Effect of the angular misalignment of laser welded T-joints on fatigue curves

Abstract This paper investigates the angular misalignment of laser welded T-joints made of thin sheets of aluminium alloys and its effect on fatigue curves. The effect of welding parameters and weld dimensions on angular distortion is analysed by linear regressions. A nonlinear finite element model is set up to consider the effect of angular misalignment on stress. The fatigue curves show that the misalignment affects the scatter, slope and fatigue strength of the S-N curves. The IIW reference curves for nominal and structural stresses are suitable for the studied joints. FAT50 is recommended instead of FAT71 for effective notch stress.