Discovery of Fatigue Strength Models via Feature Engineering and automated eXplainable Machine Learning applied to the welded Transverse Stiffener

Abstract

This research introduces a unified approach combining Automated Machine Learning (AutoML) with Explainable Artificial Intelligence (XAI) to predict fatigue strength in welded transverse stiffener details. It integrates expert-driven feature engineering with algorithmic feature creation to enhance accuracy and explainability. Based on the extensive fatigue test database regression models - gradient boosting, random forests, and neural networks - were trained using AutoML under three feature schemes: domain-informed, algorithmic, and combined. This allowed a systematic comparison of expert-based versus automated feature selection. Ensemble methods (e.g. CatBoost, LightGBM) delivered top performance. The domain-informed model $\mathcal M_2$ achieved the best balance: test RMSE $\approx$ 30.6 MPa and $R^2 \approx 0.780% over the full $\Delta \sigma_{c,50\%}$ range, and RMSE $\approx$ 13.4 MPa and $R^2 \approx 0.527% within the engineering-relevant 0 - 150 MPa domain. The denser-feature model ($\mathcal M_3$) showed minor gains during training but poorer generalization, while the simpler base-feature model ($\mathcal M_1$) performed comparably, confirming the robustness of minimalist designs. XAI methods (SHAP and feature importance) identified stress ratio $R$, stress range $\Delta \sigma_i$, yield strength $R_{eH}$, and post-weld treatment (TIG dressing vs. as-welded) as dominant predictors. Secondary geometric factors - plate width, throat thickness, stiffener height - also significantly affected fatigue life. This framework demonstrates that integrating AutoML with XAI yields accurate, interpretable, and robust fatigue strength models for welded steel structures. It bridges data-driven modeling with engineering validation, enabling AI-assisted design and assessment. Future work will explore probabilistic fatigue life modeling and integration into digital twin environments.