This study presents the numerical development of corrections factors for finite geometry effects on the stress field and stress intensity factors at transverse fillet weld toes. The correction factors have direct application to fatigue life estimated and fracture mechanics strength calculations of transverse stiffeners, short cover plates, bulkhead attachments, cruciform section, and other filler welded plate configurations. The stress field around the weld toe is based on Williams Eigenvalue Expansion for a wedge, although it does not currently contain corrections for finite boundaries.
The correction factors were developed using finite element analyses modeling small cracks for multiple series of dimensions to assess the behavior of stress intensity factors. The stress intensity factors were measured with J-Contour Integrals, normalized to a baseline stress intensity factor, and fit using numerical methods. The final result was two multi-variable correction factors that accurately capture the behavior of the stress intensity factor and stress field.