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Observations and assumptions on residual stresses and their effect on the fatigue behavior of welded aluminum structures are reviewed along with attempts to explain and evaluate experimental component fatigue strength data. Measurements from a recent research program on welded aluminum beams are reported.

Light weight as a primary factor in combination with strength and durability properties of aluminium alloys brings financial benefits accruing not only from material procurement but along the whole chain of production, manufacturing, delivery and installation, maintenance and even disposal. A significant contribution in the quest to deliver more value has been the development in the last decade of harmonized design and execution standards, the Eurocodes, National Annexes and adapted codes or recommendations for specific applications. The sustainability issue can be dealt with in a more reliable way due to the comprehensive data tools and comparative analyses available nowadays. Experience with growing numbers of applications also delivers benchmark values for initial cost and maintenance requirements.

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