Abstract
The failure load of a butt-welded T-frame with a lack of fusion defect is predicted and compared with experimental data. Energy density concepts are used to quantitatively describe the material toughness at the continuum scale. Particular attention is given to the determination of base metal and weld metal uniaxial stress-strain curves valid for large deformation. Finite-element results are used to predict the location where the energy density first reaches a critical value, and the corresponding applied load. The predicted initiation site and load compares favorably with the experimental results.

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