC2 CC3

class

Service Quasi Fatigue Quasi Fatigue Quasi Fatigue

category static static static

Non- 1 1 2 3 3 3
welded

Welded 1 2 2 3 3 4
EUROCODES
Background and Applications Further developments
Brussels, 18-20 February 2008 – Dissemination of information workshop 37

Further developments
EUROCODES
Background and Applications Further developments
Brussels, 18-20 February 2008 – Dissemination of information workshop 38

Harmonisation of imperfections /
classification

t
EUROCODES
Background and Applications Further developments
Brussels, 18-20 February 2008 – Dissemination of information workshop 39

Friction stir welding

400
∆σ
5083-O parent
100 5083-O fsw
190 %
EC9-1-3
300 %
High quality
EC9-1-3
Normal quality
10
104 105 106 107 108
N
EUROCODES
Background and Applications Conclusions
Brussels, 18-20 February 2008 – Dissemination of information workshop 40

Conclusions & recommendations

• EN 1999-1-3 is powerful fatigue design tool. It enhances:
– Safe life design (S-N curves)
– Damage tolerant design (fracture mechanics)
– Design by testing
• Evaluation and simplification of requirements for inspection and
acceptance
• Further work
– Friction stir welding
– Damage tolerant design