Influence of surface integrity on short crack growth behavior in HFMI-treated welded joints

Abstract This study investigates the influence of surface integrity and the localized fatigue phenomena on the initiation and propagation of short fatigue cracks in high-frequency mechanical impact (HFMI)-treated welded joints. The treated surface region, characterized by a compressive residual stress field, smooth notch geometry, and work hardening layer, improves welded joints’ fatigue strength. However, how these surface conditions influence the fatigue damage process zone during short crack initiation and growth is not yet well known. Therefore, this study systematically investigates the influence of different surface characteristics on fatigue life modeling of HFMI-treated welded joints made of high-strength steel. This is achieved using a non-local continuum damage mechanics-based approach of crack growth and elastic–plastic finite element simulation, explicitly modeling treated surface conditions. The simulated fatigue life is first verified with experiments and then applied to various surface conditions. The simulation results show that most of the fatigue life is spent until a crack size of 0.2 mm. The compressive residual stress field greatly extends both short crack initiation and propagation life, with its degree of contribution highly dependent on loading history and residual stress change. The role of the work hardening layer is mainly concentrated on improving fatigue life during short crack initiation and the very beginning of short crack growth.