Master's Thesis

Fatigue Life of Thin-Walled Welded Joints

Final Thesis 2.66 MB

Author of thesis: Bc. Adham Sleiman

Acad. year: 2025/2026

Supervisor: doc. Ing. Ivo Jebáček, Ph.D.

Reviewer: Ing. Petr Augustin, Ph.D.

Abstract:

This thesis presents an analytical and literature-based comparison of the fatigue behavior of bending-loaded and tensile-loaded thin-walled welded joints. The main focus is the difference in through-thickness stress distribution between axial tensile loading and bending loading, and how this difference affects the interpretation of fatigue resistance in welded details. Under axial tensile loading, the nominal stress is approximately uniform through the plate thickness, while under bending loading the maximum stress occurs at the surface and decreases toward the neutral axis. This distinction is important for weld-toe fatigue, since a crack initiated under bending may propagate into a region of lower stress range, whereas a crack under axial tension remains exposed to a more uniform stress range.
The thesis reviews fatigue mechanisms, welded-joint fatigue assessment approaches, and relevant design concepts from EN 1993-1-9, IIW recommendations, ISO 14347, BS 7608, and published studies. Particular attention is given to the BS 7608 / Maddox thickness and bending correction concept, which is used to perform a parametric analytical comparison of plate thickness and degree of bending. The analysis shows that bending-loaded fatigue data may include a beneficial stress-gradient effect and should not be directly treated as equivalent to tensile-loaded fatigue data without considering the loading mode, plate thickness, welded detail, and crack path.
Weld-toe geometry and relative stress gradient are also discussed as additional factors affecting local fatigue behavior. In the final part of the thesis, a symmetrical non-load-carrying cruciform welded specimen made from S355J2 steel is proposed for future axial tensile fatigue testing. The proposed methodology defines specimen geometry, welding documentation, strain gauge placement, secondary bending control, fatigue loading regime, failure criteria, run-out treatment, and S–N curve construction. The thesis provides a practical basis for future experimental work aimed at generating tensile fatigue data for thin-walled welded joints.

Keywords:

Welding, welded joints, fatigue behavior, tensile loading, bending loading, thin-walled structures, stress gradient, weld toe, S–N curve, BS 7608, cruciform specimen.

Date of defence

11.06.2026

Result of the defence

Defended (thesis was successfully defended)

znamkaDznamka

Grading

D

Process of defence

Student presented the outcomes, which he achieved in his thesis. Then, the committee heard the supervisor´s and reviewer´s report of master´s thesis. There were no direct questions from the reviewer in the report. Therefore, the committee asked several questions about presented experimental data, evaluation of thesis, fatigue predictions, effect of welding methods, preferred MAG welding method, location of stress concentrations, residual stresses, utilization on aircraft structure, mistakes in schemes, use of strain gauge rosette, achievement of stress data and test standardization. The student answered these questions partially, with support, for the committee’s satisfaction. After this, the committee decided to evaluate the master´s thesis defense with the grade Satisfactory D.

Language of thesis

English

Faculty

Department

Study programme

Aerospace Technology (N-AST-A)

Composition of Committee

doc. Ing. Jaroslav Juračka, Ph.D. (předseda)
doc. Ing. Ivo Jebáček, Ph.D. (místopředseda)
doc. Ing. Jiří Hlinka, Ph.D. (člen)
doc. Ing. Pavel Zikmund, Ph.D. (člen)
Ing. Miroslav Šplíchal, Ph.D. (člen)

Supervisor’s report
doc. Ing. Ivo Jebáček, Ph.D.

The submitted draft of the diploma thesis represents a well-prepared theoretical foundation for the intended research topic focused on the fatigue behaviour of welded thin-walled structures. The student demonstrates a good understanding of the basic mechanisms of fatigue failure, fatigue crack initiation and propagation, as well as the specific issues associated with welded joints.

The introductory theoretical chapters are logically structured and written in appropriate technical English. The author successfully summarizes the fundamental fatigue concepts and introduces the main approaches used in fatigue assessment of welded joints according to relevant international standards, particularly EN 1993-1-9, IIW Recommendations, and ISO standards. The explanation of stress evaluation methods, including nominal stress, hot-spot stress, and notch stress approaches, is generally clear and technically correct.

A positive aspect of the work is the ability to connect material fatigue theory with practical engineering applications. The discussion of residual stresses, weld geometry, and fatigue categories demonstrates a solid orientation in the topic and an understanding of the practical importance of fatigue assessment in welded structures.

At the current stage, however, the thesis remains focused primarily on the literature review and theoretical background. Several key objectives of the assignment are still missing or only outlined in chapter structure form. In particular, the following parts require substantial further development:

analysis of thin-walled welded structures and the influence of wall thickness, surface quality, and welding imperfections, comparison and critical evaluation of experimental results from the literature, design of the tensile fatigue test specimen, proposal of the experimental testing methodology, methodology for evaluation of S–N curves and fatigue life, final discussion and synthesis of the obtained knowledge.

The current text is therefore not yet sufficiently balanced between theoretical and applied aspects of the topic. The practical and original contribution of the thesis will depend mainly on the quality of the forthcoming analytical and experimental chapters.

From the formal point of view, the thesis is generally written at a good academic level, although several sections still contain placeholders or incomplete passages that must be finalized. Some figures and references should also be more thoroughly discussed and properly linked to the text.

Overall, the work completed so far can be evaluated positively. The student has created a good theoretical basis for the remaining parts of the thesis and demonstrates appropriate technical knowledge of the topic. Nevertheless, significant work is still required, especially in the practical and analytical sections, which will be essential for the final quality and completeness of the diploma thesis.
Evaluation criteria Grade
Splnění požadavků a cílů zadání C
Postup a rozsah řešení, adekvátnost použitých metod C
Vlastní přínos a originalita C
Schopnost interpretovat dosažené výsledky a vyvozovat z nich závěry B
Využitelnost výsledků v praxi nebo teorii E
Logické uspořádání práce a formální náležitosti C
Grafická, stylistická úprava a pravopis C
Práce s literaturou včetně citací B
Samostatnost studenta při zpracování tématu B

Grade proposed by supervisor: C

Reviewer’s report
Ing. Petr Augustin, Ph.D.

The thesis deals with the issue of fatigue in thin-walled welded joints. The introductory literature review focuses on basic concepts in the field of metal fatigue as well as specific approaches used in the area of welded joints – it provides an overview of applicable standards and describes the main analytical approaches based on nominal stress, hot-spot stress, effective notch stress and fracture mechanics. The main part of the thesis specifically addresses thin-walled welded structures, discussing among other things the effects of weld geometry, residual stresses and especially wall thickness and the type of loading (bending versus tension, or a combination) on fatigue life, supported by experimental data and empirical relationships taken from the literature. It is stated that fatigue properties from tensile and bending tests are generally not equivalent and using characteristics determined under bending loading for fatigue analyses of parts predominantly loaded in tension can be dangerous. In accordance with the assignment, a test specimen of the welded joint for tensile loading is proposed, along with a test program and methodology enabling the determination of the corresponding S-N curve. 

The content of the thesis corresponds to the assignment and the approaches used as well as the technical terminology are correct. However, the thesis is written rather briefly, with some formulations and even equations excessively repeated. Given the literature-review nature of the work, more adopted experimental data could have been included, which would have better supported the formulated conclusions.
Evaluation criteria Grade
Splnění požadavků a cílů zadání B
Postup a rozsah řešení, adekvátnost použitých metod C
Vlastní přínos a originalita B
Schopnost interpretovat dosaž. výsledky a vyvozovat z nich závěry B
Využitelnost výsledků v praxi nebo teorii B
Logické uspořádání práce a formální náležitosti A
Grafická, stylistická úprava a pravopis B
Práce s literaturou včetně citací A

Grade proposed by reviewer: B

Responsibility: Mgr. et Mgr. Hana Odstrčilová