Experimental Determination of the Forming Limits of Steel Thin-Walled Tubes

This study presents an integrated experimental methodology to determine the forming and fracture limits of welded thin-walled steel tubes, with emphasis on weld-line effects and manufacturing-induced anisotropy. The methodology combines longitudinal and transverse uniaxial tensile tests, using specimens extracted from different positions relative to the weld line, with elastomer-based tube expansion tests. Digital Image Correlation, combined with time-dependent strain analysis, was used to identify the onset of localized necking, while local strain and thickness measurements near the fracture regions supported the determination of fracture limits. This experimental work covered strain paths in the principal strain space ranging from uniaxial tension to near plane-strain expansion within the investigated conditions, enabling the experimental determination of both the Forming Limit Curve and the Fracture Forming Line for the welded tube material. Results reveal a pronounced directional dependence of mechanical response and formability. Transverse specimens exhibited higher yield and ultimate tensile strengths but lower ductility, whereas longitudinal specimens showed greater elongation and strain-hardening capacity. Strain localization and fracture were governed by the combined effects of local thickness variations, weld heterogeneity, and manufacturing-induced anisotropy. In longitudinal specimens, fracture occurred preferentially along the weld line, while in transverse specimens it developed away from the weld region, indicating distinct failure mechanisms depending on the loading direction. These findings highlight the need to account for weld-related heterogeneity and manufacturing history when assessing the formability of welded thin-walled tubes. The proposed methodology provides valuable experimental data for improving failure prediction and supporting the design, simulation, and optimization of welded tubular components.