Failure Analysis of Welded Joints in Heavy-Duty Structures

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Ravi Reddy

Independent Researcher

India

ABSTRACT
This manuscript presents a comprehensive failure analysis of welded joints in heavy-duty structures, focusing exclusively on technologies and practices available up to 2014. Welded joints are critical stress-bearing elements in bridges, offshore platforms, pressure vessels, and industrial cranes. Failures in these joints can lead to catastrophic structural collapse and significant economic losses. This study reviews common failure modes—fatigue cracking, brittle fracture, corrosion fatigue, and hydrogen-induced cracking—and correlates them with metallurgical factors, welding procedures, and service conditions. Three detailed case studies illustrate real-world incidents investigated between 2005 and 2014. Methodologies include non-destructive testing (NDT), fractographic examination, chemical analysis, and finite element stress simulation using software available before 2014. Results reveal that improper preheating, joint design with high stress concentrations, and suboptimal filler materials were primary contributors to failure. Recommendations for improved welding procedure specifications (WPS), enhanced NDT protocols, and design modifications are provided to mitigate future failures. Ten pertinent references up to 2014 are included.

KEYWORDS failure analysis, welded joints, heavy-duty structures, fatigue cracking, metallurgical defects, NDT

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