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Aiming at the base metal (BM) zone, heat affected zone (HAZ) and fusion zone (FZ) of the weld, the tip plastic zone and initiation behavior of microscopic short cracks (MSCs) in the toe of cross-welded joints are studied. Based on the theory of crack tip plastic zone and the fatigue index parameter (FIP), the shape and boundary size of the plastic zone at the tip of MSCs as well as the initiation life were calculated. The results show that the plastic zone was bone-like under plane stress and butterfly-like under plane stress; when the crack length increased from 2 μm to 30 μm, the boundary size of the plastic zone at the MSC tip increased by 15 μm and 2 μm under the action of plane stress and plane strain in the X-axis direction, respectively. As the grain gradient decreased from 0.5 to 0.1, the boundary size of the plastic zone at the tip of the MSC increased about 50%. MSC initiation occurs first in the BM zone, and life of initiation was about several hundred thousand cycles, which was consistent with the experimental result. The MSC expansion rate in BM zone was the fastest, with the average expansion rate about 2.5 × 10−3 μm/cycle; the MSC expansion rate in the FZ and HAZ was about 3.1 × 10−4 μm/cycle.

Initiation Behavior of Microscopic Short Cracks in Weld Toe of Structural Steel Q345B