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Structural durability is one of the key factors in determining the robustness of a product having a direct bearing on customer perception of quality and reliability in passenger vehicles, and is one of the major factors affecting customer loyalty. It is recognized that significant fatigue failures occur at spot welds in an automobile body structure, and accordingly various methods are adapted in the industry to predict such failures. However, most of them follow the traditional fatigue and fracture analyses, which are computationally challenging, expensive as well as mathematically complex to apply on a full vehicle system. As a result, most of these methods depend on iterative solutions e.g. Design of Experiments.