Solving Weld Fatigue Failures in ANI Tanker through Iterative FEA and Field Validation

The Challenge

ANI’s fleet of tankers was experiencing weld failures at multiple chassis locations, suspected to result from dynamic chassis twist during field operation. The failures were not captured in the original design phase, and a field-validated diagnostic and resolution was urgently required. Our Solution

Kleidouchos Engineering deployed a combined FEA and on-field testing approach:

• Performed a detailed 100 mm chassis twist FEA to locate potential fatigue hotspots.

• Instrumented the chassis with high-accuracy encapsulated strain gauges and an HBM DAQ system for live strain logging.

• Captured strain, vibration, GPS, and event data under actual operating conditions.

• Achieved excellent correlation between predicted and measured strains, confirming critical weld stress zones.
  

Iterative FEA-Led Resolution

The issue was systematically resolved through an iterative FEA process:

• Multiple design iterations were simulated using nonlinear FEA to test stress relief strategies.

• Each FEA loop was guided by field strain data to refine model accuracy.

• Final configuration reduced peak strain levels below 500 µε, eliminating low-cycle fatigue risk.

• The solution was implemented with minimal fabrication changes and zero weight penalty. The Outcome

  ✅ Weld failures eliminated ✅ No design overbuild or unnecessary reinforcement ✅ Field-validated durability ✅ Production process preserved Services Delivered

  • Strain gauging & instrumentation

  • Field data acquisition with GPS + vibration

  • High-fidelity FEA simulation

  • Iterative structural redesign

  • RPEQ-certified reporting 🔧 Looking to identify and fix fatigue failures?

    Our simulation-guided, field-validated process works.📩 Contact Kleidouchos Engineering to learn more.