scholarly journals Prediction of Reheat Cracking Behavior in a Service Exposed 316H Steam Header

2020 ◽  
pp. 2050009
Author(s):  
Haoliang Zhou ◽  
Ali Mehmanparast ◽  
Kamran Nikbin
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Early Stage ◽  
Creep Crack Growth ◽  
Cracking Behavior ◽  
Displacement Boundary ◽  
Root Cause ◽  
Reheat Cracking ◽  
Weld Toe ◽  
Steam Header

Reheat cracking in an ex-service Type 316H stainless steel steam header component has been investigated in this study. The examined steam header was in service for 87,790[Formula: see text]h and the cracks in this component were found in the vicinity of the weld toe. The root cause of this type of failure was due to the welding residual stresses. The welding-induced residual stresses had been present in the header at the early stage of the operation and were released during service. In this paper, a novel technique has been proposed to simulate the residual stress distribution normal to the crack direction by applying remote fixed displacement boundary conditions in an axisymmetric model. This approach can simulate the presence of residual stresses in actual components without the need to develop full weld simulation to quantify them. The predicted residual stress levels and distributions normal to the crack direction have been found in good agreement with the measured residual stresses available in the literature for a similar header. The creep crack growth (CCG) rates have been characterized using the fracture mechanics [Formula: see text] parameter and estimated using predictive models.

Quantification of Residual Stresses Induced by Prior Loading at High Temperatures

2011 ◽  
Author(s):  
Ali N. Mehmanparast ◽  
Catrin M. Davies ◽  
Robert C. Wimpory ◽  
Kamran M. Nikbin
Keyword(s):  
Fracture Toughness ◽  
Residual Stress ◽  
Residual Stresses ◽  
Crack Growth ◽  
Creep Crack Growth ◽  
Crack Tip ◽  
Crack Plane ◽  
Residual Stress Field ◽  
Compression Direction ◽  
Fracture Specimen

High temperature components generally undergo cyclic loading conditions. Prior tensile/compressive loading of a fracture specimen can induce compressive/tensile residual stress fields at the crack tip. These residual stresses will influence the subsequent fracture behaviour of the cracked body. This work forms part of a project to examine the influence of creep induced damage at a crack tip on subsequent fatigue crack growth and fracture toughness properties of austenitic type 316H stainless steel. Creep damage is introduced local to the crack tip of a fracture specimen by interrupting a creep crack growth test, performed at 550 °C. Prior to testing, the material was pre-compressed in order to strain harden the material. The compact tension, C(T), specimen geometry has been considered in this work. Since residual stresses are known to influence fatigue and fracture toughness properties of a cracked body, it is important that the residual stress levels at the crack tip are quantified. Neutron diffraction (ND) measurements have therefore been performed to quantify the extent of residual stress in these samples after initial loading, and compared to finite element model predictions. Two specimens have been considered with the crack plane orientated in parallel and perpendicular to the pre-compression direction. Compressive residual stresses of around 100 MPa have been measured directly ahead of the crack tip. Reasonable predictions of the principal residual stress distributions have been obtained by the simplified FE analysis. Though the tensile properties differ significantly in for specimens orientated parallel and perpendicular to the pre-compression direction, no significant differences in the residual stress field are predicted in the C(T) specimens orientated in both directions.

Residual Stress and Strain Responses of Welded Piping Joints Under Low-Cycle Fatigue Loading

2009 ◽  
Author(s):  
Pei-Yuan Cheng ◽  
Tasnim Hassan
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Fatigue Failure ◽  
Welded Joints ◽  
Low Cycle Fatigue ◽  
Fatigue Cracks ◽  
Stress And Strain ◽  
Weld Toe ◽  
Strain Responses

It is well known that residual stress of welded joints influence their fatigue lives. This influence of residual stress is manifested through strain ratcheting response at the weld toe. Among many other reasons, strain ratcheting at the weld toe is anticipated to be a reason of many premature fatigue failure of welded joints. Hence, accurate simulations of weld toe residual stress and strain responses are essential for fatigue life simulation of welded joints. This paper presents results form an ongoing study on fatigue failure of welded piping joints. A modeling scheme for simulating weld toe residual stress and strain response is developed. Uncoupled, thermo-mechanical, finite element analyses are employed for imitating the welding procedure, and thereby simulating the temperature history during welding and initial residual stresses. Simulated residual stresses are validated by comparing against the measured residual stresses. Finite element simulations indicate that both residual stress and resulting strain responses near the weld toe are the key factors in inducing fatigue cracks at the weld toe. Research needs in revealing the fatigue failure mechanisms at the weld toe are discussed.

Finite Element Study of Residual Stresses in a plate T-Joint Fatigue Specimen

1990 ◽  
Vol 204 (2) ◽  
pp. 127-134 ◽  
Author(s):  
D H B Mok ◽  
R J Pick
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Applied Load ◽  
Small Region ◽  
Finite Element Code ◽  
Fatigue Specimen ◽  
Numerical Predictions ◽  
Weld Toe ◽  
Element Study

Using the finite element code ABAQUS to make numerical predictions, this paper studies the crack shape development and thickness effects on a series of welded plate T-joint fatigue specimens. It was found that redistribution of the residual stress only occurs in a small region near the weld toe, the extent depending greatly on the magnitude of the applied load.

Residual Stresses in CANDU Feeder Bends: Effect of Bend Radius

2006 ◽  
Author(s):  
M. Yetisir ◽  
R. Donaberger ◽  
R. Rogge
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Cold Work ◽  
Symmetry Plane ◽  
Large Radius ◽  
Bend Radius ◽  
Root Cause ◽  
Number Of Bends ◽  
Crack Susceptibility ◽  
Calculated Level

Since 1997, sections of nine feeder pipes have been removed at the Point Lepreau Generating Station (PLGS) because of cracking. All PLGS feeder cracks are axial in orientation and are located in the feeder bends. In all cases, cracks were either at the inside surface of the bend flanks (approximately 60° from the intrados symmetry plane) or at the outside surface of the bend extrados. Root cause analyses indicated that the residual stress has a significant role in these failures. In a typical feeder, there are a number of bends and welds, which are potential locations of high residual stresses. To reduce inspection scope, or to identify the highest risk components, a relative ranking of crack susceptibility is needed. This can be achieved using the residual stress data of these components. This paper compares the measured residual stress data in tight-radius and large-radius CANDU feeder bends. It was found that residual stresses are significantly higher for the bends with small bend radius (r) over diameter (D) ratios (for example, r/D = 1.5) as compared to those bends with large r/D ratios (r/D > 4). The differences in the magnitude of residual stress are consistent with the measured and calculated level of cold work in the two types of bends. It was concluded that the likelihood of cracking in large-radius bends is significantly smaller than that in tight-radius bends.

Fatigue Life Prediction of Ship Welded Materials

2005 ◽  
Vol 297-300 ◽  
pp. 743-749
Author(s):  
Min Koo Han ◽  
Mamidala Ramulu
Keyword(s):  
Residual Stress ◽  
Stress Intensity Factor ◽  
Stress Intensity ◽  
Intensity Factor ◽  
Residual Stresses ◽  
Crack Propagation ◽  
Crack Closure ◽  
Fatigue Cracks ◽  
Welding Process ◽  
Weld Toe

Fatigue crack propagation life of weld toe crack through residual stress field was estimated using Elber's crack closure concept. Propagation of weld toe crack is heavily influenced by residual stresses caused by the welding process, so it is essential to take into account the effect of residual stresses on the propagation life of a weld toe crack. Fatigue cracks at transverse and longitudinal weld toe was studied, these two cases represent the typical weld joints in ship structures. Numerical and experimental studies are performed for both cases. Residual stresses near the welding area were estimated through a nonlinear thermo-elasto-plastic finite element method and the residual stress intensity factor with Glinka's weight function method. Effective stress intensity factor was calculated using the Newman-Forman-de Koning-Henriksen equation, which is based on the Dugdale strip yield model in estimating the crack closure level, U, at different stress ratios. Calculated crack propagation life coincided well with experimental results.

Effect of Residual Stresses Caused by Thermal Treatment on Creep Crack Growth Rate in Aluminium Gas Cylinders

1998 ◽  
Author(s):  
Raafat Ibrahim ◽  
Dmitry Ischenko
Keyword(s):  
Residual Stress ◽  
Growth Rate ◽  
Residual Stresses ◽  
Crack Growth ◽  
Creep Crack Growth ◽  
Stress Distributions ◽  
Creep Crack ◽  
Quenching Process ◽  
Creep Crack Growth Rate ◽  
Gas Cylinders

Abstract Aluminum gas cylinders, which are in common use for various purposes, are susceptible to creep crack growth. Residual stresses introduced during the quenching process in aluminum gas cylinders contribute to the development of cracks. This may result in leakage or fracture of the cylinders. Finite element studies were conducted to evaluate the effect of the quenching process on through thickness inelastic strain and the residual stress distributions in the neck area of gas cylinders. Numerical modeling and experimental studies confirmed that a high level of tensile residual stresses exists on the inner surface of aluminum gas cylinders’ neck which is susceptible to cracking. The relationship between the amount of residual stresses and cooling conditions was established. The obtained residual stress distributions were included in the calculation of the creep crack growth rates. It was shown that residual stresses caused by manufacturing processes have a significant effect on the creep crack growth rate.

Measurements of Residual Stresses in 316 Stainless Steel Weldments

2010 ◽  
Author(s):  
C. M. Davies ◽  
D. Hughes ◽  
R. C. Wimpory ◽  
David W. Dean ◽  
K. M. Nikbin
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Crack Growth ◽  
Creep Crack Growth ◽  
Compact Tension ◽  
Compact Tension Specimen ◽  
Stress Distributions ◽  
Tension Specimen ◽  
Creep Crack ◽  
Term Creep

Neutron diffraction measurements have been performed to quantify the residual stresses distributions in austenitic type 316 stainless steel Manual Metal Arc (MMA) weldment sections, which are similar to those used in creep crack growth testing. Measurements have been taken along the expected crack path in these samples to determine the influence of residual stresses on high temperature crack growth. The influence of EB welding extension pieces onto the weldments sections, in order to increase specimen size, and sample cutting for compact tension specimen manufacture are also examined. Similar stress distributions have been measured in nominally identical MMA weldments sections, where peak stresses of up to 120 MPa have been shown. The effects of the EB weld used to attach extension pieces to the weldments sections dominate over the MMA weldments residual stress distributions in these samples, and increases the peak stresses by up to a factor of three. Significant stress relaxation takes place during compact tension specimen manufacture, and in addition creep strain accumulation will further relax these residual stresses. Residual stress effects are therefore considered to only influence the creep crack initiation period in short-term creep crack growth tests. However, in long-term creep crack growth tests, the residual stresses may also influence subsequent creep crack growth behaviour.

An Optimized Heat Treatment Process to Reduce the Weld Residual Stress by Auxiliary Heating

2019 ◽  
Author(s):  
Yun Luo ◽  
Teng Gao ◽  
Wenchun Jiang
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Residual Stresses ◽  
Axial Stress ◽  
Axial Direction ◽  
Auxiliary Heating ◽  
Weld Residual Stress ◽  
Before And After ◽  
Weld Toe ◽  
Stress And Deformation

Abstract Local post welding heat treatment (PWHT) is a popular method to reduce the residual stress of bigger weld structures. In this paper, the weld residual stresses before and after local PWHT were investigated. The results show that there are larger axial stresses concentration in weld toe and an inconsistent deformation along axial direction during heating stage which may leads to crack. The residual stresses in outer surface are decreased greatly after local PWHT. An optimized local PWHT with auxiliary heating (AH) temperature 800°C and width 800mm were proposed. The axial stress and deformation inconsistent in weld can be reduced by AH, thus leads to the reduction of crack risk in weld toe.

Neutron Diffraction Residual Stress Measurements in Electron Beam Welded Compact Tension Specimens

2014 ◽  
Vol 777 ◽  
pp. 99-104
Author(s):  
Priyesh Kapadia ◽  
Catrin M. Davies ◽  
Thilo Pirling ◽  
David W. Dean ◽  
Kamran M. Nikbin
Keyword(s):  
Residual Stress ◽  
Electron Beam ◽  
Neutron Diffraction ◽  
Residual Stresses ◽  
Crack Growth ◽  
Creep Crack Growth ◽  
Compact Tension ◽  
Diffraction Measurement ◽  
Machining Processes ◽  
Residual Stresses And Strains

In a study to investigate the effect of residual stress relaxation on Creep Crack Growth (CCG) a novel fracture mechanics specimen has been designed. Compact Tension, C(T), specimens are fabricated from blocks with Electron Beam (EB) welds such that residual stresses induced during welding are retained in the specimen. Finite element analyses of EB welding and machining processes have been developed to predict the stresses in such C(T) specimens which will drive crack growth in future CCG studies. The residual stresses and strains in these samples have been quantified using the neutron diffraction measurement technique at various stages of the fabrication process and have been used to validate numerical simulations of the fabrication processes.

Stability and Relaxation of Welding Residual Stresses

2011 ◽  
Vol 681 ◽  
pp. 55-60 ◽  
Author(s):  
Majid Farajian ◽  
Thomas Nitschke-Pagel ◽  
Klaus Dilger
Keyword(s):  
Residual Stress ◽  
Yield Strength ◽  
Residual Stresses ◽  
Low Cycle Fatigue ◽  
Weld Bead ◽  
Small Scale ◽  
Internal Stresses ◽  
Cycle Fatigue ◽  
Residual Stress Field ◽  
Weld Toe

Residual stress relaxation of butt-welded small scale steel specimens under static and cyclic mechanical loading was investigated. The experiments were carried out on different types of steel with yield strengths between 300 and 1200MPa. The x-ray and neutron diffraction techniques were applied for the residual stresses analysis. The maximum values of initial residual stresses were measured at the weld bead centerline and were not as frequently assumed as high as the yield strength of the material. From fatigue point of view the internal stresses at the weld toe are of importance. It was observed that only a fraction of maximum residual stress accommodated in the weld bead centerline, is available at the weld toe. Under static tensile and compressive loading by increasing the load level the residual stress field relaxes continuously. The relaxation sets in with delay under compression since the tensile residual stresses should be first overcome. Under cyclic loading, once the first relaxation takes place further cyclic relaxation is either not considerable or continues moderately depending on loading conditions. In high cycle fatigue the residual stresses are stable until 2x106 cycles. In low cycle fatigue however the variation of the residual stresses continues until failure. This variation is partly related to crack initiation and propagation. The von Misses failure criterion with the local yield strength as material resistance against plastic deformation was able to describe the relaxation of surface welding residual stresses in low cycle fatigue.

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