An extensive literature review was conducted primarily to develop a comprehensive understanding of the quantitative behavior of residual stress (RS) distribution in weld joints. Based on prior data, various levels of the peak RS and distribution profiles were applied to a finite element analyses (FEA) model as an initial loading to evaluate the effect of RS on the Mode-I stress intensity factor (SIF), KI. The RS was not found to have a significant effect on the SIF values when the peak RS was less than 300 MPa. The enhanced effect of RS on the KI values was found to be more pronounced at a lower crack ratio, while the analytical form of the RS distribution had a minor effect. The effective boundary corrections function, FResidual, was derived under the effect of RS for 1T CT specimen for various crack geometries of the crack ratio, (a/W) of 0.2, 0.40, 0.50, 0.60, and 0.75, and with peak RS varying from 100 MPa to 600 MPa. The obtained effective function of KI can be employed to quantitatively evaluate the effect of RS on the fatigue performance of welded joints.

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