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A method of fatigue life prediction of spot welded joint under multi-axial loads has been developed by fatigue life estimation working groups in the committee on fatigue strength and structural reliability of JSAE. This method is based on the concept of nominal structural stress ( σ ns) proposed by Radaj and Rupp, and improved so that D value is not involved in stress calculation. The result of fatigue life estimation of actual vehicle with nominal structural stress which was calculated through newly developed method had very good correlation with the result of multi-axial loads fatigue test carried out with test piece including high strength steel.

A method of fatigue life estimation for the spot-welds of vehicle body structures by means of Finite Element Analysis (FEA) was studied. 6 general forces applied to a nugget of spot-weld under multiaxial loads were determined and the Nominal Structural Stress (σns) was calculated from them. It was confirmed that fatigue strength of the spot-welds under various multiaxial loads could be estimated universally by using σns. Based on the theory of elasticity of plates, stress of spot-weld nugget was analyzed. The theoretical equations for determining the principal stress at the nugget edge from6 general forces acting on a nugget were derived. And the principal stress was defined as the σns. The value of σns was determined by FEM that used a solid model and compared with the theoretical calculation value. They agreed quite well. Fatigue tests of DC specimens under various multiaxial loads (shear plus cross tension and tensile shear plus torsion) were conducted.

Fatigue strength of adhesive bonded box beams with longitudinal partition was investigate. From results of the fatigue tests, it was seen that the fatigue strength of bonded beams was higher than that of spot welded beams. Fatigue strength of bonded beams was independent of plate thickness and partition. The flexural rigidity of the box beams in the plane of partition can increase without decrease of torsional rigidity and torsional fatigue strength, if the partition is jointed by adhesive bonding instead of spot welding.

Fatigue strength of steel sheet adhesive joints was investigated. From the results of the fatigue tests, it was obtained that the fatigue strength of the tensile-shear adhesive joints was much higher than that of the T-type tension adhesive joints. Stress distributions on adhesive layer have been analyzed by theoretical analysis method. All of the data obtained by the fatigue tests fell almost on one S/N curve, in spite of the differences of joints type and plate thickness, if the equivalent stress(Mises stress) range of the adhesive layer at the periphery of the end of the jointed part obtained by theoretical analysis was taken as the ordinate of S/N curve.