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ABSTRACT
This study aims to clarify the influence of shape around weld toe and hardness of weld metal on fatigue crack life in fillet lap joints for automotive chassis elements. Gas metal arc (GMA) welding was performed using 980 MPa class hot rolled steel sheet as the test material. The shape around weld toe and hardness of weld metal were changed by the combination of the shield gas composition and the welding wire. The smoothing of the weld toe significantly improved the fatigue life compared to the hardened weld metal. The total fatigue life was separated into crack initiation life and crack propagation life by measuring the decreasing ratio in the stiffness of the specimen during the fatigue test. Then, the effect of smoothing the weld toe and hardening the weld metal on each life was examined. The changes in the propagating crack front shape and the propagation rate during fatigue test were examined by the beach mark technique. As a result, it was suggested that the smoothing of weld toe improves not only the crack initiation life but also the propagation life by delaying the crack propagation rate in the early stage of crack propagation. The mechanism of retardation of crack propagation rate due to smoothing of weld toe was discussed from the viewpoint of crack shape and aspect ratio.