Specimen Curvature and Size Effects on Crack Growth Resistance From Compact Tension Specimens of CANDU Pressure Tubes

2019 ◽  
Author(s):  
Bruce W. Williams ◽  
William R. Tyson ◽  
C. Hari M. Simha ◽  
Bogdan Wasiluk
Keyword(s):  
Fracture Toughness ◽  
Crack Growth ◽  
Crack Extension ◽  
Compact Tension ◽  
Crack Growth Resistance ◽  
Pressure Tube ◽  
Small Scale ◽  
J Integral ◽  
Tube Material ◽  
Pressure Tubes

Abstract CSA Standard N285.8 requires leak-before-break and fracture protection for Zr-2.5Nb pressure tubes in operating CANDU reactors. In-service deuterium uptake causes the formation of hydrides, which can result in additional variability and reduction of fracture toughness. Pressure tube fracture toughness is assessed mainly through rising pressure tube section burst tests. Given the length of the ex-service pressure tubes required for burst testing and the requirement to increase the hydrogen content of irradiated ex-service pressure tubes, only a limited number of burst tests can be performed. Using small-scale compact tension, C(T), specimens are advantageous for obtaining a statistically significant number of fracture toughness measurements while using less ex-service pressure tube material. This work focuses on the study of C(T) geometry designs in order to obtain crack growth resistance and fracture toughness closer to those deduced from burst tests. Because C(T) specimens must be machined from pressure tubes of about 100 mm in diameter and 4 mm in wall thickness, they are out-of-plane curved. As well, they undergo significant tunnelling during crack extension. These two factors can result in a violation of the ASTM standard for fracture toughness testing. The current work examined the influence of specimen curvature and tunnelled crack front on the crack growth resistance curve, or J-R curve. Finite element (FE) models using stationary and growing cracks were used in a detailed numerical investigation. To capture crack tunnelling in the FE models, a damage mechanics approach was adopted, with the critical strain to accumulate damage being a function of crack front stress triaxiality. The J-integral numerically estimated from the domain integral approach was compared to the J-integral calculated from the analytical equations in the ASTM E-1820 standard. In most cases, the difference between the numerical and the standard estimations was less than 10%, which was considered acceptable. It was found that at higher load levels of load-line-displacement, specimen curvature influenced the J-integral results. Crack tunnelling was shown to have a small influence on the estimated J-integrals, in comparison with the straight crack fronts. A modest number of experiments were carried out on unirradiated Zr-2.5Nb pressure tube material using three designs of curved C(T) specimens. It was found that the specimens of both designs that featured a width of 34 mm had more than twice the crack extension of the specimens of the 17-mm width design. The 17-mm width specimens are used mainly to assess the small-scale fracture toughness of pressure tube material. Additionally, the applied J-integral at the maximum load was about 1.4 times higher for the larger-width C(T) specimens. These C(T) specimens also produced J-R curves with greater crack extensions, which were closer to those obtained from the pressure tube section burst tests. Artificially hydrided pressure tube material was not considered in the current work, to avoid any potential source of experimental variability; however, it should be considered in future work.

Ductile Crack Growth Resistance and Rotation Behavior of Miniature C(T) Specimen

2020 ◽  
Author(s):  
Tomoki Shinko ◽  
Masato Yamamoto
Keyword(s):  
Fracture Toughness ◽  
Size Effect ◽  
Crack Growth ◽  
Crack Extension ◽  
Crack Tip ◽  
Crack Growth Resistance ◽  
Specimen Size ◽  
Ductile Crack ◽  
Rotation Center ◽  
Ductile Crack Growth

Abstract A utilization of a miniature compact tension (Mini-C(T)) specimen is expected to enable effective use of limited remaining surveillance specimens for the structural integrity assessment of a Reactor Pressure Vessel (RPV). For developing a direct fracture toughness evaluation method using Mini-C(T) specimen in the upper-shelf temperature range as well as ductile-brittle transition temperature range, this study is aimed to experimentally characterize the Mini-C(T) specimen’s size effect on ductile crack growth resistance and interpolate its mechanism. Mini-C(T) specimen and 0.5T-C(T) specimen were prepared from a Japanese RPV steel SQV2A, and the ductile crack growth tests were conducted on them at room temperature. As a result, the crack growth resistance of Mini-C(T) and 0.5T-C(T) specimens are comparable if the crack extension Δa is less than 0.5 mm. On the other hand, if Δa exceeds 0.5 mm, the crack growth resistance of Mini-C(T) specimen becomes lower than that of 0.5T-C(T) specimen. The measurements of stretch zone width and depth support the fact that the fracture toughness for ductile crack initiation of Mini-C(T) specimen is lower than that of 0.5T-C(T) specimen. From the rotational (crack mouth opening) deformation of Mini-C(T) specimen was measured by simultaneously measuring load-line and front face displacements. The distance between the crack tip and the rotation center of Mini-C(T) specimen is smaller than that of 0.5T-C(T) specimen during the test. Furthermore, The plastic zone in front of the crack tip reaches the rotation center up to the crack extension of Δa = 0.3 mm on Mini-C(T) specimen, indicating that the mechanism of the specimen size effect of Mini-C(T) specimen is likely a plastic constraint due to the influence of the rotation center locating near the crack tip. This suggests that the specimen size effect of Mini-C(T) specimen on ductile crack growth resistance is expected to be corrected by considering an effect of the plastic constraint.

Comparison of J-Integral Values and J-R Curves Between Carbon Steel Compact Tension Specimen and Pipe Specimen

2004 ◽  
Author(s):  
Masahiro Takanashi ◽  
Satoshi Izumi ◽  
Shinsuke Sakai ◽  
Naoki Miura
Keyword(s):  
Fracture Toughness ◽  
Carbon Steel ◽  
Crack Initiation ◽  
Compact Tension ◽  
Compact Tension Specimen ◽  
Small Scale ◽  
Outer Diameter ◽  
J Integral ◽  
Tension Specimen ◽  
Elastic Plastic

In the present study, the transferability of elastic-plastic fracture toughness from a small-scale to a large-scale specimen was experimentally confirmed for carbon steel pipe with mild toughness. Fracture toughness tests were carried out on a pipe specimen 318.5 mm in outer diameter, 10.3 mm in thickness and having a through-wall crack, and also on a compact tension specimen 9.7mm in thickness, 25.4 mm in width, that had been cut out from the pipe specimen. Test results indicated the J-integral value of the pipe specimen at the crack initiation to be nearly twice that of the CT specimen. Finite element analysis conducted on the two specimens indicated this difference to arise primarily from the constraint near the crack front. Discussion was also made of the effects of crack orientation on elastic-plastic fracture toughness of CT specimens. The J-integral value at crack initiation in the specimen whose crack direction coincided with the pipe axial was found to be almost 54 % more than for specimens whose crack direction was circumferential.

Effects of Hydride Morphology and Test Temperature on Fracture Toughness of Zr-2.5Nb Pressure Tube Material

2009 ◽  
Author(s):  
Jun Cui ◽  
Gordon K. Shek
Keyword(s):  
Fracture Toughness ◽  
Test Temperature ◽  
Fracture Behavior ◽  
Room Temperature ◽  
Fracture Initiation ◽  
Compact Tension ◽  
Pressure Tube ◽  
Primary Coolant ◽  
Tube Section ◽  
Pressure Tubes

CANDU® reactor uses Zr-2.5Nb alloy pressure tubes as the primary coolant containment. Fracture toughness properties of the pressure tubes are required for evaluation of fracture initiation and leak-before-break. This paper presents an experimental study on the effects of hydride morphology and test temperature on axial fracture toughness of a cold-worked, unirradiated Zr-2.5Nb pressure tube. Compact tension specimens were prepared from one tube section which contained as-received hydrogen concentration and another section which was electrolytically hydrided to 70 ppm hydrogen. Reoriented hydrides were formed in the hydrided tube section in ten thermal cycles under an applied tensile hoop stress of 160 MPa. The hydride morphologies were characterized by a parameter referred to as the hydride continuity coefficient (HCC), which provided a measure of the extent to which the hydrides were reoriented with respect to the applied stress direction. Partially reoriented hydrides with HCC between 0.3–0.4 were formed under the stress and temperature cycles used to precipitate the hydrides. J-R curves were generated to characterize the fracture behavior of the specimens tested at five different temperatures: 25°C (room temperature), 100°C, 150°C, 200°C and 250°C. Test results indicate that, for the as-received specimens, the fracture toughness is relatively high at room temperature and not significantly affected by the test temperature between room temperature and 250°C. For the 70 ppm hydrided specimens containing partially reoriented hydrides, the fracture toughness is significantly lower than that of the as-received specimens at room temperature. At 100°C, the fracture toughness is higher than that at room temperature but the average value is still lower than that of the as-received specimens. The specimens exhibit either brittle or ductile fracture behavior with a sharp transition to an upper-shelf toughness value. At 150°C, the specimens achieve an upper-shelf toughness level. Between 150°C and 250°C, the fracture toughness is similar to that of the as-received specimens and not affected by the reoriented hydrides.

Fracture Protection of CANDU Zr-2.5Nb Pressure Tubes With High Hydrogen Equivalent Concentration

2015 ◽  
Author(s):  
Preeti Doddihal ◽  
Douglas Scarth ◽  
Paula Mosbrucker ◽  
Steven Xu
Keyword(s):  
Fracture Toughness ◽  
Heavy Water ◽  
Pressure Tube ◽  
Normal Operation ◽  
Tube Material ◽  
High Hydrogen ◽  
Equivalent Concentration ◽  
Corrosion Reaction ◽  
Pressure Tubes ◽  
Heavy Water Reactor

The core of a CANDU®1 (CANada Deuterium Uranium) pressurized heavy water reactor includes horizontal Zr-2.5Nb alloy pressure tubes that contain the fuel. Pressure-temperature limits are used in CANDU® reactors for normal operation heat-up and cool-down conditions to maintain margins against fracture. The pressure-temperature limits are determined by postulating a 20 mm long axial through-wall crack in the pressure tube and using a fracture toughness-based calculation procedure. Due to a corrosion reaction with the heavy water coolant, pressure tubes absorb deuterium isotope in service, resulting in an increase in hydrogen equivalent concentration. Experiments have shown that high hydrogen equivalent concentration reduces the fracture toughness of pressure tube material at low temperatures during reactor heat-up and cool-down from normal operating temperatures. New fracture toughness curves that are applicable to material with high hydrogen equivalent concentration have been developed to address this issue. These curves are being used to develop new pressure-temperature limits for fracture protection of CANDU® pressure tubes. The methodology for deriving the pressure-temperature limits for a CANDU® Zr-2.5Nb pressure tube using the new fracture toughness curves is presented in this paper. Preliminary results of pressure-temperature limits for a CANDU® reactor are also provided.

A Numerical Study on Fracture Toughness of CANDU Pressure Tube

2017 ◽  
Author(s):  
Elisabeth Keim ◽  
Tomas Nicak ◽  
Bogdan Wasiluk
Keyword(s):  
Fracture Toughness ◽  
Fracture Behavior ◽  
Numerical Study ◽  
Compact Tension ◽  
Operating Conditions ◽  
Pressure Tube ◽  
Crack Tip Opening Displacement ◽  
Opening Displacement ◽  
Two Phase ◽  
Pressure Tubes

CANDU pressure tubes carry nuclear fuel and belong to the primary heat transport system. They are fabricated from cold-worked Zr-2.5Nb alloy prone to deuterium ingress under normal operating conditions. Increased hydrogen equivalent concentration and reactor pressure-temperature transients result in development of a brittle phase, hydride, changing mechanical behavior. The hydride downgrades fracture toughness properties in the transition region and reduces material ductility. Canadian Nuclear Safety Commission founded a two-phase project to improve understanding of the parameters governing fracture toughness properties and load carrying capacity of Zr-2.5Nb pressure tubes with elevated hydrogen equivalent concentrations. This paper presents preliminary results obtained in the first phase. The fracture behavior of a curved compact tension specimen (CCTS) and a pressure tube burst specimen (PT) with axial through-wall crack used in destructive burst test were studied in details. The intention was to identify any differences between fracture behavior of the CCTS and the PT potentially affecting fracture toughness estimates. The stress and deformation states ahead of the crack front, calculated fracture toughness parameters including J-integral and crack tip opening displacement (CTOD), as well as fracture constraint by means of elastic T-stress have been discussed.

Application of the R-Curve Concept to Fatigue Crack Growth

1978 ◽  
Vol 100 (4) ◽  
pp. 416-420 ◽  
Author(s):  
D. P. Wilhem ◽  
M. M. Ratwani
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Crack Extension ◽  
Stress Ratio ◽  
Cyclic Stress ◽  
Crack Growth Resistance ◽  
Resistance Curve ◽  
Cyclic Stress Ratio ◽  
Wide Range

Crack growth resistance for both static (rising load) and for cyclic fatigue crack growth has been shown to be a continuous function over a range of 0.1 μm to 10 cm in crack extension for 2024-T3 aluminum. Crack growth resistance to each fatigue cycle of crack extension is shown to approach the materials ordinary undirectional static crack resistance value when the cyclic stress ratio is zero. The fatigue crack extension is averaged over many cycles and is correlated with the maximum value of the crack tip stress intensity, Kmax. A linear plot of crack growth resistance for fatigue and static loading data shows similar effects of thickness, stress ratio, and other parameters. The effect of cyclic stress ratio on crack growth resistance for 2219 aluminum indicates the magnitude of differences in resistance when plotted to a linear scale. Prediction of many of these trends is possible using one of several available crack growth data correlating techniques. It appears that a unique resistance curve, dependent on material, crack orientation, thickness, and stress/physical environment, can be developed for crack extensions as small as 0.076 μm (3 μ inches). This wide range, crack growth resistance curve is seen of immense potential for use in both fatigue and fracture studies.

The Fracture Toughness of Hardened Tool Steels

1987 ◽  
Vol 109 (4) ◽  
pp. 314-318 ◽  
Author(s):  
D. F. Watt ◽  
Pamela Nadin ◽  
S. B. Biner
Keyword(s):  
Fracture Toughness ◽  
Crack Growth ◽  
Slow Crack Growth ◽  
Crack Opening ◽  
Compact Tension ◽  
Testing Procedure ◽  
Tool Steels ◽  
Opening Displacement ◽  
Tempering Temperature ◽  
Toughness Testing

This report details the development of a three-stage fracture toughness testing procedure used to study the effect of tempering temperature on toughness in 01 tool steel. Modified compact tension specimens were used in which the fatigue precracking stage in the ASTM E-399 Procedure was replaced by stable precracking, followed by a slow crack growth. The specimen geometry has been designed to provide a region where slow crack growth can be achieved in brittle materials. Three parameters, load, crack opening displacement, and time have been monitored during the testing procedure and a combination of heat tinting and a compliance equation have been used to identify the position of the crack front. Significant KIC results have been obtained using a modified ASTM fracture toughness equation. An inverse relationship between KIC and hardness has been measured.

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