Abstract
In out-of-plane gusset welded joint, fatigue cracks usually initiate from the boxing weld toe in which high stress concentration exists. The fatigue strength can be improved by making smooth shape of boxing weld toe. Grinding process is a popular method for finishing weld toe. This process can remove weld imperfections and create a smooth transition between weld and base plate. But fatigue crack initiation points sometimes move to weld roots. This research is aiming at making clear the reason of root failure through fatigue tests and FEM stress analyses. On the basis of the results, the method to prevent root failure has been proposed.
