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A common technique to prevent the propagation of fatigue cracks in bridge girders is to drill crack-stop holes at crack tips. Stress concentrations at the crack tips are reduced and fatigue life of the bridge is extended. The size of the crack-stop hole needed to prevent further crack growth is determined by using known material properties and relationships developed through experimentation. However, these equations often result in a crack-stop hole diameter larger than can be practically drilled; physical limitations force crack-stop holes to be undersized in the field. To improve effectiveness of undersized holes to that of full-sized holes, a method is needed to strengthen undersized crack-stop holes. This study investigated the potential of a technique to improve the fatigue life of undersized, crack-stop holes. It uses piezoelectric actuators operated at ultrasonic frequencies to convert electrical signals into mechanical work. The technique produced residual compressive stresses of the same order of magnitude as those produced by static cold expansion. A suite of finite element models was created to quantify and characterize the residual stresses surrounding the cold-expanded, undersized, crack-stop holes. Results were compared with analyses in the literature.

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