Assessment of internal defects in flush ground butt welds in marine structures

In this paper, acceptance criteria of internal planar defects for the highest design S-N curve for surface ground butt welds in fatigue design standards has been assessed based on fatigue tests of tethers containing internal defects. The results from crack growth analysis from defects placed close to the surface are compared with test data from constant amplitude testing of tethers with circumferential welds that includes flaws or small planar defects close to the surface. Floating structures and support structures are subjected to variable loads and the calculated response leads to a long-term stress range distribution with many small stress ranges. This means that if the cracks are small, the resulting stress intensity may be less than the threshold stress intensity factor and the crack does not grow for this stress cycle, or it grows at a reduced crack growth rate in the near threshold region. A methodology to account for this is presented based on a two-parameter Weibull long-term stress range distribution that is representative for load response of floating structures and for support structures for wind turbines. It is shown that the threshold value and the reduced crack growth rate in the near threshold region for small internal defect heights can be used to lift the fatigue test data from constant amplitude testing to be in better correspondence with a higher S-N curve when considering an actual long-term loading.