Fatigue Algorithm for Modeling Many Weld Toe Cracks Propagating at Welded Joints

2016 ◽  
Author(s):  
Kin Shun Tsang ◽  
John H. L. Pang ◽  
Hsin Jen Hoh
Keyword(s):  
Stress Intensity Factor ◽  
Fatigue Crack ◽  
Fatigue Life ◽  
Stress Intensity ◽  
Fatigue Crack Growth ◽  
Welded Joints ◽  
Multiple Cracks ◽  
Surface Cracks ◽  
Paris Law ◽  
Weld Toe

Fatigue crack growth at welded joints often propagates from as many as tens to hundreds of small weld toe cracks along the weld toe line in offshore welded structures. This paper will present a fatigue algorithm for modeling many small weld toe cracks propagating from a welded joint. Cracks usually initiate at the weld toe region of the structures and propagate as surface cracks at the stress concentration regions of the weld-toe line. The presence of such weld defects or crack-like flaws can have a severe detrimental effect on their fatigue life and fracture resistance. Currently, there is a lack of studies that considers the effects of multiple cracks and their distribution density in welded joints. This work focuses on the fatigue analysis and modeling of multiple weld toe cracks, specifically in T-butt joints. Fatigue crack growth prediction is usually determined by the stress intensity factor range and crack propagation rate through Paris law. To predict the Stress Intensity Factor (SIF) of a weld toe crack, the magnification (Mk) factor was used. The Mk factor is influenced by the size of the welded attachment, as well as the size and depth of the weld toe crack. Simplified solutions for practical prediction of Mk factors were determined from 3D extended finite element method (XFEM) by modelling a semi-elliptical weld toe crack in a T-butt weld for cracks of different dimensions. The accuracy of the Mk factor solutions was verified by comparison to HSE fatigue data on 16 mm thick tubular joints. The Mk factor solutions were used to predict the growth of fatigue cracks using a model based on Paris Law and SIF solutions by Newman and Raju with plastic zone size corrections. Fatigue life was predicted for plates with and without attachments. It could be seen that the predicted life of a weld toe crack was severely reduced with the addition of a welded attachment. The model was extended to the multiple surface cracks commonly observed at the weld toe, where each crack is treated as independent, following established code procedures. The multiple cracks will coalesce as they propagate, until a single dominant crack emerges and fracture occurs. In this paper, the relationship between the fatigue life and the number and density distribution of the initial cracks was investigated. Fatigue life was predicted for plates with attachments with 1, 2, 10 and 100 cracks initially. The results show that as the number of cracks increases, the predicted fatigue life decreases.

scholarly journals Prediction of Corrosive Fatigue Life of Submarine Pipelines of API 5L X56 Steel Materials

Materials ◽  
2019 ◽  
Vol 12 (7) ◽  
pp. 1031 ◽  
Author(s):  
Xudong Gao ◽  
Yongbo Shao ◽  
Liyuan Xie ◽  
Yamin Wang ◽  
Dongping Yang
Keyword(s):  
Growth Rate ◽  
Stress Intensity Factor ◽  
Fatigue Crack ◽  
Fatigue Life ◽  
Stress Intensity ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Shape Factor ◽  
Bohai Sea ◽  
Paris Law

Corrosive fatigue failure of submarine pipelines is very common because the pipeline is immersed in a sea environment. In Bohai sea, many old pipelines are made of API 5L X56 steel materials, and it is necessary to provide an accurate method for predicting the residual life of these pipelines. As Paris law has been proven to be reliable in predicting the fatigue crack growth in metal materials, the two constants in Paris law for API 5L X56 steel materials are obtained by using a new proposed shape factor based on the analysis of experimental data measured from fatigue tests on compact tension specimens immersed in the water of Bohai sea. The results of the newly proposed shape factor show that, for a given stress intensity factor range (ΔK), the fatigue crack growth rate (da/dN) in seawater is 1.6 times of that that in air. With the increase of fatigue crack growth rate, the influence of seawater on corrosive fatigue decreases gradually. Thereafter, a finite element model for analyzing the stress intensity factor of fatigue crack in pipelines is built, and the corrosive fatigue life of a submarine pipeline is then predicted according to the Paris law. To verify the presented method, the fatigue crack growth (FCG) behavior of an API 5L X56 pipeline with an initial crack under cyclic load is tested. Comparison between the prediction and the tested result indicates that the presented method is effective in evaluating the corrosive fatigue life of API 5L X56 pipelines.

Numerical Simulation of Coalescence Behavior of Multiple Surface Cracks

2011 ◽  
Author(s):  
Masanori Kikuchi ◽  
Yoshitaka Wada ◽  
Kazuhiro Suga ◽  
Chikako Ohdama
Keyword(s):  
Numerical Simulation ◽  
Stress Intensity Factor ◽  
Fatigue Crack ◽  
Stress Intensity ◽  
Fatigue Crack Growth ◽  
Intensity Factor ◽  
Experimental Studies ◽  
Multiple Cracks ◽  
Surface Cracks ◽  
Crack Tips

Study on the interaction of multiple cracks during fatigue crack growth processes is important for the integrity evaluation of nuclear structure. By using S-version FEM, this problem has been simulated by authors. In this study, coalescence behavior of 2 surface cracks is simulated using the method. It is assumed that 2 surface cracks exist on the same plane, and grow towards each other by fatigue. As the inner crack tips overlap, coalescence of 2 cracks occurs, and shape of cracks change significantly over very short cycles. This process is simulated in detail, and changes of stress intensity factor distributions along crack front are studied precisely. Three cases of changing crack sizes are simulated and coalescence behaviors are studied. Experimental studies are also conducted and results are compared with those of numerical simulations. Results are compared with conventional evaluation code and discussed.

Numerical Determination of Paris Law Constants for Carbon Steel Using a Two-Scale Model

2022 ◽  
pp. 1-15
Author(s):  
M. Mlikota
Keyword(s):  
Growth Rate ◽  
Stress Intensity Factor ◽  
Fatigue Crack ◽  
Stress Intensity ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Scale Model ◽  
Numerical Determination ◽  
Paris Law

For most engineering alloys, the long fatigue crack growth under a certain stress level can be described by the Paris law. The law provides a correlation between the fatigue crack growth rate (FCGR or da/dN), the range of stress intensity factor (ΔK), and the material constants C and m. A well-established test procedure is typically used to determine the Paris law constants C and m, considering standard specimens, notched and pre-cracked. Definition of all the details necessary to obtain feasible and comparable Paris law constants are covered by standards. However, these cost-expensive tests can be replaced by appropriate numerical calculations. In this respect, this paper deals with the numerical determination of Paris law constants for carbon steel using a two-scale model. A micro-model containing the microstructure of a material is generated using the Finite Element Method (FEM) to calculate the fatigue crack growth rate at a crack tip. The model is based on the Tanaka-Mura equation. On the other side, a macro-model serves for the calculation of the stress intensity factor. The analysis yields a relationship between the crack growth rates and the stress intensity factors for defined crack lengths which is then used to determine the Paris law constants.

Fatigue Damage Analysis on Crack Growth and Fatigue Life of Welded Bridge Members with Initial Crack

2006 ◽  
Vol 324-325 ◽  
pp. 251-254 ◽  
Author(s):  
Tai Quan Zhou ◽  
Tommy Hung Tin Chan ◽  
Yuan Hua
Keyword(s):  
Stress Intensity Factor ◽  
Fatigue Crack ◽  
Fatigue Life ◽  
Stress Intensity ◽  
Fatigue Crack Growth ◽  
Intensity Factor ◽  
Crack Growth ◽  
Fatigue Damage ◽  
Initial Crack ◽  
Traffic Loading

The behavior of crack growth with a view to fatigue damage accumulation on the tip of cracks is discussed. Fatigue life of welded components with initial crack in bridges under traffic loading is investigated. The study is presented in two parts. Firstly, a new model of fatigue crack growth for welded bridge member under traffic loading is presented. And the calculate method of the stress intensity factor necessary for evaluation of the fatigue life of welded bridge members with cracks is discussed. Based on the concept of continuum damage accumulated on the tip of fatigue cracks, the fatigue damage law suitable for steel bridge member under traffic loading is modified to consider the crack growth. The proposed fatigue crack growth can describe the relationship between the cracking count rate and the effective stress intensity factor. The proposed fatigue crack growth model is then applied to calculate the crack growth and the fatigue life of two types of welded components with fatigue experimental results. The stress intensity factors are modified by the factor of geometric shape for the welded components in order to reflect the influence of the welding type and geometry on the stress intensity factor. The calculated and measured fatigue lives are generally in good agreement, at some of the initial conditions of cracking, for a welded component widely used in steel bridges.

Multiple Fatigue Crack Growth Prediction Using Stress Intensity Factor Solutions Modified by Empirical Interaction Factors

2011 ◽  
Vol 134 (1) ◽  
Author(s):  
Shinji Konosu ◽  
Kyosuke Kasahara
Keyword(s):  
Stress Intensity Factor ◽  
Fatigue Crack ◽  
Stress Intensity ◽  
Fatigue Crack Growth ◽  
Intensity Factor ◽  
Crack Growth ◽  
The Body ◽  
Multiple Cracks ◽  
Growth Prediction ◽  
Interaction Factors

It is generally believed that multiple fatigue crack growth prediction is difficult with the use of conventional stress intensity factor (SIF) solution calculations because of issues such as SIF magnification and shielding effects. Therefore, almost all the existing Fitness for Service (FFS) rules such as the ASME Code Section XI and JSME Code adopt the procedure whereby multiple cracks grow independently after applying a certain alignment rule based on the initial crack configuration and are combined immediately into an enveloping crack when the crack tips touch. In some cases, the results of the procedures in the existing FFS rules are less accurate in predictions of the service life of cracked components. Therefore, there is still room for improvement, although the procedures are simple for utilities. This paper describes a new approach to predict fatigue crack growth life of multiple nonaligned cracks by the use of SIF solutions modified by empirical interaction factors. Several examples of two nonaligned cracks illustrate the accuracy and effectiveness of the procedure by comparison with numerical analysis by the body force method for two-dimensional problems and with the experimental results given in the literature for three-dimensional problems.

Evaluation of Stress Intensity Factor Range in the Prediction of Fatigue Crack Growth at Rib-to-Deck Welded Joints of Orthotropic Steel Decks

2013 ◽  
Vol 671-674 ◽  
pp. 969-973 ◽  
Author(s):  
Guang Yu Shi ◽  
Xiao Xiao Li ◽  
Gao Nan Zhang
Keyword(s):  
Stress Intensity Factor ◽  
Fatigue Crack ◽  
Stress Intensity ◽  
Fatigue Crack Growth ◽  
Intensity Factor ◽  
Crack Growth ◽  
Welded Joints ◽  
Stress Intensity Factor Range ◽  
Transverse Stresses ◽  
Orthotropic Steel Decks

This paper studies the evaluation of the proper stress intensity factor ranges in the fracture mechanics-based fatigue analysis of the rib-to-deck welded joints of orthotropic steel decks. It is pointed out in the paper that the stress intensity factor ranges used in Paris law for the fatigue crack growth at a rib-to-deck welded joint can not be taken as a value proportional to the corresponding stress ranges since the compressive stresses are the dominant transverse stresses in the cyclic stresses under the action of truck traffics. The proper fatigue design loads to characterize the standard truck loading for the accurate calculation of the tensile transverse stresses at the rib-to-deck joints is also discussed in the paper. It is shown that the loads from two neighboring wheel-axles of heavy trucks have to be taken into account.

Multiple Fatigue Crack Growth Prediction Using Standard Stress Intensity Factor Solutions

2010 ◽  
Author(s):  
Shinji Konosu ◽  
Kyosuke Kasahara
Keyword(s):  
Stress Intensity Factor ◽  
Fatigue Crack ◽  
Stress Intensity ◽  
Fatigue Crack Growth ◽  
Intensity Factor ◽  
Crack Growth ◽  
The Body ◽  
Multiple Cracks ◽  
Growth Prediction ◽  
Dimensional Models

It is generally believed that multiple fatigue crack growth prediction is difficult with the use of standard stress intensity factor (SIF) solution calculations because of the complicated nature of such issues as magnification and shielding effects. Therefore, almost all the existing FFS rules such as the ASME Section XI Code and JSME Code adopt the procedure whereby multiple cracks grow independently after applying a certain alignment rule based on the initial crack configuration and are combined immediately into an enveloping crack when the crack tips touch. In some cases, the results of the procedures in the existing FFS rules can be unrealistic and may lead to unreliable predictions of the service life of cracked components. This paper describes a new approach to predicting multiple nonaligned fatigue crack growth life by the use of standard SIF solutions. Several examples, as compared with numerical analysis by the body force method for two-dimensional models and experimental results in the literature for three-dimensional models, illustrate the accuracy and effectiveness of the procedure.

Fatigue Modelling of Semi-Elliptical Surface Cracks in Welded Pipe Geometries

2016 ◽  
Author(s):  
Hsin Jen Hoh ◽  
John H. L. Pang ◽  
Kin Shun Tsang
Keyword(s):  
Stress Intensity Factor ◽  
Fatigue Life ◽  
Stress Intensity ◽  
Stress Concentration ◽  
Stress Intensity Factors ◽  
Surface Cracks ◽  
Intensity Factors ◽  
Magnification Factor ◽  
Weld Toe ◽  
Welded Pipe

Offshore pipelines and risers transfer oil and gas across long distances, from seabed to production facility to the surface. The long pipelines are formed by welding together pipe segments. The welded joints formed are a source of stress concentration and defects from which fatigue cracks can grow. Hence, it is imperative that the effect of the weld geometry on the stress concentration be understood so that appropriate measures can be taken to assess the potential remaining service life of the welded structure. The effects can be understood by the linear elastic fracture mechanics approach, where the stress intensity factors quantify the stress concentration. While the classical equations of Newman and Raju have been long available for semi-elliptical surface cracks in plates, no similarly elegant stress intensity factor solutions are available for pipes. There have been solutions in tabular form which can be cumbersome in practice. Moreover, solutions of welded pipe geometries have not been developed. The objectives of the current work are to develop closed-form solutions for stress intensity factors for external semi-elliptical surface cracks in plates. The welded pipe geometry will also be studied to develop solutions for the weld toe magnification factors of welded pipe geometries. The stress intensity factors can be used to determine the propagation rate of cracks in pipe or welded pipe geometries. The stress intensity factors are obtained by the J-integral output of the three-dimensional finite element method. First, a plate with a circular crack is modelled. The initial step transforms the model to a plate with a semi-elliptical crack with the appropriate crack aspect ratio and width. A second transformation follows to transform the geometry to pipe form. The main parameters studied are the relative crack depth to thickness, crack aspect ratio, radius and thickness. The developed stress intensity factor solutions can be reduced to the classical equations. The new solutions show good agreement compared to previous work. A similar approach is developed to study the welded pipe geometry to develop weld toe magnification factor solutions. The weld toe magnification factor solutions for certain geometries are presented as a function of the relative crack depth. The stress intensity factor solutions are then applied to predict the crack growth rates of cracks in pipe geometries. The prediction was conducted by a program written to assess the fatigue life of single and multiple cracks in pipes and welded pipes. The fatigue life assessment of welded pipes using the weld toe magnification factor solutions shows how significantly the weld geometry affects fatigue life.

Effect of Temperature on Fatigue Crack Growth in CPVC

2003 ◽  
Vol 125 (1) ◽  
pp. 71-77 ◽  
Author(s):  
Muhammad Irfan-ul-Haq ◽  
Nesar Merah
Keyword(s):  
Stress Intensity Factor ◽  
Fatigue Crack ◽  
Stress Intensity ◽  
Fatigue Crack Growth ◽  
Intensity Factor ◽  
Crack Growth ◽  
Effect Of Temperature ◽  
Stress Intensity Factor Range ◽  
Crack Growth Behavior ◽  
Different Temperatures

This study addresses the effect of temperature on fatigue crack growth (FCG) behavior of CPVC. FCG tests were conducted on CPVC SEN tensile specimens in the temperature range −10 to 70°C. These specimens were prepared from 4-in. injection-molded pipe fittings. Crack growth behavior was studied using LEFM concepts. The stress intensity factor was modified to include the crack closure and plastic zone effects. The effective stress intensity factor range ΔKeff gave satisfactory correlation of crack growth rate (da/dN) at all temperatures of interest. The crack growth resistance was found to decrease with temperature increase. The effect of temperature on da/dN was investigated by considering the variation of mechanical properties with temperature. Master curves were developed by normalizing ΔKeff by fracture strain and yield stress. All the da/dN-ΔK curves at different temperatures were collapsed on a single curve. Crazing was found to be the dominant fatigue mechanism, especially at high temperature, while shear yielding was the dominant mechanism at low temperatures.

Mechanisms of Fatigue Crack Growth in WC-Co Cemented Carbides

2005 ◽  
Vol 297-300 ◽  
pp. 1120-1125 ◽  
Author(s):  
Myung Hwan Boo ◽  
Chi Yong Park
Keyword(s):  
Growth Rate ◽  
Stress Intensity Factor ◽  
Fatigue Crack ◽  
Stress Intensity ◽  
Fatigue Crack Growth ◽  
Intensity Factor ◽  
Crack Growth ◽  
Stress Ratio ◽  
Cemented Carbides ◽  
Stress Intensity Factor Range

In order to study the influence of stress ratio and WC grain size, the characteristics of fatigue crack growth were investigated in WC-Co cemented carbides with two different grain sizes of 3 and 6 µm. Fatigue crack growth tests were carried out over a wide range of fatigue crack growth rates covering the threshold stress intensity factor range DKth. It was found that crack growth rate da/dN against stress intensity factor range DK depended on stress ratio R. The crack growth rate plotted in terms of effective stress intensity factor range DKeff still exhibited the effect of microstructure. Fractographic examination revealed brittle fracture at R=0.1 and ductile fracture at R=0.5 in Co binder phase. The amount of Co phase transformation for stress ratio was closely related to fatigue crack growth characteristics.

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