The Influence of Localized Plasticity and Crack Tip Constraint in Undermatched Welds

Four weldments of varying levels of weld joint to baseplate strength mis-match were examined to determine the effects of this ratio on fracture performance. Cracks were placed within the weld metal at several ratios of weld fusion margin. This margin is defined as the ratio of crack tip proximity to the weld fusion line and crack length Lsub crka. Finite element studies were then performed on each variation of weld fusion margin and mis-match level to determine the crack driving force not accounted for in a typical fracture analysis, which assumes monolithic, homogenous weld metal specimens and ignores the weldbaseplate interaction. Assuming homogenous weld metal specimens results in J-R curves that exhibit markedly different crack growth resistance behavior depending on crack tip proximity to the weld fusion line. Once local plasticity and the additional constraint caused by the weldbaseplate interface are included in the analysis, fracture behavior is independent of crack tip proximity to the fusion line up to and slightly beyond initiation. Errors in fracture toughness at weld fusion margins greater than or equal to 1.5 are less than 10 and can reasonably be ignored. Errors at smaller values of Lsub crka are considerable, and effects of local plastic deformation and constraint must be accounted for in the fracture analysis. Furthermore, uncorrected estimates of initiation toughness Jsub IC in specimens where the weld fusion margin is less than 1.5 results in overly conservative estimates. The percentage of weld mis-match was found not to be a major factor in determining either crack growth resistance or crack initiation behavior. An increased propensity toward unstable fracture was observed in specimens with smaller Lsub crka ratios. This effect may be attributed to a local microstructural defect and requires further study.