Fatigue Crack Propagation Law of Corroded Steel Box Girders in Long Span Bridges

In order to investigate the fatigue performance of orthotropic anisotropic steel bridge decks, this study realizes the simulation of the welding process through elastic-plastic finite element theory, thermal-structural sequential coupling, and the birth-death element method. The simulated welding residual stresses are introduced into the multiscale finite element model of the bridge as the initial stress. Furthermore, the study explores the impact of residual stress on crack propagation in the fatigue-vulnerable components of the corroded steel box girder. The results indicate that fatigue cracks at the weld toe of the top deck, the weld root of the top deck, and the opening of the transverse diaphragm will not propagate under the action of a standard vehicle load. However, the inclusion of residual stress leads to the propagation of these cracks. When considering residual stress, the fatigue crack propagation paths at the weld toe of the transverse diaphragm and the U-rib weld toe align with those observed in actual bridges. In the absence of residual stress, the cracks at the toe of the transverse diaphragm with a 15% mass loss rate are categorized as type I cracks. Conversely, when residual stress is considered, these cracks become I-II composite cracks. Residual stress significantly alters the cumulative energy release rate of the three fracture modes. Therefore, incorporating the influence of residual stress is essential when assessing the fatigue performance of corroded steel box girders in long-span bridges.