This paper aims to explore the fatigue life estimation approach of welded joints with precrack under coupled impact and fatigue loading, and the base metal is dissimilar 5083H111 and 5754 aluminum alloy. Impact tests are first carried out on the dissimilar lightweight materials welded joint with precrack located in the middle of the specimen, and a stress and strain field is obtained to determine the fatigue damage model parameters by using finite element dynamic analysis to simulate the impact process. Based, on the S-N curve of welded joints, the predicted life expectancy is found to be inconsistent with the experimental results. According to the continuum damage mechanics, the lifetime assessment model is presented to calculate both impact and fatigue damage. The estimated results agree well with the experimental ones.

In order to improve fuzzy fatigue reliability and make weight reduction of A-type frame in an electric mining dump truck considering multi-source uncertainties from design, manufacturing and use stage, a multi-objectives optimization method based on the interval theory was proposed in this paper. The thickness of four steel plates in welded A-type frame was regarded as certain design variables, while the elastic modulus and density of material was considered as uncertain variables as well as the load at front traction joint. The relationship between optimization objectives and variables was constructed by the response surface method, and was transformed by the interval method. Then, the optimization problem was solved by the non-dominated sorting genetic algorithm, which was found that the fuzzy fatigue reliability reached up to 98.45 % at the expense of some weight.

In order to avoid slackening of differential housing and gear joined by bolts, the laser-welding process is proposed in this paper, and the strength of a connecting joint was estimated by numerical analysis with consideration of welding residual stress. The process parameters of laser welding for dissimilar materials QT600 cast iron and 20MnCr5 structural alloy steel were introduced, and chemical composition analysis and microstructure analysis were conducted on the welded joints. The finite element model of laser-welded differential housing and gear was established to obtain the welding residual stress by applying a moving heat source. To verify the accuracy of the simulated result, static pressing tests were employed. The maximum tensile residual stress was 319.4 MPa, located at the same point as the maximum temperature. The simulated stress agreed well with the experimental data. Finally, the dynamic strength of laser-welded differential housing and gear under forward, reverse, and start-up conditions was assessed by regarding welding residual stress as the initial stress field, which showed that all safety factors were greater than 1.4.