Abstract The mechanical behaviour of end cracking during one-sided SAW was computer-simulated by thermal elastic analysis with the introduction of a dummy element. Experiments on small sized specimens and on-site large specimens have been carried out. The rotational deformation, the mechanism of formation of the end cracking and factors affecting it were investigated. It was concluded that for preventing the formation of end cracks, the end opening displacement and the rate of end opening should be reduced as far as possible. Theoretical analysis and on-site large specimen experiments showed that end cracking can be effectively prevented only if the arrangement of tack welds over the weld end is appropriate, and the stiffness and restraint of slit tab plate are moderate. By the aid of the above mentioned study, end cracking was successfully avoided in over 130 specimens of 12, 14, 16, 18 and 20mm thickness with weld length more than 1000m.
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