Comparison of Experimental and Numerical Analysis Data for BMI Mock-Up With Dissimilar Metal Welds

Author(s):  
Seung-Cheon Yu ◽  
Yoon-Suk Chang ◽  
Young-Jin Kim ◽  
Sung-Woo Kim ◽  
Seong-Sik Hwang ◽  
...  

During the last decade, several defects due to primary water stress corrosion cracking (PWSCC) have been reported at bottom-mounted instrumentation (BMI) and control rod drive mechanism nozzles. The exact locations were dissimilar metal weld parts which are greatly important because the cracking could lead to leakage of primary coolant. The PWSCC of BMI mock-up’s penetration with dissimilar metal welds was examined by using doped steam test method by Korea Atomic Energy Research Institute. In this work, numerical analyses are performed for the same environment condition with the doped steam test. With respect to the numerical analyses, heat transfer analyses are carried out based on thermal conduction. The welding paths are simulated by using lumped path method for conservative evaluation and model change (remove/rebirth) method. Then residual stress analyses are conducted using the heat transfer analysis results, in which annealing effect of welding process simulation is considered for resetting the plastic deformation. However, the plastic behaviour of steels during phase transformations is not considered with experimental data. In addition, the consequence of weld residual stress that is known as the cause of PWSCC is being investigated.

Author(s):  
A. N. Gershuni ◽  
A. P. Nishchik ◽  
V. G. Razumovskiy ◽  
I. L. Pioro

Experimental research of natural convection and the ways of its suppression in an annular vertical channel to simulate the conditions of cooling the control rod drivers of the reactor protection system (RPS) in its so-called wet design, where the drivers are cooled by primary circuit water supplied due to the system that includes branched pipelines, valves, pump, heat exchanger, etc., is reported. Reliability of the drivers depends upon their temperature ensured by operation of an active multi-element cooling system. Its replacement by an available passive cooling system is possible only under significant suppression of natural convection in control rod channel filled with primary coolant. The methods of suppression of natural convection proposed in the work have demonstrated the possibility both of minimization of axial heat transfer and of almost complete elimination of temperature non-uniformity and oscillation inside the channel under the conditions of free travel of moving element (control rod) in it. The obtained results widen the possibilities of substitution of the active systems of cooling the RPS drivers by reliable passive systems, such as high-performance heat-transfer systems of evaporation-condensation type with heat pipes or two-phase thermosyphons as heat-transferring elements.


2013 ◽  
Vol 284-287 ◽  
pp. 915-918
Author(s):  
Tsung Pin Hung ◽  
Chao Ming Hsu ◽  
Ah Der Lin ◽  
Jao Hwa Kuang

The weld bead temperature distribution and shape during pulsed Nd:YAG laser lap welding are studied. A volumetric heat source model is derived to include the surface flux and the keyhole heat transfer effects in the pulsed laser lap welding process. The proposed pulsed laser heat transfer mode is employed in a simulation with the commercial finite element software Marc. The numerically computed results of the weld pool dimensions are compared with the experimental results. The comparison shows a good agreement between the simulated and measurement results, indicating that the proposed model is feasible. The results reveal that the pulse duration and spot pitch have considerable influence on the temperature field distribution and the residual stress distribution.


Author(s):  
Yu-Ping Yang ◽  
William C. Mohr

A catastrophic furnace roll failure was observed in a continuous hot dip line. The failure occurred in the weld joining an end bell to a roll shell and resulted in the complete separation of the end bell from the roll shell. The roll had been in service for approximately 7 months before failure. Typically, rolls in this furnace roll position have a short life, less than 1 year. The roll shell and the end bell were made of high-temperature alloy. The journal was made of stainless steel. Inconel welding electrode was used as the weld filler material. The roll shell and the end bells were shrink fitted before welding. The welding process was flux-cored arc welding (FCAW). Upon completion of welding post-weld heat treatment (PWHT) was applied for 3 hours at 1093°C to the entire roll. To extend the roll life, a new design and a new welding method, electron beam welding (EBW) without filler metal, were proposed. To evaluate the effectiveness of the new design and the new welding process, four kinds of numerical analyses were conducted on the new design for both FCAW and EBW which included a weld residual stress analysis, a PWHT analysis, a heat transfer analysis, and a creep-fatigue analysis. Analysis results showed that the new design with EBW has lower stress and creep strain than with FCAW, which could improve the roll creep-fatigue life.


Author(s):  
Satya S. Gajapathi ◽  
Sushanta K. Mitra ◽  
Patricio F. Mendez

The prospect of micro/nano technology requires the development of advanced production processes which joins them into complex systems to interact with the macro world. This has led to the evolution of micro welding. During the micro welding process, the flow of heat needs to be checked so that the essential mechanical and electrical properties of the material are not lost. Also, the amount of melting and excess evaporation has to be controlled. These can be attained by welding using localized heat sources. In the present work, electron beam micro welding process is studied and heat transfer analysis has been carried out numerically, to obtain the temperature distribution in the material. For a specified depth of melting, the effect of Peclet number on the welding process is investigated. The study shows that the high Peclet number electron beam micro welding process provides two important advantages — Control of the maximum temperature on the surface which prevents excess material loss, and limited heat transfer under the beam.


Author(s):  
Sang-Min Lee ◽  
Jeong-Soon Park ◽  
Young-Hwan Choi ◽  
Hae-Dong Chung ◽  
Doo-Ho Cho ◽  
...  

There are some ferritic low alloy steel components including dissimilar metal welding parts in a nuclear power plant. Residual stress induced by welding process is one of the factors that may lead a sound component to have a defect. Therefore it is necessary that the distribution of residual stress is obtained to predict the behavior of a dissimilar metal welding part. In this paper, the distribution of residual stress obtained by finite element analysis is investigated to assess the stress intensity factor of a corner crack in pressurizer vent nozzle penetration weld. Then the stress intensity factor and plastic zone correction of a corner crack are calculated under internal pressure, thermal stress and residual stress in accordance with Electric Power Research Institute equation [1]. The resulting stress intensity factor and plastic-zone correction were compared with those obtained from Structural Integrity Associates.


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