Surface to Through-Wall Crack Transition Model for Circumferential Cracks in Pipes

2021 ◽  
Author(s):  
Do Jun Shim ◽  
Jeong-Soon Park ◽  
Robert Kurth ◽  
David L. Rudland
Keyword(s):  
Finite Element ◽  
Crack Growth ◽  
Surface Crack ◽  
Outer Diameter ◽  
Transition Model ◽  
Finite Element Analyses ◽  
Transition Behavior ◽  
Final Surface ◽  
Proposed Model ◽  
Crack Transition

Abstract In the present paper, finite element analyses were performed to update and also extend the applicable ranges of the existing KI and COD solutions for non-idealized through-wall cracks. Then, a surface to through-wall crack transition model was proposed based on these solutions. The proposed model provides a criterion which determines when the final surface crack should transition to a through-wall crack. It also provides a criterion to determine the two crack lengths (at the inner and outer diameter surfaces) of the initial non-idealized through-wall crack. Furthermore, crack growth of non-idealized through-wall cracks can be simulated by using the proposed method. Finally, the proposed model was verified by demonstrating that it can well predict the surface to through-wall transition behavior when compared to the natural crack growth simulations.

Development of Non-Idealized Surface to Through-Wall Crack Transition Model

2013 ◽  
Author(s):  
Do-Jun Shim ◽  
Robert Kurth ◽  
David Rudland
Keyword(s):  
Crack Growth ◽  
Surface Crack ◽  
Crack Opening ◽  
Crack Depth ◽  
Outer Diameter ◽  
Transition Model ◽  
Opening Displacement ◽  
Final Surface ◽  
Proposed Model ◽  
Crack Transition

Recent work by the authors have shown that a subcritical surface crack (SC) can transition to a through-wall crack (TWC) with significant differences between the inner diameter (ID) and outer diameter (OD) crack lengths. In the current versions of the xLPR code (Ver. 1.0), an idealized through-wall crack (which has the same area as the final surface crack) is formed once the surface crack penetrates the wall thickness. This type of crack transition was selected since no general stress intensity factor (K) and crack-opening displacement (COD) solutions were available for crack shapes that would form during the transitioning stages, i.e., non-idealized through-wall cracks. However, it has been demonstrated that this idealized through-wall crack may result in an overestimate of the leak rate. Thus, it is necessary to further investigate and develop a model that can handle the surface crack to through-wall crack transition. In this paper, a surface to through-wall crack transition model was proposed using existing K and COD solutions for non-idealized through-wall cracks. This model includes a criterion for transitioning the final surface crack to the initial non-idealized through-wall crack which determines when the transition should occur (based on surface crack depth) and determines the two crack lengths (at ID and OD surfaces) of the initial non-idealized through-wall crack. Furthermore non-idealized through-wall crack growth can be conducted using the proposed model. Example results (crack shape and COD) obtained from the proposed model were compared to those obtained from the natural crack growth simulations for a circumferential crack. Results presented in this paper demonstrated the applicability of the proposed model for simulating crack transition. Limitation of the present model and plans for future work are also discussed in the paper.

Nonidealized Surface to Through-Wall Crack Transition Model for Axial Cracks in Cylinders

2015 ◽  
Vol 138 (1) ◽  
Author(s):  
Do-Jun Shim ◽  
Jeong-Soon Park ◽  
David Rudland
Keyword(s):  
Crack Front ◽  
Surface Crack ◽  
Crack Opening ◽  
Crack Depth ◽  
Outer Diameter ◽  
Transition Model ◽  
Opening Displacement ◽  
Proposed Model ◽  
Primary Water ◽  
Crack Transition

Recent studies have shown that a subcritical surface crack, due to primary water stress corrosion cracking (PWSCC), can transition to a through-wall crack (TWC) with significant differences between the inner diameter (ID) and outer diameter (OD) crack lengths. This behavior has been observed for both circumferential and axial cracks. Recently, a surface to TWC transition model has been developed for circumferential cracks using existing K and COD (crack opening displacement) solutions for nonidealized circumferential TWCs. In this paper, a similar crack transition model (CTM) was developed for axial cracks. As a first step, a study was conducted to define the appropriate crack front shape for nonidealized axial TWCs. Then, elastic finite element analyses were carried out to develop K and COD solutions using these crack front shapes. The newly developed solutions were utilized for the CTM. The present CTM includes a criterion for transitioning the final surface crack to the initial nonidealized TWC. This criterion determines when the transition should occur (based on surface crack depth) and determines the two crack lengths (at ID and OD surfaces) of the initial nonidealized TWC. Furthermore, nonidealized TWC growth calculation can be conducted using the proposed model. Example results (crack length and COD) obtained from the proposed model were compared to those obtained from the natural crack growth simulations. Results presented in this paper demonstrated the applicability of the proposed model for simulating axial crack transition.

Modeling of Subcritical Crack Growth due to Stress Corrosion Cracking: Transition From Surface Crack to Through-Wall Crack

2011 ◽  
Author(s):  
Do-Jun Shim ◽  
David Rudland ◽  
David Harris
Keyword(s):  
Finite Element ◽  
Crack Growth ◽  
Surface Crack ◽  
Leak Rate ◽  
Outer Diameter ◽  
Element Analysis ◽  
Equivalent Area ◽  
Inner Diameter ◽  
Low Probability ◽  
Crack Transition

Recent work conducted using the Advanced Finite Element Analysis (AFEA) method to simulate the ‘natural’ crack growth of a circumferential PWSCC demonstrated that a subcritical surface crack can transition to a through-wall crack with significant differences between the inner diameter and outer diameter crack lengths. In the current version of the xLPR (Extremely Low Probability of Rupture) code, once the surface crack penetrates the wall thickness, an idealized through-wall crack (which has an equivalent area as the final surface crack) is formed. This type of crack transition was selected since no general stress intensity factor (K) solutions were available for crack shapes that would form during the transitioning stages, i.e., non-idealized or slanted through-wall cracks. However, during the pilot study of the xLPR code, it has been identified that this crack transition method may provide non-conservative results in terms of leak-rate calculations. In this paper, in order to compare the ‘natural’ versus ‘idealized’ crack transition behavior, limited example cases were considered where both crack transitions were simulated using 3D finite element analyses. In addition, leak-rate calculations were performed to study how the two different crack transition methods can affect the leak-rates. The results of the present study demonstrate that the ‘idealized’ transition from surface to through-wall crack can significantly affect the leak-rate calculations.

Surface to Through-Wall Crack Transition Model for Axial Cracks in Pipes

2014 ◽  
Author(s):  
Do-Jun Shim ◽  
David Rudland ◽  
Jeong-Soon Park
Keyword(s):  
Crack Front ◽  
Surface Crack ◽  
Crack Depth ◽  
Outer Diameter ◽  
Transition Model ◽  
Proposed Model ◽  
Axial Crack ◽  
Front Shape ◽  
Inner Diameter ◽  
Crack Transition

Recent studies have shown that a subcritical surface crack, due to PWSCC, can transition to a through-wall crack with significant differences between the inner diameter and outer diameter crack lengths. This behavior has been observed for both circumferential and axial cracks. Recently, a surface to through-wall crack transition model has been developed for circumferential cracks using existing K and COD solutions for non-idealized circumferential through-wall cracks. In this paper, a similar crack transition model was developed for axial cracks. As a first step, a study was conducted to define the appropriate crack front shape for non-idealized axial through-wall cracks. Then, elastic finite element analyses were carried out to develop K and COD solutions using these crack front shapes. The newly developed solutions were utilized for the crack transition model. The present crack transition model includes a criterion for transitioning the final surface crack to the initial non-idealized TWC. This criterion determines when the transition should occur (based on surface crack depth) and determines the two crack lengths (at ID and OD surfaces) of the initial non-idealized TWC. Furthermore non-idealized TWC growth can be conducted using the proposed model. Example results (crack length and COD) obtained from the proposed model were compared to those obtained from the natural crack growth simulations. Results presented in this paper demonstrated the applicability of the proposed model for simulating axial crack transition.

A New Stress-Intensity Factor Solution for an External Surface Crack in Spheres

2021 ◽  
Author(s):  
James C. Sobotka ◽  
Yi-Der Lee ◽  
Joseph W. Cardinal ◽  
R. Craig McClung
Keyword(s):  
Stress Intensity Factor ◽  
Finite Element ◽  
Crack Front ◽  
Surface Crack ◽  
Degrees Of Freedom ◽  
External Surface ◽  
Crack Plane ◽  
Finite Element Analyses ◽  
Stress Variations ◽  
Geometric Formulation

Abstract This paper describes a new stress-intensity factor (SIF) solution for an external surface crack in a sphere that expands capabilities previously available for this common pressure vessel geometry. The SIF solution employs the weight function (WF) methodology that enables rapid calculations of SIF values. The WF methodology determines SIF values from the nonlinear stress variations computed for the uncracked geometry, e.g., from service stresses and/or residual stresses. The current approach supports two degrees of freedom that denote the two crack tips located normal to the surface and the surface of the sphere. The geometric formulation of this solution enforces an elliptical crack front, maintains normality of the crack front with the free surface, and supports two degrees of freedom for fatigue crack growth from an internal crack tip and a surface crack tip. The new SIF solution accommodates spherical geometries with an exterior diameter greater than or equal to four times the thickness. This WF SIF solution has been combined with stress variations common for spherical pressure vessels: uniform internal pressure on the interior surface, uniform tension on the crack plane, and uniform bending on the crack plane. This paper provides a complete overview of this solution. We present for the first time the geometric formulation of the crack front that enables the new functionality and set the geometric limits of the solution, e.g., the maximum size and shape of the crack front. The paper discusses the bivariant WF formulation used to define the SIF solution and details the finite element analyses employed to calibrate terms in the WF formulation. A summary of preliminary verification efforts demonstrates the credibility of this solution against independent results from finite element analyses. We also compare results of this new solution against independent SIFs computed by finite element analyses, legacy SIF solutions, API 579, and FITNET. These comparisons indicate that the new WF solution compares favorably with results from finite element analyses. This paper summarizes ongoing efforts to improve and extend this solution, including formal verification and development of an internal surface crack model. Finally, we discuss the capabilities of this solution’s implementation in NASGRO® v10.0.

Application of ASME Code Section XI Appendix L Using 3-D Finite Element Analyses

2020 ◽  
Author(s):  
Charles Fourcade ◽  
Minji Fong ◽  
James Axline ◽  
Do Jun Shim ◽  
Chris Lohse ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Crack Growth ◽  
Cyclic Stress ◽  
Finite Element Analyses ◽  
Element Analysis ◽  
Aspect Ratios ◽  
Flaw Tolerance ◽  
Asme Code ◽  
Stress Ratios

Abstract As part of a fatigue management program for subsequent license renewal, a flaw tolerance evaluation based on ASME Code, Section XI, Appendix L may be performed. The current ASME Code, Section XI, Appendix L flaw tolerance methodology requires determination of the flaw aspect ratio for initial flaw size calculation. The flaw aspect ratios listed in ASME Section XI, Appendix L, Table L-3210-2, for austenitic piping for example, are listed as a function of the membrane-to-gradient cyclic stress ratio. The Code does not explicitly describe how to determine the ratio, especially when utilizing complex finite element analyses (FEA), involving different loading conditions (i.e. thermal transients, piping loads, pressure, etc.). The intent of the paper is to describe the methods being employed to determine the membrane-to-gradient cyclic stress ratios, and the corresponding flaw aspect ratios (a/l) listed in Table L-3210-2, when using finite element analysis methodology. Included will be a sample Appendix L evaluation, using finite element analysis of a pressurized water reactor (PWR) pressurizer surge line, including crack growth calculations for circumferential flaws in stainless steel piping. Based on this example, it has been demonstrated that, unless correctly separated, the membrane-to-gradient cyclic stress ratios can result in extremely long initial flaw lengths, and correspondingly short crack growth durations.

Failure Assessment Diagrams of Semi-Elliptical Surface Crack with Constraint Effect

2007 ◽  
Vol 353-358 ◽  
pp. 1952-1955
Author(s):  
Hyung Yil Lee ◽  
Jin Haeng Lee ◽  
Tae Hyung Kim
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Surface Crack ◽  
J Integral ◽  
Finite Element Analyses ◽  
Constraint Effect ◽  
Failure Assessment ◽  
T Stress ◽  
Cracked Structures ◽  
Constraint Effects

For accurate failure assessment, a second parameter like T-stress describing the constraint is needed in addition to the single parameter J-integral. In this work, selecting the structures of surface-cracked plate and pipe, we perform line-spring finite element modeling, and accompanying elastic-plastic finite element analyses. We then present a framework, which includes the constraint effects in the R6 FAD approach for failure assessment of cracked-structures.

New Analytical Model of Bolted Joints

2004 ◽  
Vol 126 (4) ◽  
pp. 721-728 ◽  
Author(s):  
Ouqi Zhang ◽  
Jason A. Poirier
Keyword(s):  
Finite Element ◽  
Analytical Model ◽  
External Load ◽  
Bolted Joints ◽  
Finite Element Analyses ◽  
Conventional Theory ◽  
New Model ◽  
Proposed Model ◽  
Compression Members ◽  
Additional Member

The conventional theory of bolted joints adopts equivalent cylinders, cones or spheres for compression members. In this model, the member deformation is determined by the member stiffness that remains unchanged whether the external load is present. In fact, the external load causes an additional member deformation that is not determined by the member stiffness measured at pre-load. The external load also causes a member rotation, which not only reduces the member stiffness, but also delays the separation of the joint. Based on these observations, a new model of bolted joints is developed. Finite element analyses is performed to verify the proposed model.

scholarly journals A Plastic Fracture Mechanics Analysis of Small Case B Fatigue Cracks Under Multiaxial Loading Conditions

1997 ◽  
Author(s):  
Y. Wang ◽  
J. Pan
Keyword(s):  
Finite Element ◽  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Fatigue Cracks ◽  
Finite Element Analyses ◽  
Growth Criterion ◽  
General Yielding ◽  
Deformation Patterns ◽  
Generalized Plane Strain

The near-tip fields of small Case B cracks in power-law hardening materials are investigated under generalized plane-strain and general yielding conditions by finite element analyses. The results for two different crack orientations are examined and compared. The results indicate that the plastic deformation patterns near the tips of the cracks of two different orientations are remarkably similar in terms of the global coordinates. The results of the J integral from the finite element analyses are used to correlate to a fatigue crack growth criterion for Case B cracks. The trends of constant ΔJ contours on the Γ-plane for two cracks of different orientations are virtually the same. Further, the trends are compared reasonably well with those of the experimental results of constant fatigue life and constant fatigue crack growth rate.

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