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Effect of weld shape imperfections on the structural hot-spot stress distribution

This paper presents a probabilistic study of the effect of the weld shape imperfections on the structural hot-spot stress distribution along the weld toe using the Monte Carlo simulation and the finite element analysis method. A structural detail consisting of a plate strip with a transverse butt-welded joint and a tapered thickness step is used as a case study. The weld shape is modelled based on the weld profile parameters defined as random variables allowing the simulation of typical imperfections as a function of the imperfection level of welding. The analysis uses a linear finite element model built with the second-order solid elements. A finite element analysis program is used to calculate the stress distribution on the vicinity of the weld toe and a standard extrapolation procedure is used to obtain the structural hot-spot stresses. Different weld shape imperfections are generated and their effect on the hot-spot stresses is calculated afterwards. The notch effect of weld toe is not included in the analysis.