Algorithms for determination of weld toe radius and weld toe angle in welded joints

This paper addresses the challenge of precise determination of weld toe radius and flank angle in welded joints. Despite the importance of these parameters for fatigue strength, existing research has not provided clear computational methods for their accurate evaluation. To address this research gap, various evaluation algorithms were developed and applied to both artificially generated profiles of butt-welded and fillet-welded joints and real digital scan data of a reference specimen. The study derives initial recommendations for data quality and the selection of evaluation methods based on weld seam geometry and point spacing. These recommendations consider the demonstrated areas of validity and limitations. The results show that a least squares approach offers the greatest potential to accurately determine weld toe radii. Additionally, the flank angle can be well determined using the gradient of the weld seam profile. The results improve the understanding in assessment of weld seam geometries, enabling automated and precise weld quality inspection in the future. This study may contribute in the future derivation of normative and harmonization regulations for the determination of weld toe parameters.