A data-driven analysis for fatigue failure mode identification in load-carrying fillet welded joint with mechanical data augmentation

Weld toe and weld root failures dominate the fatigue failures of the load-carrying cruciform fillet welded joints. Compared to weld toe failure, the weld root failure is strongly affected by its inherent weld quality and throat size, which is more unpredictable and should be eliminated. This work proposes a weld sizing criterion in terms of two weld leg sizes and weld penetration to avoid root failure. The criterion is obtained by a data-driven approach with the help of the mechanical-directed data augmentation technique. The traction-stress-based method is applied for the data augmentation to identify the fatigue failure mode, which is statistically tested against 372 experimentally obtained fatigue data.

Automated summary

Weld toe and weld root failures are the dominant fatigue failures in load-carrying cruciform fillet welded joints. Among them, weld root failure is more affected by weld quality and throat size, and should be eliminated. This study proposes a weld sizing criterion based on two weld leg sizes and weld penetration, obtained using a data-driven approach and mechanical-directed data augmentation technique.