A crack removal has the purpose to stop crack propagation and prevent future crack reinitiation, thus fatigue life of the component is extended. A profile design for the removal of fatigue cracks that grow under bending loading is presented. The design is based on the preferred shape development of surface defects under bending loading. Preferred shape development of surface defects was experimentally identified and validated with observations previously reported by other authors. The design of a crack removal profile consists on determining a notch geometry and its dimensions to cut out a crack. The crack removal profile presented here induces crack reinitiation, if it would occur, on the surface plate at the notch ends rather than in the bottom of the notch, so original plate thickness is reinstalled for propagation and inspection is easier. This repair procedure is recommended for the removal of fatigue cracks in tubular joints of offshore jackets steel structures.

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