Online Software Tool for Predicting Weld Residual Stress and Distortion

2008 ◽  
Author(s):  
Yu-Ping Yang ◽  
Wei Zhang ◽  
Wei Gan ◽  
Shuchi Khurana ◽  
Junde Xu ◽  
...  
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
High Performance ◽  
Local Heating ◽  
Welding Parameters ◽  
Analysis Tool ◽  
Element Analysis ◽  
Weld Residual Stress ◽  
Welding Processes

Weld residual stress and distortion are inevitable during welding due to rapid local heating and cooling, high-temperature material reactions and weld-fixture effects. To predict weld residual stress and distortion, an engineer has to understand welding processes and the finite element analysis method. It is difficult for an engineer without finite element background to calculate the weld residual stress and distortion. With the development of weld modeling technology, automatic meshing generation, and high performance computation, a web-based analysis tool (E-Weld Predictor), was developed to predict weld residual stress and distortion. This allows an engineer to calculate the weld residual stress and distortion on line. The engineer does not need to have finite element analysis knowledge to perform the calculation. By providing welding parameters, defining a weld joint, giving geometry dimensions, and specifying a material, weld residual stress and distortion are automatically calculated in a remote high performance computer. A report will then be sent to the engineer to review. This paper introduces the development of E-Weld Predictor. The software structure, the theory, the implementation, and the validation of E-Weld Predictor are discussed in detail. It also shows the simulation process of applying this software in predicting temperature, microstructure, residual stress and distortion.

Fast Three-Dimensional Finite Element Analysis of Weld Overlay Application on a Formed Feeder Elbow

2011 ◽  
Author(s):  
Francis H. Ku ◽  
Pete C. Riccardella
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Nuclear Reactor ◽  
Three Dimensional ◽  
Fe Method ◽  
Element Analysis ◽  
Weld Overlay ◽  
Welding Processes

This paper presents a fast finite element analysis (FEA) model to efficiently predict the residual stresses in a feeder elbow in a CANDU nuclear reactor coolant system throughout the various stages of the manufacturing and welding processes, including elbow forming, Grayloc hub weld, and weld overlay application. The finite element (FE) method employs optimized FEA procedure along with three-dimensional (3-D) elastic-plastic technology and large deformation capability to predict the residual stresses due to the feeder forming and various welding processes. The results demonstrate that the fast FEA method captures the residual stress trends with acceptable accuracy and, hence, provides an efficient and practical tool for performing complicated parametric 3-D weld residual stress studies.

Advanced Finite Element Analysis (AFEA) Evaluation for Circumferential and Axial PWSCC Defects

2010 ◽  
Author(s):  
D.-J. Shim ◽  
S. Kalyanam ◽  
E. Punch ◽  
T. Zhang ◽  
F. Brust ◽  
...  
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Crack Growth ◽  
Crack Front ◽  
Nodal Point ◽  
Nuclear Industry ◽  
Element Analysis ◽  
Weld Residual Stress ◽  
Axial Crack

The Advanced Finite Element Analysis (AFEA) methodology has been developed by the US NRC and the nuclear industry to evaluate the natural crack growth of primary water stress corrosion cracking (PWSCC) in nickel-based alloy materials. The AFEA methodology allows the progression of a planar crack subjected to typical SCC-type growth laws by calculating stress intensity factors at every nodal point along the crack front, and incrementally advancing the crack front in a more natural manner. This paper describes the enhancements that have been made to the existing AFEA methodology. The most significant enhancement was the feature to evaluate axial crack growth where the crack was contained within the susceptible material. In this paper, this methodology was validated by performing an AFEA evaluation for the axial crack that was found in the V.C. Summer hot leg dissimilar metal weld. Other enhancements to the AFEA methodology include; upgrade to the PipeFracCAE© software developed by Engineering Mechanics Corporation of Columbus, feature to handle non-idealized circumferential through-wall cracks, mapping of weld residual stress for crack growth, and determination of limiting crack size using elastic-plastic J-integral analysis that included secondary stress (weld residual stress and thermal transient stress) effects.

Residual stresses in a large circular disc caused by local heating and cooling at its centre

1971 ◽  
Vol 6 (2) ◽  
pp. 89-98 ◽  
Author(s):  
T R Gurney
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Temperature Distribution ◽  
Stress Distribution ◽  
Residual Stresses ◽  
Local Heating ◽  
Residual Stress Distribution ◽  
Element Analysis ◽  
Heating And Cooling

By means of a form of finite-element analysis and use of a theoretical, radially symmetrical, temperature distribution, the residual stresses resulting from spot heating at the centre of a large circular plate have been calculated. The investigation was concerned in particular with defining the effect of variations in material yield stress, rate of heat input, and peak temperature on the residual-stress distribution.

Estimation of Stress Corrosion Cracking Growth Behavior Under Weld Residual Stress in the Bottom of a Reactor Pressure Vessel by Finite Element Analysis

2015 ◽  
Vol 137 (4) ◽  
Author(s):  
Fuminori Iwamatsu ◽  
Katsumasa Miyazaki ◽  
Masahito Mochizuki
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Crack Growth ◽  
Pressure Vessel ◽  
Growth Behavior ◽  
Element Analysis ◽  
Weld Residual Stress ◽  
Code Procedure ◽  
Reactor Pressure

A method for evaluating crack growth by repeatedly modeling and analyzing the transitional crack shapes is developed for a general computing environment in which a commercial finite element preprocessor and analysis code are used. The proposed method calculates stress intensity factors (SIFs) by finite element analysis (FEA) by directly distributing estimated weld residual stress obtained from noncracked components on the crack surface on the basis of the superposition principle. In present case, to specify a nonuniform residual stress distribution, a subroutine for a commercial FEA code (ABAQUS) was developed. Arbitrary crack shapes during the crack propagation were expressed by applying the submodeling technique which allowed arbitrary crack shapes to be meshed. The sequence of steps in the proposed method was designed to make it possible to consider complicated stress distributions, such as weld residual stress, and to express arbitrary crack shapes. The applicability of the proposed FEA based method was verified by comparing the result of a stress corrosion cracking (SCC) growth analysis results of a flat plate obtained with the proposed method and with the ASME code procedure. As an application example, the SCC growth behavior of a crack at the bottom of a nuclear reactor pressure vessel (RPV) involving a dissimilar metal weld and a unique geometry was evaluated by the proposed method. The evaluation results were compared with results obtained using a conventional method, i.e., the influence function method (IFM). Since both sets of results were in reasonable agreement, it was concluded that IFM can be applied to this case. Previously, it was difficult to assess the applicability of conventional methods, such as the code procedure and IFM, to a complicated problem because of the existence of complicated residual stress fields, dissimilar metals, and the complicated crack shapes involved. The proposed method using FEA allows the applicability of conventional methods to complicated crack growth evaluations to be assessed.

Evaluation of Compressive Strengths of HPS Plate Systems Stiffened with Trapezoidal Stiffeners

2013 ◽  
Vol 671-674 ◽  
pp. 1025-1028
Author(s):  
Dong Ku Shin ◽  
Kyungsik Kim
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
High Performance ◽  
Nonlinear Finite Element ◽  
Linear Strain ◽  
Element Analysis ◽  
Geometric Imperfections ◽  
Eurocode 3 ◽  
Initial Geometric Imperfections ◽  
Plate System

The ultimate compressive strengths of high performance steel (HPS) plate system stiffened longitudinally by closed stiffeners have been investigated by the nonlinear finite element analysis. Both conventional and high performance steels were considered in models following multi-linear strain hardening constitutive relationships. Initial geometric imperfections and residual stresses were also incorporated in the analysis. Numerical results have been compared to compressive strengths from Eurocode 3 EN 1993-1-5 and FHWA-TS-80-205. It has been found that although use of Eurocode 3 EN 1993-1-5 and FHWA-TS-80-205 may lead to highly conservative design strengths when very large column slenderness parameters are encountered

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