This thesis work is concerned with effect of material grade on fatigue strength of welded joints. Fatigue strength evaluation of welded joints in as welded and post weld treated condition was carried out with effective notch method. Results of peak stress method have also been compared with those of effective notch method for as welded joints. In addition, using the results of effective notch method, the effect of important weld and global geometry factors on notch stress concentration factor has been studied with 2-level design of experiment and a mathematical relation among stress concentration factor and the geometric factors has been proposed. Overall, thickness of the base plate and toe radius is found to be the most important factors determining fatigue strength of the joint. Welding induced residual stresses have also been predicted using 2D and 3D FEM analysis to see their effect on fatigue strength of the joints. Also, transversal residual stresses were measured using X-ray diffraction method to assess the accuracy of predicted results. Based on simulation results, effect of geometric factors on maximum value of transversal residual stress was also investigated.

This thesis was done i cooperation with SKB Clab in Oskarshamn and studies use of sonic waves for detecting voids and irregularities in the weld joints of copper capsules used for long term storage of radioactive waste. Since these could pose material failure and thereby risk radioactive contamination of ground water it is very important to find means of quality control before storage.  During the welding procedure changes occur to the integrity of the material. The homogenous metal – in this case copper – is distorted and voids appear in and around the welded volume. A non-destructive inspection method is needed to make sure that the metal holds for the strains of long term storage. These strains are not completely known at the moment and therefore the goal of this thesis is mainly to add another tool of inspection for future studies. The tests are done using ultrasonic mapping of the welded volume. This is achieved by sending ultrasonic pulse through test samples – welded copper pieces – and recording its reflection. The recorded signals are gathered in data matrices and processed using several different signal processing methods in search of irregularities and voids. To enhance the understanding of the results a graphical user interface (GUI) is developed that allows users to visualize the results.  The welded pieces, the ultrasonic mapping and its resulting data sets were delivered to this thesis and the scope of the thesis is to develop the GUI and apply known signal processing methods to the data set.  It is shown that the irregularities do appear and that ultrasonic detection and use of the processing method is useful for quality control of the material. Further field studies are needed to identify maximum number, size and perhaps shapes of irregularities that can be within tolerance levels of the storage project.

Background This research study is in collaboration with the Blekinge Institute of Technology and Volvo Cars Body Components (VCBC). VCBC is a car manufacturer that manufactures car body components in Olofström, Sweden. VCBC is also a supplier for Volvo Cars production sites around the world, which puts more responsibility on VCBC and their work process. One of the limitations of this research will be a focus on a production line for nut welding, where various projection welding features are present.   Objectives The objectives of the study are to investigate the problems with the production line and present a conceptual solution which can make the process more efficient and effective in terms of e.g. the cycle time, value-adding activities, improvements of traditional work processes or equipment, ergonomics safety, reduction of frequent errors, etc. Most of the objectives are influenced by principles in lean manufacturing theory but will be compiled and integrated with new innovative solutions that are influenced by digitalization and industry 4.0. Methods The methods and tools which will be used for this research will be primarily from process engineering and systems engineering. Autodesk AutoCAD, Siemens Process Designer PLM and Robot Load are some of the software that will be used. Some tools and strategies used for the methodological approach are e.g. The design thinking process, Six Sigma, FMEA, Question-Method-Matrix, Material flow analysis, and Value stream analysis. Results A concept layout solution was generated, which consists primarily of a model in Autodesk AutoCAD and a simulated prototype in Siemens Process Designer PLM. Through several analyzes, based on the objectives of the research, it has been conducted that the concept is more efficient than the current process. Specifications such as cycle time, production line area, value-adding activities, etc. have been improved drastically. Several innovative idea solutions based on digitalization and industry 4.0 were also generated by implementing them as a way of tackling the challenges with lean theories and develop the traditional work process in a factory. Conclusions The contribution of the research analysis is the implementation of lean theories together with modern strategies, tools and software are from systems engineering and process engineering together with ideation and problem-solving techniques. This itself has contributed to all goal objectives of the research study being achieved, assessed and validated.

Fatigue assessment of welded joints using finite element methods is becoming very common. Research about new methods is being carried out every day that show a more accurate estimation of the fatigue life cycle than the previous ones. Some of these methods are investigated in this thesis for a thorough understanding of the weld fatigue evaluation process.The thesis study presents several methods as candidates for analysis of selected case studies for comparison. The sensitivity of methods towards FE model properties was studied. The ease of implementation for further automatization of the method was highly considered from the early stages of the project. A comparison study amongst feasible methods was then performed after analysis.The selected three case studies provided a wide range of difficulties in terms of geometry and loading and made them suitable for the methods to be evaluated. It should be noted that case studies only with fillet welds were considered during the literature study and analysis. Implementation of some methods on a case study where they have not previously been tested before gave a challenging task during the analysis phase. The proposed method after comparison and ranking of the methods based on several criteria such as accuracy, robustness, etc. was the hot spot stress method. The main advantages of this method are its low computational time, less complexity during both pre- and post-processing, and the ability to work for both solid and shell models.Finally, the report gives a walk-through of several functionalities of the post-processor tool built to enhance workflow for the hot spot based fatigue assessment of welds. Pseudo-codes for some functions of the tool are given for clarity. A summary of the workflow is presented as a flowchart. The outputs of the case studies were then evaluated using the tool and compared with the manual evaluation to check the effectiveness of the tool on different scenarios. The tool shows flexibility in handling different types of weld geometry with good agreement to the results obtained manually but only for welds lying on a flat surface. Some of the advantages of the tool are its capability to handle multiple welds simultaneously and the flexibility to the user in selecting the way the results are presented. Most of the postprocessing steps are automatized, while some require user inputs.

A series of research studies have recently identified an issue called strain localization in welded wire reinforced (WWR) members. This phenomenon reportedly concentrates strains at welded cross wire locations and severely limit ductility. Those that identified the phenomenon used it to imply that WWR is unsafe because it does not warn of failure. This dissertation is investigating details to mitigate the strain localization effect and demonstrate the WWR can be used safely. A moment curvature analysis is developed using Response2000 program and calibrated using experimental data. Parametric study was developed to present a recommendation of details and minimum reinforcement required for WWR slabs. The effect of different types of WWR coating on mechanical properties were investigated. The dissertation next examined the effects of strain rate on the mechanical properties of WWR and traditional rebar. In total, fifty four slabs have been constructed using WWR and rebar with various cross wire spacing, using a realistic design. The strain localization phenomenon was not demonstrated, but WWR slabs are somewhat less ductile than traditionally reinforced members. The WWR members were shown to provide adequate ductility for warning of impending failure visually and with a well-accepted ductility measure. The WWR members were also shown the ability of load redistribution. The effect of coating demonstrates that both galvanizing WWR and coating WWR with epoxy has a positive effect on mechanical properties, along with adding corrosion resistance. The effect of strain rate shows that increase in loading rate tend to increase the yield and ultimate stresses and percent area reduction, however the loading rate increase does not have a significant effect on elastic modulus, elongation and uniform elongation.

ABSTRACT The task was to design and assess the supporting structure of the lookout tower. Material steel and wood. The lookout tower is 27.22 m high and decreases in height from the base of the srka. Construction system with continuous columns and horizontal reinforcement.

In order to investigate the viability of friction stir welding for use in Naval construction, mode one elastic-plastic fracture toughness of friction stir processed HSLA-65 was determined using current ASTM 1820 and BS 7448 standards. Double-sided welds were used to achieve 12.7 mm thick samples. A constant feed rate of 100 mm/min was used for all welds. To explore the effect of weld parameters on toughness, welds were produced using two rotational speeds: 340 RPM and 490 RPM. The weld centerline, advancing side hardened region (ASHR), and TMAZ/HAZ regions were sampled, in addition to un-welded parent material. All elastic-plastic fracture toughness values were thickness dependent. For welds produced at 340 RPM, toughness ranged from 33% to 75% below parent material. By increasing the rotational speed to 490 RPM, weld toughness was likewise less than the parent material, but increased 12% to 50% relative to welds produced at 340 RPM. The lowest measured toughness was in the ASHR samples for both parameters. This region of the weld exhibited mixed mode stress-strain conditions and toughness 75% and 62% less than parent material. Toughness values for all samples failed to meet qualification requirements of both ASTM 1820 and BS 7448 due to non-uniform crack extension. Irregular crack extension was caused by the through thickness change in tensile properties due to welding and the affect this had on the plastic zone size compared to the thickness. Increased weld toughness from 340 RPM to 490 RPM was attributed to microstructural differences as a result of increased rotational speed. In addition, higher crack extensions were observed in the second weld pass relative to the first for both rotational speeds. This was attributed to weld tempering of the first pass by the second. The ASHR samples exhibited the highest crack extensions. In this location, the weld microstructure consisted of Widmanstatten ferrite, a microstructure known to be detrimental to toughness.

Lightweight cellular concrete (LCC) is a cement, water, and air entrained mixture that consists of 25-80% voids. The air voids reduce the material strength but also decrease the material weight. Due to its lightweight properties LCC is an attractive alternative to soil backfill for retained structures, such as mechanically stabilized earth (MSE) walls. Although LCC is widely used behind MSE walls, limited information exists regarding the pullout strength of MSE wall reinforcements in LCC backfill. This research attempts to fill the knowledge gap through performing pullout tests on welded wire and ribbed strip reinforcements in MSE walls to determine the pullout friction coefficient (F*), reinforcement pullout behavior, and LCC properties. A large-scale test box (10 feet wide x 12 feet long x 10 feet high) supported by a steel resisting frame, was constructed, and filled with LCC backfill. Both the west and east MSE wall faces consisted of concrete walls. The west wall was supported by 16 ribbed strip reinforcements, while the east wall was supported by nine short, welded wire reinforcements. After backfilling the MSE wall, pullout tests were performed of the 12 ribbed strip reinforcements and all nine welded wire reinforcements. To determine different pullout friction coefficients (F*), different surcharge loads were applied through LCC self-weight, concrete reaction beams, and hydraulic jacks at the top of backfill. After performing the pullout tests on the large-scale test box, additional pullout tests were performed in two smaller (10 feet wide x 6 feet deep x 30 in. tall) MSE walls, each containing four ribbed strip reinforcements to determine the F* of ribbed strip reinforcements at moderate surcharge pressures. Results from these tests produced F* recommendations for ribbed strip and welded wire reinforcements. Additionally, a total of 130 LCC cylinder specimens were used to identify LCC material properties. Results of these tests show that the unconfined compressive strength of LCC is greatly dependent on the cast and cured unit weight, as well as the sample maturity. Comparing the UCS results to other work reveals a wide variation of UCS versus cured density, even though the same ASTM standard was applied for all tests. An equation for the secant modulus of LCC was created using UCS data from this thesis and other research conducted at Brigham Young University (BYU). Direct shear tests were also conducted on LCC cylinders cut to fit the confinement of a direct shear machine. The direct shear test results from this thesis agree with other research conducted at BYU.

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