Residual stresses influence on the fatigue strength of structural components

Several production processes, both conventional and innovative, may result in residual stresses arising in critical areas of a component. The main issues include high distortion, reduced fatigue life, fracturing or delamination. In this context, standard fatigue design codes traditionally consider residual stresses through conservative assumptions, leading to either sub-optimal design or unexpected failures. Recently, innovative computational techniques have been developed to address residual stresses in a more comprehensive way. As a result, a more effective material utilisation and a more accurate fatigue life assessment can be achieved. The present work examines the influence of residual stresses on the fatigue endurance of S355JR structural steel components. Both welded and notched components were analysed, carrying out numerical and experimental analyses. In the case of welded components, residual stresses resulting from the welding process were numerically evaluated by means of an uncoupled thermal-structural simulation, while for notched specimens a preload causing limited yielding was used to induce a local residual stress field comparable to that obtained for welded specimens nearby the critical locations. Even if he work is still in progress, tests carried out with different specimens under different loading conditions allowed to understand the effect of residual stresses on the fatigue life.