The impact of production-dependent geometric properties on fatigue-relevant stresses in laser-welded corrugated core steel sandwich panels

Abstract

For bridge deck applications, laser-welded corrugated core steel sandwich panels with dual weld lines per crest and trough have been shown to be highly material-and economically efficient. The nature of welding induces a variation in the geometric properties of the joint that connects the core to the faces. The geometric properties of the joint are the weld width, weld misalignment, and plate gap between the core and the faces. This paper aims to investigate the impact of the variation of the production-dependent geometric properties of the joint on the fatigue-relevant stresses. A secondary aim of this paper is to investigate the impact of contact between the core and the faces on the weld region stresses. Within this paper, the production of four sandwich panels is documented and the manufacturing-dependent geometric properties of their joints are quantified. In order to investigate the impact of the natural variation of the parameters, a parametric study based on finite element analyses is executed. The result of the parametric study shows, among several other findings, that misalignment of the weld line in relation to the core direction can lead to considerable increases in stresses, determinant for the fatigue life of the panel.

Numerical and Metallurgical Analysis of Laser Welded, Sealed Lap Joints of S355J2 and 316L Steels under Different Configurations

“…For the 2nd configuration, three separate regions of effective plastic strain can be identified. The computation times of the welding process (without cooling) were equal to 1.2 s, therefore, for these specific points, some changes in the plots can be observed [ 55 , 56 , 57 ].…”

Effect of the Computational Model and Mesh Strategy on the Springback Prediction of the Sandwich Material

“…For example, Gladkovsky [13] researched a feature of interface structure at explosive welding and Nilsson [14] tested the fatigue properties of laser stake-welds. Generally, the joining of sandwich materials represents very important research and was investigated by many authors such as, e.g., [15][16][17]. Nevertheless, before the application of sandwich material, it is very important not only to verify these results but also to incorporate the chosen material and its material behaviour into the whole production process.…”