Strain-Controlled Fatigue Behavior of

ASTM A36 and A514 Grade F Steels and

5083-0 A l u m i n u m W e l d Materials
For steel weld materials, tensile and strain-controlled fatigue properties
vary with hardness and, although the hardness relationships for
aluminum vary from steel, the mean stress relaxation behavior of all weld
materials is found to be a function of the same material parameters

BY Y. HIGASHIDA, ). D. BURK, A N D F. V. LAWRENCE, JR.

ABSTRACT. The tensile and strain-
controlled fatigue properties of base
metal (BM), weld-metal ( W M ) , and
heat-affected zone (HAZ) material
were determined for weldments of
ASTM A36 and A514 grade F steels and
5083-0 aluminum. The mean stress
relaxation behavior of these weld
materials was also investigated. The
HAZ properties were determined from
specimens produced using a weld
thermal-cycle simulator. The W M
properties were obtained using speci-
mens machined from weld metal
deposits.
For the steel weld materials, the
tensile and strain-controlled fatigue
properties were found to vary w i t h
hardness. The fatigue resistance at
lives greater than the transition fatigue
life was found to increase as the hard-
ness of the steel weld materials (BM's,
WM's, HAZ's) increased. Properties of
BM and W M fof the 5083-0 aluminum
welds did not obey the hardness rela-
tionships found for the steels, but the
mean stress relaxation behavior of all
the weld materials considered was
found to be a function of the same
material parameters.
Introduction
The most common sites for fatigue
crack initiation in welds are the weld
toe, the weld root, or internal discon-
tinuities. '-' In the first case, the crack
initiates in untempered weld metal
(WM) or grain coarsened heat-
affected zone 5 (HAZ) near the edge of
the weld reinforcement and then
propagates through the HAZ and base
metal (BM). In the latter cases, the
crack initiates and propagates in tem-
pered weld metal. These sites are
shown schematically in Fig. 1.
Previous studies of the fatigue
behavior of weldments, summarized
by Gurney 2 and Pollard and Cover,3
have dealt w i t h fatigue behavior of
weldments w i t h o u t separating the
effects of W M and HAZ microstruc-
tures. Only a limited number of stud-
ies have been undertaken to study the
fatigue behavior of W M and HAZ, and
most of these have been studies of
fatigue crack propagation which have
shown that the HAZ does not strongly
influence the crack propagation
rate. 612 Most studies of fatigue crack
initiation in W M and HAZ using
smooth specimens have been con-
ducted under stress control 1 3 1 8 .
Weld toe fatigue cracks usually
initiate in the grain coarsened region
of the heat affected zone (hereafter
HAZ).1'-' The w i d t h of the grain coars-
ened region in the welded joint is too
small to permit direct measurements
of strain-controlled fatigue properties.
For A514 welds, the w i d t h of the coars-
ened region is about 0.05 in. (1.3 mm)
Y. HIGASHIDA is Research Engineer, Hirat- and b are the fatigue strength coeffi-
suka Research Laboratory, Sumitomo Heavy
Industries, Ltd., japan; j. D. BURK is Lead
Engineer, Matetials and Processes Depart-
ment, McDonnell Douglas Astronautics
Co., St. Louis, Missouri; F. V. LAWRENCE, IR.the life of a smooth specimen under
is Professor, Department of Metallurgy and
Mining and Civil Engineering at the Univer-
sity of Illinois, Urbana-Champaign, Illinois. amplitudes are identical.
or less. It was necessary, therefore, to
reproduce the weld thermal cycle in a
smooth specimen large enough for the
normal methods of strain controlled
fatigue testing.
Three methods have been c o m m o n -
ly employed to reproduce HAZ m i -
crostructures in test specimens: furnace
heating,"' 1 " high frequency induction
heating, 1718 - 2 " and direct resistance
heating.21"25 The direct resistance heat-
ing method was judged most suitable
and was used in this investigation.
Strain Controlled Fatigue Properties
The smooth specimen fatigue be-
havior of a metal tested under reversed
strain control may be characterized by
four material parameters, 26-28 w h i c h
relate the strain amplitude ( e a ) to the
failure life (2N r )-see Table 1:
. = 't (2N,y + (2N f ) 0)
Mean stress (cr0) effects may be
included through the modification 2 9 :
(O-'r
. = e
'r (2N f ) c + (2N f ) b (2)
where [ and c are the fatigue ductil-
ity coefficient and exponent, and cr',
cient and exponent. An additional
useful index of fatigue resistance is the
transition fatigue life (2N l r ) w h i c h is
strain control at which the elastic
(A e K /2) and plastic ( A e p / 2 ) strain

334-s I N O V E M B E R 1978
 Fig. 1Possible fatigue crack initiation sites in a weld: Aone pass weld metal
(WM(1P)), B-heat-affected zone (HAZ), and C-two pass tempered weld metal
(WM(2P))
-m*
As shown by equation (2), the mean
stress (o-) has an influence on crack
initiation life. The mean stress (cr) at
any reversal (2N) has been shown to
relax according to the power func-
tion: 26 - 30
O-0.-2S = cr,, , ( 2 N - 1 ) k
where a. , is the initial mean stress
and k is the relaxation exponent which
is dependent on strain amplitude
(a)-
The monotonic and cyclic stress-
strain properties of a material may be
represented by elastic and plastic
strain components as:28
Monotonic
a Specimen Preparation
= +
E Base metal specimens of A514 steel
Cyclic
where K (K') and n (n') are the mono-
tonic (cyclic) strength coefficient and
strain-hardening exponent.
Object and Scope
ASTM A36 and A514 steels and 5083-
0 aluminum were chosen for study
because:
1. A36 steel is a typical construc-
tional grade ferritic-pearlitic steel
widely used for land vehicles and
structures and is easily welded w i t h o u t
(3)
special heat treatments.
2. A514 steel is a typical, construc-
tional grade, low-alloy, martensitic
steel widely used for pressure vessels
and structures and is also readily
welded.
3. 5803-0 aluminum is a readily
weldable hardening aluminum alloy
used in cyrogenic applications.
Completely reversed, uniaxial strain-
controlled tests of the smooth speci-
(4)
mens were employed to study fatigue
behavior of BM, HAZ, and one- and
two-pass W M ' s for A36 and A514
welds and BM and W M behavior of
5083-0 welds. Mean stress relaxation
tests were also conducted for each
material at a constant mean strain and
at various strain amplitudes.
Experimental Program
(5)
(A514-BM) and 5083-0 aluminum
(5083-0-BM) were machined from VA
in. (19 mm) and 1 in. (25 mm) thick
(6) plate keeping their axes parallel to the
rolling direction of the plateFig. 2A.
The HAZ specimens were machined
from base plate and then subjected to
the simulated weld thermal cycles
after which they were machined to the
final dimensions as shown in Fig. 2B.
Heat-affected zone specimens of 5083
aluminum base metal were not
made.
Five series of weld metal specimens
were prepared: E60S-3-WM(1 P) was
machined from a one-pass butt
welded joint of A36 steel plates using a
Ae in. (1.6 mm) diameter E60S-3 elec-
W E L D I N G RESEARCH S U P P L E M E N T I 335-s
trode; E60S-3-WM(2P) was machined
from a two-pass butt welded joint of
A36 steel plates using the same elec-
trode as E60S-3-WM(1P);
WM(1P) was machined from a one-
E110-
pass butt weld of A514 steel using a yM
in. (1.6 mm) diameter E110 electrode;
E110-WM(2P) was machined from a
two-pass butt weld of A514 steel using
the E110 electrode; and 5183-WM was
machined from a two-pass double-V
butt weld of 5083-0 aluminum using a
5183 electrode.
All welding was in the flat position
using gas metal arc (GMA) processes.
After welding, the weld deposits were
radiographed to check for internal
defects. The welded plates were then
saw-cut into blanks w i t h their axes
normal to the welding axis. The blanks
were then machined to the dimen-
sions shown in Fig. 2A for monotonic
tension tests and Fig. 2C for fatigue
tests.
Chemical compositions are shown
in Table 2, and the welding parameters
are listed in Table 3.
Simulation of HAZ
The weld thermal cycle at the HAZ
adjacent to the fusion line was
measured. Chromel-alumel thermo-
couples (0.020 in. (0.51 mm) diameter)
were spot welded onto the surface of a
A36 or A514 steel plate near the fusion
line. The location of the thermocouple
was determined by preliminary mea-
surements to define the fusion line
position. The thermocouples were
electrically and thermally shielded and
were connected to an oscilloscope.
The thermal cycle was photographical-
 (25) Radius
Table 1 List of symbols 5/8 NF Threads
cr,c
t. lr, m
True stress and strain
Strain amplitude, transi-
(A) 0.250 (7.25)
_J -
L 5/8(16)
tion strain, and mean
strain Dia.
Ac /2 Plastic strain amplitude T
o~ Mean stress 650 (16.25)
o-. i, o-. 2N Initial and current mean
stress 4-1/2 (112)
2N,, 2 N l r , 2N Reversals to failure, tran-
sition fatigue life, rever-
(25) Radius
sals 5 / 8 NF Threads
K, K' M o n o t o n i c and cyclic 0.180 (4.57)
| strength coefficient
n, n' M o n o t o n i c and cyclic
strain hardening expo- 5/8(16)
nent Dia.
E Elastic modulus
r, Cr, True strain and stress at I h-0.350 (8.89)
fracture
f 1. o-f' Fatigue ductility and 5 (127)
strength coefficients
c, b Fatigue ductility and
strength exponent (25) Radius
k Relaxation exponent 5/8 NF Threads
BHN, DPH Brinnell and diamond ^0.250 (7.25)
pyramid hardness n u m -
ber 5/8 (16)
s u , o-; Ultimate strength and
Did
cyclic yield stress

ly recorded. Typical traces are shown

in Fig. 3. Fig. 2Smooth specimens of Abase metal, B-heat-affected zone, and C-weld
A weld thermal cycle simulator was metal materials; all dimensions are in inches (mm)
developed (Fig. 4) to reproduce uni-
formly the measured weld thermal
cycle in a specimen large enough for
monotonic tension and fatigue tests. Table 2Chemical C ompositions of Base and Filler Metals, Wt-%
The specimen in (Fig. 2A) was held in a
pair of water-cooled OFHC copper Material C Mn P S Si Ni Cr Mo Cu Fe
grips. The grips and specimen were ASTM A36' " 1
0.21 1.1 0.12 0.021 <0.10 <0.10 <0.08 <0.10 0.10 Bal.
mounted on a w o o d e n stand and fixed E60S-3 0.09 1.0 0.017 0.024 0.50 - - - - Bal.
to prevent transverse distortion of the ASTM A514"" 0.20 0.82 0.010 0.016 0.24 0.08 0.51 0.20 <0.01 Bal.
specimen at high temperatures but not E110 0.08 1.70 0.005 0.009 0.46 2.40 0.05 0.50 - Bal.
longitudinal movement. The specimen Si Fe Cu Mn Mg Cr Zn Ti Zr Al
was heated by a current from the
secondary of the step d o w n transform- ASTM 5083-0 0.14 0.22 0.05 0.64 4.50 0.08 0.04 0.03 <0.001 Bal.
5183 0.12 0.17 0.02 0.57 4.96 0.07 0.03 0.09 - Bal.
er (Fig. 4), and the temperature was
measured by a thermocouple spot " C o m p o s i t i o n s based o n c h e m i c a l a n a l y s i s - o t h e r s are typical as s u p p l i e d c o m p o s i t i o n s .
welded to the center of the specimen.
The heating rate was controlled by
setting the temperature controller to flow of argon gas directed onto the HAZ specimens and compared w i t h
some fraction of total output. specimen. Once the correct condition the actual weld HAZ. Figure 5 shows
When the temperature of the speci- was determined, it was possible to the results of a Vickers Pyramid hard-
men reached the maximum tempera- subject specimens to reproducible ness traverse 0.1 mm (0.004 in.) below
ture desired, the current was shut off; weld thermal cycles such as that the plate surface for A36 and A514
and the specimen was allowed to cool. shown in Fig. 3. one-pass butt welds. The results of a
The cooling rate was controlled by the Hardness and metallographic stud- hardness traverse for A36 and A514
flow of the grip cooling water and the ies were performed on the simulated simulated HAZ specimens are shown

Table 3 - W e l d i n g Parameters

Travel Shielding
Plate Electrode speed, Preheat Heat gas
Weld (base/ thickness, diameter, Voltage, Current, mm/ temperature, input, composition,
filler metal) mm"" mm"" V A min."" (C) k)/mm,!" vol-%

A36/E60S-3 22.2 1.59 35 500 370 22 2.80 Ar-2% O.,

A514F/E110 19.1 1.59 30 290 432 96 1.20 Ar-2% O z
5083-0/5183 25.4 1.59 24 280 420 22 0.95 He-25% Ar

" 1 m m = 0.04 in.

336-sl N O V E M B E R 1978
 1 ! Thermocouple
/~
2400 /

2000
. Recorder
( T i m e Versus Specimen

1600 -
Temperature)
~M-
I Water-Cooled

1200
_

-
t
1
1

'1
II
1
1

^V
A5I4 B - \ <%>,
A36 B - ,
Copper Grips

if ***^^~
800 f 1 ^
1 1
;1
A5I4A-' ^^-s^,
400
If
fji
Temperature
Controller

1
o 5 r * " C)
i
5
i
10
i
15 20 25 30
Time , seconds

Fig. 3Simulated (A) and measured (B) weld thermal cycles for A514 Fig 4-Schematic of weld thermal cycle simulator
Grade F and A36 steel welds

Goqe Length Specimen Die. ,

A5I4-8M HAZ

Refined -
Zone
600

500 -Yyv^'W^ r
400 \-A5l4-HAZ

3 6 - E U ^ ^ J ^ V A r ^ ^
3CC

E 6 0 S - 3 - W M (IP) 200
'IhiMAi
Jx-finV Vs
V

^A36-HAZ
IOO
0.4 0.3 0.2 0.1 _0 _^
0.1 0.2 0.3 0.4 0.5
J_ I , I , I
Distance from the Weld Center Line , inches

Fig. 5Vickers hardness survey 0.1 mm below
for A514 and A36 butt welds
in Fig. 6 w h i c h i n d i c a t e s t h a t t h e s i m u -
lated H A Z s p e c i m e n s w e r e h o m o g e -
n e o u s in h a r d n e s s w i t h i n t h e gage
length.
B o t h average v a l u e s a n d ranges in
hardness n u m b e r s i n s i d e t h e gage
l e n g t h of e a c h s p e c i m e n w e r e v e r y
close to t h o s e o f each a c t u a l w e l d
H A Z (Figs. 5 a n d 6). For e x a m p l e , t h e
average hardness n u m b e r s o f the
actual H A Z (grain-coarsened region)
a n d s i m u l a t e d H A Z w i t h i n t h e gage
l e n g t h w e r e 257 D P H a n d 255 D P H f o r
t h e A36 s t e e l , r e s p e c t i v e l y , a n d 497
D P H a n d 496 D P H f o r t h e A 5 1 4 s t e e l .
Hardness v a l u e s f o r t h e A 5 1 4 , A 3 6 , a n d
5083-0 w e l d m a t e r i a l s are l i s t e d in
the weld plate surface Distance from the Center of the Specimen, inches Distance, inches
Fig. 6Vickers hardness survey along the axis and across the
diameter of both A514 and A36 simulated HAZ smooth speci-
mens
in. (12.7 m m ) gage l e n g t h ) w a s u s e d t o
Tables 4 t o 6.
m e a s u r e strain f o r t h e base a n d w e l d
Metallographic examination was
metal c y l i n d r i c a l s p e c i m e n s , w h i l e a
carried o u t o n b o t h t h e actual w e l d
0.26 i n . (6.6 m m ) gage l e n g t h e x t e n -
HAZ and the simulated H A Z speci-
someter was used for t h e H A Z speci-
mens. E x c e l l e n t c o r r e l a t i o n w a s o b -
mens. T h e w e l d m e t a l s p e c i m e n s w e r e
served i n c o m p a r i s o n b e t w e e n t h e
hourglass-shaped and required the
actual w e l d H A Z and t h e s i m u l a t e d
m e a s u r e m e n t o f d i a m e t r i c strain a n d
HAZ microstructures.
its c o n v e r s i o n t o axial s t r a i n b y m e a n s
of an a n a l o g c o m p u t e r . 3 2
Mechanical Testing
Fatigue tests w e r e c o n d u c t e d w i t h
T e n s i o n tests w e r e c o n d u c t e d u s i n g t h e same a p p a r a t u s u s e d f o r m o n o t o n -
a 20 k i p M T S h y d r a u l i c test s y s t e m ic t e n s i o n tests. A x i a l s t r a i n was
similar t o t h a t d e s c r i b e d by F e l t n e r a n d controlled for the s m o o t h specimens
M i t c h e l l . 1 ' A c l i p - o n e x t e n s o m e t e r (0.5 of A514, A 3 6 , a n d 5083-0 w e l d m a t e r i -

Table 4-Tensile Properties of Base, W e l d , and Heat-Affected Materials for ASTM A514F/E110 Welds

Material A514-BM A514-HAZ E110-WM(1P) E110-WM(2P)

Hardness, D P H / B H N 320/303 496/461 382/362 327/310

Modulus of elasticity, E, x 10s ksi (MPa) 30.3 (210) 30.3 (210) 30.3 (210) 30.3 (210)
0.2% offset yield strength, ksi (MPa) 129 (890) 171 (1180) 121 (835) 110 (760)
Ultimate tensile strength, Su, ksi (MPa) 136 (938) 204 (1408) 150 (1035) 132 (910)
Reduction in area, % 63.0 52.7 57.6 59.3
True fracture strength, cr,, ksi (MPa) 216 (1490) 326 (2250) 320 (2208) 241 (1663)
True fracture ductility, e, 0.994 0.750 0.857 0.899
Strain hardening exponent, n 0.060 0.092 0.092 0.085
Strength coefficient, K, ksi (MPa) 172 (1187) 306 (2110) 226 (1560) 187 (1290)

WELDING R E S E A R C H S U P P L E M E N T I 337-s
Table 5-Tensile Properties of Base, W e l d , and Heat-Affected Materials for ASTM A36/E60S-3 Butt Welds

Material A36-BM A36-HAZ E60S-3-WM(1P) E60S-3-WM(2P)

Hardness, D P H / B H N 168/160 255/243 245/233 211/201

Modulus of elasticity, E, x 10' ksi (MPa) 27.5 (190) 27.4 (189) 27.4 (189) 27.4 (189)
0.2% offset yield strength, ksi (MPa) 32 5 (224) 77.5 (534) 84.1 (580) 59.2 (408)
Ultimate tensile strength, Su, ksi (MPa) 60.0 (414) 96.7 (667) 103 (710) 84.0 (580)
Reduction in area, % 69.7 (481) 52.5 (362) 44.6 (308) 60.7 (419)
True fracture strength, cr,, ksi (MPa) 138 (952) 133 (918) 143 (987) 147 (1014)
True fracture ductility, , 1.19 0.745 0.590 0.933
Strain hardening exponent, n 0.0146/0.258 0.102 0.098 0.130
Strength coefficient, K, ksi (MPa) 113 (780) 142 (980) 143 (987) 123 (849)

Table 6-Tensile Properties of Base and W e l d Metal Materials for ASTM 5083-0/5183
Aluminum Welds
Property
Hardness, D P H / B H N
Modulus of Elasticity, E X 103 ksi (MPa)
0.2% offset yield strength, ksi (MPa)
Ultimate tensile strength, Su, ksi (MPa)
Reduction in area, %
True fracture strength, cr,, ksi (MPa)
True fracture ductility, e,
Strain hardening exponent, n
Strength coefficient, K, ksi (MPa)
als as p r e v i o u s l y d i s c u s s e d . A s i n e -
wave f u n c t i o n generator was used to
g e n e r a t e t h e s t r a i n o r -stress h i s t o r y .
Test f r e q u e n c i e s v a r i e d f r o m 0.1 t o 10
Hz. Stress-strain hysteresis l o o p s w e r e
r e c o r d e d at i n t e r v a l s t o d e t e r m i n e
c y c l e - d e p e n d e n t c h a n g e s in stress a n d
plastic strain a m p l i t u d e s .
M e a n stress r e l a x a t i o n tests w i t h
c o n s t a n t m e a n strain b u t variable
strain a m p l i t u d e w e r e c o n d u c t e d . A
t y p i c a l s t r a i n - b l o c k - s e q u e n c e u s e d is
s h o w n in Fig. 7. A s t a b i l i z a t i o n b l o c k
was a p p l i e d t o each s p e c i m e n to
e n s u r e s t a b i l i z a t i o n o f t h e hysteresis
l o o p b e f o r e i n d u c i n g a m e a n stress
0.006-
0 004
0.002
s t r u c t u r e s s t u d i e d are s h o w n in Figs. 8
t o 10. For t h e A 3 6 w e l d m a t e r i a l s (Fig.
8), t h e E 6 0 S - 3 - W M ( 1 P ) has t h e h i g h e s t
yield and ultimate strength, the A36-
5083-BM 5183-WM
H A Z has t h e s e c o n d , a n d t h e A 3 6 - B M
106/93 105/92 has t h e l o w e s t .
10.3 (71) 10.3 (71) The order for higher true fracture
19 (131) 20 (138) d u c t i l i t y is o p p o s i t e . For t h e A 5 1 4 w e l d
42.6 (294) 43.3 (299) materials (Fig. 9 ) , t h e o r d e r f o r h i g h e r
30 33
ultimate tensile strength and l o w e r
60 (414) 61 (421)
t r u e f r a c t u r e d u c t i l i t y is: A 5 1 4 - H A Z ,
0.36 0.40
0.129 0.133 E 1 1 0 - W M ( 1 P ) , A 5 1 4 - B M , a n d E110-
43.4 (300) 44.5 (307) WM(2P). However, the order for high-
er y i e l d s t r e n g t h is: A 5 1 4 - H A Z , A 5 1 4 -
BM, E110-WM(1P), and E110-
a n d s t u d y i n g its r e l a x a t i o n b e h a v i o r .
WM(2P).
Each i n i t i a l m e a n stress o f t h e m e a n
For t h e 5083-0 w e l d m a t e r i a l s (Fig.
stress r e l a x a t i o n b l o c k s w a s i n d u c e d
10), t h e s t r e n g t h , d u c t i l i t y , a n d u l t i -
by a p p l y i n g a m e a n s t r a i n . M e a n stress
m a t e s t r e n g t h are e s s e n t i a l l y i d e n t i c a l
(cr0) as a f u n c t i o n o f c y c l e s w a s t h e n
f o r base a n d w e l d m e t a l .
measured under a constant strain
In g e n e r a l , t h e s t r e n g t h a n d d u c t i l i t y
amplitude.
o f t h e w e l d m a t e r i a l s are r e l a t a b l e t o
t h e hardnessTables 4 t o 6.
Results
Cyclic Stress-Strain Behavior
Monotonic Stress-Strain Behavior
T h e c y c l i c stress-strain c u r v e s o b -
Tensile properties of A36, A514, and t a i n e d f o r e a c h m a t e r i a l are s h o w n
5083-0 w e l d m a t e r i a l s are l i s t e d in w i t h each o f t h e r e s p e c t i v e t e n s i l e
Tables 4 t o 6. T h e m o n o t o n i c t r u e stress-strain c u r v e s in Figs. 8 t o 10. A l l
stress-strain c u r v e s f o r t h e t e n m i c r o - A36 a n d A 5 1 4 w e l d m a t e r i a l s ( e x c e p t
A36-BM and A36-WM(2P)) s h o w vary-
ing degrees of cyclic s o f t e n i n g , w h i l e
SB - Stobalization Block t h e 5083-0 w e l d m a t e r i a l s s h o w a large
RB - Relaxation Block a m o u n t of cyclic hardening. The cyclic
y i e l d s t r e n g t h (o\') w a s o b t a i n e d b y
c u r v e f i t t i n g cr'. as a f u n c t i o n o f t h e
B r i n e l l hardness n u m b e r ( B H N ) :
o-; = - 1 8 . 4 + 0.331 B H N (ksi) (7)
E q u a t i o n 7 is v a l i d f o r t h e A 3 6 a n d
A514 m a t e r i a l s b u t d o e s n o t a p p l y t o
t h e 5083-0 m a t e r i a l s .
Fatigue Behavior

The fatigue properties for t h e A36,

A514, a n d 5083-0 w e l d m a t e r i a l s are
Time, t g i v e n in T a b l e s 7 t o 9. T h e f a t i g u e
s t r e n g t h c o e f f i c i e n t (cr',) a n d t h e f a -
tigue strength exponent (b) were
-0.002 c a l c u l a t e d as a f u n c t i o n o f reversals t o
failure using a least-squares fit to t h e
m e a s u r e d elastic s t r a i n d a t a . T h e f a -
t i g u e d u c t i l i t y c o e f f i c i e n t s ( ',) a n d
-0004- -
t h e f a t i g u e d u c t i l i t y e x p o n e n t (c) w e r e
o b t a i n e d in a s i m i l a r m a n n e r u s i n g t h e
Fig. 7Strain control history for mean stress relaxation test ol aluminum plastic s t r a i n d a t a a n d t h e n u m b e r o f
5183-WM reversals t o f a i l u r e . E x c e l l e n t a g r e e -

338-s! N O V E M B E R 1978
 HAZ A 36 Group
^' ^^ HAZ
-" A 514 Group

80 ^^~ WM(IP)
- 160 / ' - WM(IP)
-
WMI2P)

60 L, 120
- K^ / ^ - ~- ^** WM(2P) .
BM

40
- /
/;
BM
80 I C^ - - " " " " /

~1 j i Cyclic
Cyclic 40
20 0 0005 /
Monotonic

0
l
0.005
- Monotonic

Fig. 8Monotonic and cyclic stressstrain response for A36 steel Fig. 9Monotonic and cyclic stressstrain response for ASIA steel
weld materials weld materials

70 t h e d i f f e r e n c e in f a t i g u e r e s i s t a n c e
between A36-BM and the others
b e c o m e s largest at l o n g lives.
For t h e A 5 1 4 w e l d m a t e r i a l s (Fig. 12),
60 the relationship b e t w e e n hardness and
f a t i g u e resistance m e n t i o n e d f o r A 3 6 -
Cyclic Curves
B M a n d A 3 6 - H A Z is also v a l i d f o r
A514-BM and A514-HAZ.
As seen in Fig. 12, A 5 1 4 - B M is s l i g h t -
ly s u p e r i o r at s h o r t lives, A 5 1 4 - W M ( 2 P )
is s l i g h t l y s u p e r i o r at i n t e r m e d i a t e
lives, a n d A 5 1 4 - H A Z is s i g n i f i c a n t l y
s u p e r i o r at l o n g lives. A 5 1 4 - W M ( 1 P ) is
always i n f e r i o r at t h e lives g r e a t e r t h a n
a b o u t 200 reversals.
For t h e A514 w e l d m a t e r i a l s (Fig. 12),
13), t h e 5 1 8 3 - W M is v e r y s i m i l a r in
f a t i g u e b e h a v i o r t o t h e 5083-0 base
metal w i t h t h e base m e t a l p r o d u c i n g
s l i g h t l y g r e a t e r f a t i g u e r e s i s t a n c e at t h e
s h o r t e r lives. T h i s r e s u l t is n o t s u r p r i s -
ing considering the similar hardness
(Table 6) o f t h e t w o m a t e r i a l s .

5183 Weld Metal

Mean Stress Relaxation Behavior Test
5 0 8 3 - 0 Base M e t a l
Results

T h e results of a t y p i c a l m e a n stress
test, c o n d u c t e d at a p o s i t i v e m e a n
strain, are s h o w n in Fig. 14. T h e lines
0.002 0004 0.006 0.008 0.012 w e r e o b t a i n e d by l e a s t - s q u a r e s f i t of
Strain, e the data to c o n f o r m to the p o w e r
f u n c t i o n o f e q u a t i o n (4). T h e relaxa-
Fig. 10-Monotonic and cyclic stressstrain response for 5083-0 aluminum weld'
materials t i o n e x p o n e n t (k) w a s c a l c u l a t e d by a
least-squares fit for m e a n stress relaxa-
t i o n test d a t a f o r t h e A 3 6 , A 5 1 4 , a n d
ment was obtained between the W M ( 1 P ) , b u t a l w a y s lies b e l o w t h e 5083-0 w e l d m a t e r i a l s a n d are l i s t e d in
e x p e r i m e n t a l d a t a a n d e q u a t i o n (1) as f o r m e r . For A 3 6 - B M a n d A 3 6 - H A Z , t h e T a b l e 10.
seen in Figs. 11 t o 13. h i g h e r hardness m a t e r i a l s h a v e t h e As m e n t i o n e d in p r e v i o u s s t u d -
For t h e A 3 6 w e l d m a t e r i a l s (Fig. 1 1 ) , h i g h e r f a t i g u e r e s i s t a n c e at l o n g lives ies, 19 - 22 it w a s o b s e r v e d t h a t t h e s t r a i n
A 3 6 - W M ( 1 P ) has t h e h i g h e s t f a t i g u e b u t a l o w e r f a t i g u e r e s i s t a n c e at s h o r t amplitude influenced the cyclic mean
resistance f o r all lives. T h e c u r v e of lives. T h e A 3 6 - B M is i n f e r i o r t o t h e stress r e l a x a t i o n b e h a v i o r s i g n i f i c a n t l y ,
A 3 6 - W M ( 2 P ) is s i m i l a r t o t h a t o f A 3 6 - o t h e r m a t e r i a l s in t h e A 3 6 g r o u p , a n d w h i l e m e a n strain d i d n o t . T h e relaxa-

Table 7 - C y c l i c and Fatigue Properties of Base, W e l d , and Heat-Affected Materials for ASTM A514F/E110 Welds

Material A514-BM A514-HAZ E110-WM(1P) E110-WM(2P)

Cyclic yield strength, 0.2% offset, ksi (MPa) 87.6 (604) 136 (938) 94.2 (650) 87.4 (603)
Cyclic strain hardening exponent, n' 0.091 0.103 0.177 0.166
Cyclic strength coefficient, K', ksi (MPa) 158 (1090) 256 (1765) 293 (2021) 242 (1670)
Fatigue strength coefficient, cr',, ksi (MPa) 189 (1305) 290 (2000) 274 (1890) 204 (1408)
Fatigue ductility coefficient, (.', 0.975 0.783 0.848 0.595
Fatigue strength exponent, b -0.079 -0.087 -0.115 -0.079
Fatigue ductility exponent, c -0.699 -0.713 -0734 -0.590
Transition fatigue life, 2 N l r , reversals 3,461 1,138 1,536 6,448

WELDING R E S E A R C H S U P P L E M E N T I 339-s
Table 8-Cyclic and Fatigue Properties of Base, Weld, and Heat-Affected Materials for ASTM A36/E60S-3 Welds

Material A36-BM A36-HAZ E60S-3-WM(1P) E60S-3-WM(i

Cyclic yield strength, 0.2% offset, ksi (MPa) 33.6 (232) 58.2 (402) 55.8 (385) 52.6 (363)
Cyclic strain hardening exponent, n' 0.249 0.215 0.155 0.197
Cyclic strength coefficient, K', ksi (MPa) 159 (1097) 216 (1490) 146 (1007) 179 (1235)
Fatigue strength coefficient, cr',, ksi (MPa) 147 (1014) 105 (724) 131 (904) 149 (1028)
Fatigue ductility coefficient, ', 0.271 0.218 0.607 0.602
Fatigue strength exponent, b -0.132 -0.066 -0.075 -0.090
Fatigue ductility exponent, c -0.451 -0.492 -0.548 -0.567
Transition fatigue life, 2N, r , reversals 200,000 13,234 28,022 19,259

tion exponent (k) is plotted in Fig. 15

as a function of the strain amplitude
( e ) for all the materials studied.
From Fig. 15, it can be seen that the
A36 weld materials have the greatest
relaxation rate while the A514 weld
materials have the least for a given
strain amplitude. The relaxation be-
havior of the 5183-WM is interme-
diate. Materials with the higher transi-
tion fatigue lives, A36 weld materials
(Tables 7 to 9), have the greater relaxa-
tion rates, while the materials w i t h the
shorter transition fatigue lives, A514
and 5183 weld materials, have the
lower relaxation rates at a given strain
amplitude.
Discussion
Variation of Weld Materials Properties with
Hardness
The relationships between hardness
and mechanical and fatigue properties
equation (2)have been established
by Landgraf33 and M o r r o w et al." for
steels. A comparison of these k n o w n
relationships between hardness and
fatigue properties and the test results
for A36 and A514 BM's, W M ' s , and
HAZ's was made.
Table 9-Cyclic and Fatigue Properties of Base and Weld Materials for ASTM 5083-0/5183
Aluminum Welds
Material 5083-BM 5183-WM
Cyclic yield strength, 0.2% offset, ksi (MPa) 42 (290) 39 (269)
Cyclic strain hardening exponent, n' 0.114 0.072
Cyclic strength coefficient, K', ksi (MPa) 84 (580) 73.5 (507)
Fatigue strength coefficient, cr',, ksi (MPa) 103 (711) 92.5 (638)
Fatigue ductility coefficient, e ', 0.405 0.581
Fatigue strength exponent, b -0.122 -0.107
Fatigue ductility exponent, c -0.692 -0.890
Transition fatigue life, 2N l r , reversals 640 205
Landgraf33 found a linear relation- ( , ) were found to decrease w i t h
ship between the transition fatigue life increases in hardness (Fig. 18). A single
(2N l r ) and hardness which is shown by relationship, however, was not found
the solid line in Fig. 16. Both A36 and for either the A36 and A514 weld mate-
A514 weld materials conform to the rials or the steels previously investi-
linear relationship w h i c h is shown as a gated by Landgraf33 (shown as dashed
dashed extension of the solid line. The lines in Fig. 18). The monotonic strain
true fracture strength (cr,) has been harding exponent (n), also shown in
found to be equal to half the Brinell Fig. 18, was found to be a parabolic
hardness number (BHN) for steels33 for function of hardness w i t h its m i n i m u m
low and intermediate hardnesses as occurring at 400 BHN.
shown in Fig. 17. The cr, for the A36 The cyclic strain hardening expo-
and A514 weld materials was also nent (n') was plotted vs. hardness (Fig.
found to obey this relationship (Fig. 19), and was found to decrease as the
17). hardness increased for the A36 and
Values of the true fracture ductility A514 weld materials. No trend was

E60S-3-WM (2P)#

-E60S-3-WM (IP)A A5I4-HAZ I

A EIIO-WM ")-
A36-BM-

IO _IO IO2 IO3 10* 10= 10" 10' 10"

IO
10 ICT IO 3 KT 10s IO6 IO' 10
Reversals to Failure , 2Nf Reversals to Failure, 2Nf
Fig. 11Strain-life fatigue behavior of A36 steel weld materials Fig. 12Strain-life fatigue behavior of A514 steel weld materials

340-sl N O V E M B E R 1978
 -i 1 1 1 1 r- ness increases. T h e s e [ r e n d s are c o n -
sistent w i t h t h e r e l a t i o n s h i p : ' 2 "

rV-* (1D
c

a n d t h e o b s e r v e d d e c r e a s e in n' w i t h
i n c r e a s i n g h a r d n e s s s h o w n in Fig. 19.

Factors Influencing Mean Stress Relaxation

Behavior

T h e m e a n stress r e l a x a t i o n b e h a v i o r
of a m a t e r i a l has b e e n f o u n d t o b e a
function of the strain amplitude
( e j'2s.27.3o M e a s u r e d m e a n stress re-
E
< laxation exponentsequation (4)
A 5183 - W M w h i c h d e t e r m i n e t h e r e l a x a t i o n rate
and mean stress f a t i g u e damage
b e h a v i o r w e r e p l o t t e d as a f u n c t i o n o f
10 hardness in Fig. 2 1 . H e r e it c a n be seen
that k depends on hardness for the
A514 w e l d m a t e r i a l s b u t n o t f o r t h e
A36 w e l d m a t e r i a l s . H o w e v e r , by
d i v i d i n g t h e plastic s t r a i n a m p l i t u d e
(determined from the total strain
I 1 a m p l i t u d e ) b y t h e elastic m o d u l u s (E)
I 10 10' 10" I0M 10 10 10' a n d t r a n s i t i o n strain ( ,,.) o f t h e m a t e -
Reversals To Failure, 2 N f rial, a linear r e l a t i o n s h i p s h o w n in Fig.
22 was o b t a i n e d w h i c h a p p e a r s t o b e
Fig. 13-Strain-life fatigue behavior of 5083-0 aluminum weld materials
v a l i d f o r all t h e m a t e r i a l s s t u d i e d : 2 7

r e p o r t e d b y Landgraf, h o w e v e r , f o r
h i g h e r hardness steels as s h o w n b y t h e
steel scatter b a n d in Fig. 19.
Based o n h a r d n e s s , t h e m o n o t o n i c
a n d c y c l i c p r o p e r t i e s ( n , cr,, e ,, a n d
n') may be e s t i m a t e d . T h e f a t i g u e
s t r e n g t h (cr,) a n d d u c t i l i t y (e ',) c o e f f i -
c i e n t s m a y be a p p r o x i m a t e d b y t h e i r
monotonic counterparts."
cr', cr, (8)
?S i (9)
T h e c y c l i c s t r e n g t h c o e f f i c i e n t is
cr',
K (10)
( e ',)n'
T h e f a t i g u e d u c t i l i t y (c) a n d s t r e n g t h
(b) e x p o n e n t s are also f u n c t i o n s o f
hardness f o r t h e A 3 6 a n d A 5 1 4 w e l d
materials. The f a t i g u e strength e x p o -
n e n t increases as h a r d n e s s increases as
s h o w n in Fig. 20, w h i l e t h e f a t i g u e
d u c t i l i t y e x p o n e n t decreases as h a r d -
A tc/2
K = 4625 (ksi) ' ^
E tr
T h e t r a n s i t i o n strain ( e l r ) is h a l f t h e
strain a m p l i t u d e ( e J w h i c h c o r r e -
sponds to 2 N , r .
Acknow/edgmen is
This s t u d y has b e e n s u p p o r t e d in
part b y t h e U n i v e r s i t y o f I l l i n o i s Frac-
t u r e C o n t r o l P r o g r a m ; t h e U. S. A r m y
Corps of E n g i n e e r s , G r a n t D A C A 88-
75-C-0014; a n d t h e U. S. N a v y - N a v a l

-0.6

-0.5
ff
0,2N * 0 , I " - ' > '

-0,4

5I83 WM

-0.3
-0,2N * " 0 , i ( 2 N - I ) '

0|l I I I I Mill I ' I I""I I I I I I i I i i in -0.2

I 10 I0 2 IO3 IO4 10

Fig. 14-Normalized mean stress relaxation test results for 5183

aluminum weld metal -O.i

0 0.001 0.002 0.003 0.004 0JD05

Fig. 15 (right)-Relaxation exponent (k) as a function of the stral
amplitude for A36, A514, and 5083-0 weld materials Strain Amplitude, t a

WELDING RESEARCH SUPPLEMENT I 341-s

Table 10-Cycl c Mean Stress Relaxation Exponent (k) for A514, A36, and 5083-0 Base and Weld Materials""

A51<I A 1ft 5083-0

BM HAZ WM(IP) WM(2P) BM HAZ WM(1P) WM(2P) BM WM""

0.0010 0.009 0.007 0.009 0.012 0.012 0.030 0.030 0.028 0

(0.015) (0.008) (0.016) (0.01 1) (0.001) (0.030) (0.031) (0.032)
0.0015 0.015 0.007 0.018 0.016 0.068 0.061 0.065 0.075
(0.025) (0.008) (0.017) (0.011) (0.04b) (0.060) (0.065) (0.063)
0.0020 0.023 0.010 0.016 0.019 O.I 22 0.122 0.101 0.151 0.032
(0.027) (0.013) (0.019) (0.026) (0.106) (0.127) (0.100) (0.127)
0.0025 0.038 0.013 0.026 0.030 0.090
(0.046) (0.017) (0.035) (0.037)
0.0030 0.062 0.021 0.046 0.041 0.221 0.213 0.180 0.256 0.256
(0.079) (0.023) (0.043) (0.060) (0.191) (0.209) (0.166) (0.180)
0.0035 0.084 0.029 0.073 0.063
(0.116) (0.034) (0.066) (0.076)
0.0040 0.152 0.048 0.100 0.087 0.273 0.282 0.283 0.337
(0.150) (0.082) (0.100) (0.223) (0.257) (0.196) (0.198)
0.0050 0.351 0.349 0.359 0.457
(0.232) (0.283) (0.267) (0.258)

' " T h e number in parentheses w e r e tests c o n d u c t e d under a negative mean strain { m). The mean strains used w e r e 0.004 (A514), 0.005 (A36), and 0.003 (5083-0). All values of k are
negative.
" " A c t u a l strain a m p l i t u d e s ( J w e r e 0.0011, 0.0020, 0.0026, 0.0030.

IO6, , 1 , , 1 r -

A 514 Group 500

A A 36 Group

400

300

200

"A *A
100 A 514 Group
A A 36 Group

100 200 300 400 500 600 700 800

J L Hardness , BHN
100 200 300 400 500 600 700 800
Hardness, BHN
Fig. 17 True fracture strength (cr,) as a function of hardness*

Fig. 16Transition fatigue life (2Ntr) as a

function of hardness"
0.28 . I 1 1 1 i 1
\A A5I4 Group
A 5 I 4 Group
E 0.24 A A36 Group
A A36 Group

*-
c 0.20 1
c i
i
o i
a. i
UJ 0.I6 i
i
CT i
C A\ i
i
O.I 2 i
O)
T3
i
W i
a i
/
X 0.08 \ *
.
o V , ^ ,'
i.
* .-"**'
V) 0.04

1 1 1 1 1 I
IOO 200 300 4 0 0 500 600 700 800 IOO 2 0 0 300 400 500 600 700 800

Hardness, BHN Hardness, BHN

Fig 18Monotonic strain hardening exponent (n) and true fracture ductility ( e,) as a function of hardness33

342-sl NOVEMBER 1978

Ship Systems Command,
N00024-73-C-5344. M e c h a n i c a l t e s t i n g
a n d m e t a l l o g r a p h y w a s p e r f o r m e d in
the laboratories of the D e p a r t m e n t s of
Metallurgy and M i n i n g , Civil Engineer-
ing, and Theoretical a n d
M e c h a n i c s at t h e U n i v e r s i t y o f I l l i n o i s ,
Urbana, Illinois.
References
1. Lawrence, F. V., |r., and Radziminski, |.
B., "Fatigue Crack Initiation and Propaga-
tion in High-Yield-Strength Steel W e l d
Metal," Welding lournal, 49 (10), Oct. 1970,
Research Suppl., pp. 445-s to 452-s.
2. Gurney. T. A., Fatigue of Welded
Structures, Cambridge University Press,
Cambridge, U. K., 1968.
3. Pollard, B., and Cover, R. J., "Fatigue of
Steel Weldments," Welding lournal, 51
(11), Nov. 1972, Research Suppl., pp. 544-s
to 554-s.
4. Burk, ). D., and Lawrence, F. V., |r.,
"The Effect of Lack-of-Penetration and Lack-
of-Fusion on the Fatigue Properties of 5083-
0 A l u m i n u m Alloy Welds," W e l d i n g Re-
Grant 028 7. Maddox, S. J., "Some Further Fatigue
A 5 I 4 Group Crack Propagation Results Relevant to
0.24 A A 3 6 Group Welded Joints in Steel," British W e l d i n g
Institute Members' Report E/37/70, 1970.
020 8. Maddox, S. )., "Fatigue Crack Propaga-
tion Data Obtained from Parent Plate,
Applied 0 16
Weld Metal and HAZ in Structural Steels,"
British Welding Institute Members' Report
0I2
E/48/72, 1972.
9. Maddox, S. J., "Some Further Fatigue
0.08
Crack Propagation Results Relevant to
Welded loints in Steel," British Welding
0.04
Research International, Vol. 3, No. 1, 1973,
pp. 72-99.
I00 200 300 400 500 600 700 800 10. Dowse, 'K. R., and Richards, C. E.,
Hordness, BHN "Fatigue Crack Propagation Through Weld
Heat Affected Zone," Metallurgical Trans-
Fig- 19Cyclic strain hardening exponent
as a function of hardness33 actions, Vol. 2, No. 2, 1971, pp. 599-603.
11. Bucci, R. )., Clark, W. G., )r., and Paris,
P. C , "Fatigue Crack Propagation G r o w t h
searchCouncil Bulletin No.234,January1978. Rates under a W i d e Variation of AK for an
5. Lancaster, |. F., The Metallurgy of ASTM A517 Grade F (T-1) Steel," Stress
Welding, Brazing and Soldering, American Analysis and Growth of Cracks, Proceeding
Elsevier, New York, 1965. of the 1971 National Symposium on Frac-
6. Maddox, S. )., "Fatigue Crack Propaga- ture Mechanics, Pan I, ASTM STP 513,
tion in W e l d Metal and H A Z , " Metal American Society for Testing and Materials,
Construction and British Welding lournal, 1972, pp. 177-195.
Vol. 2, No. 7, 1970, pp. 285-289. 12. Parry, M., Nordberg, H., and Hertz-

-0.I4
-I.0 1 1
-012
-0.8
/ -0.I0
7/Steels
-0.6 - A A
^ / / / , / / / // // '//
A
A -0.08 -
-0.4 A 5I4 Group
A A 3 6 Group -0.06
-0.2 A 5I4 Group
-0.04 A A 36 Group
I I I I
IOO 200 300 400 500 600 700 -0.02
Hardness, BHN
OS _
Fig- 20 Fatigue ductility (c) and strength (b) exponents as a 100 200 300 400 500 600 700
33
lunc tion of hardness Hardness , BHN

-0.5 -0.4

e
a A 3 6 Group A 514 Group

0.002 a 0
/
-0.4 0.003 a 0
0.004 /
-0.3-
A.
0/
-0.3

I

a a
-0.2 a
a -0.2
0 A5I4F BM
D A5I4F HAZ

-O
a A EIIO WM (IP)
9
-0. I 0 /
0 EIIO WM ( 2 P )

A36 BM

-O.I
A /O o A36 HAZ

100 200 300 400 500 * E 6 0 S WM ( I P )

m\A o
E 6 0 S WM ( 2 P )
Hardness, BHN
9 5I83 WM
Fig. 21Relaxation exponent (k) as a function of hardness

I I I
20 40 60 80
Fig. 22Relaxation exponent (k) as a function of plastic strain
amplitude (t^tp/2) and elastic modulus (E) and transition strain Ap/2
X 10, ksi
It ,J

WELDING RESEARCH SUPPLEMENT I 343-s

berg, R. W., "Fatigue Crack Propagation in
A514 Base Plate and Welded loints," Weld-
ing lournal, 51 (10), O c t . 1972, Research
Suppl., pp. 485-s to 490-s.
13. Flanigan, A. E., and Kaufman, M.,
"Microcracks and the Low-Temperature
Cooling Rate Embrittlement of Welds,"
Welding lournal, 30 (12), Dec. 1951,
Research SuppE, pp. 613-s to 622-s.
14. Ohta, S., and Satoh, S., "Fatigue Prop-
erties in Notched Steel Plates and the
Effects of Welding on Them (Report 1),"
lournal of the lapan Welding Society, V o l .
44, No. 9, 1975, pp. 65-72.
15. Watanabe, M., Nagai, K., Otsuka, A.,
and Nagata, Y., " A Study of Fatigue Strength
in Weld Metal and HAZ of M i l d Steel
W e l d , " lournal of the lapan Welding Soci-
ety, Vol. 36, No. 4, 1967, pp. 55-63.
16. Kenyon, N.. Morrison, W . B. and
Quarrell, A. G., "Fatigue Strength of
Welded loints in Structural Steels," British
Welding lournal, Vol. 13, No. 3, 1966, pp.
123-137.
17. Muraki,)., Ishiguro, T. and Yokota, H.,
"Fatigue Characteristics of W e l d Heat
Affected Zone in High Tensile Strength
Steels, Treated w i t h a Synthetic Apparatus
for Weld Thermal Cycles (Report 1)," lour-
nal of the Japan Welding Society, Vol. 36,
No. 3, 1967, pp. 27-35.
18. Muraki, )., Ishiguro, T. and Yokota,
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To Update Your Book "Weldability of Steels"

You Can Now Order
Revised WRC Bulletin 191 March 1978

Suggested Arc-Welding Procedures for Steels Meeting Stan-

dard Specifications

by C. W. Ott and D. J . Snyder

The authors of WRC BULLETIN 191 have completely revised the 40-page table "Steel Compositions with
Suggested Practices Generally Required for Sound Welding" and the list of steels specified by ASTM, AISI, SAE
and API.
This revised Bulletin incorporates all of the changes and additions that have been made in the list of the steels
specified by the above organizations through June 1977.
Consequently, the second edition of the book. "Weldability of Steels" by R. D. Stout and W. D. Doty, which was
published by WRC in 1971, and WRC BULLETIN 1 9 1 , published in January 1974, can be brought up-to-date by
purchasing a copy of REVISED BULLETIN 191 MARCH 1978.
Publication of this revised Bulletin was sponsored by the Weldability (Metallurgical) Committee of the Welding
Research Council.
The price of Revised Bulletin 191 is $9.00 per copy. Orders should be sent with payment to the Welding
Research Council, 345 E. 47th St., New York, NY 10017.

344-s I N O V E M B E R 1978