This study proposes a rapid method for quantifying fatigue degradation in welded joints with undercut defects. Cruciform joints with precisely machined undercut defects were fabricated through wire cutting, and fatigue tests were conducted with damage evolution monitored by acoustic emission (AE) signals. A finite element model incorporating AE-based fatigue damage mechanics was developed on the ABAQUS platform to simulate the fatigue failure process, and its reliability was validated against experimental data. The model was further employed to investigate the influence of undercut depth and radius on fatigue strength. Parametric analyses revealed that increasing defect depth and decreasing defect radius both markedly reduce fatigue performance, with depth exerting a dominant effect. Certain combinations of depth and radius led to similar reductions in fatigue strength, highlighting the coupled impact of geometric parameters. Based on numerical simulations, practical fatigue performance evaluation curves were proposed, including a simplified allowable-depth curve for cases where only defect depth can be measured. By integrating AE-based damage mechanics with defect-geometry numerical modeling, the proposed approach provides a rapid and reliable tool for assessing fatigue degradation and quality control of undercut-affected welded joints, ensuring structural safety while significantly improving assessment efficiency.
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