Probeless Tool Aided Friction Stir Welding as a Fabrication Technique for Tungsten Embedded Mechanical Composite of Copper

Friction stir welding (FSW) is a relatively new solid state metallurgical joining technique. It flourishes on the simple principle of utilising frictional heat by the stirring motion of a non-consumable rotating tool to create the seam. Feasibility of FSW aided by a newly designed probeless tool was investigated for fabricating copper-tungsten mechanical composite. The most effective parameter combination was determined by conducting a parametric study of the probeless tool aided FSW copper. Strength of the mechanical composite fabricated at this condition was evaluated through punch shear testing. Punch shear testing established that the friction stir welded interface of the copper-tungsten composite was 87% as strong as the base metal (i.e. copper). Advantages of the designed technique have been summarised.

Understanding Welding Cost: Using Flux-Cored Arc Welding (FCAW) for Cost Reduction and Productivity Improvement

Welding is often listed as a production operation that companies would like to reduce overall cost and improve productivity; however, most companies merely implement cost reduction programs focused on lowering welding consumable costs. Though significant and important, these associated material costs typically represent only a small percentage to the total cost, i.e., 10 to 20% (welding consumables 8 to 15% and power and equipment 2 to 5%) of the overall welding cost in a typical U.S. welding operation. To further reduce welding costs, companies need to look further. Since labor and overhead, which relates directly to productivity, represents approximately 80 to 85% of the overall cost of any given welding operation they also offer the greatest opportunities for significant cost reduction. Simply changing from Shielded Metal-Arc Welding (SMAW) to Flux-Cored Arc Welding (FCAW) can reduce labor cost and increase productivity. Due to the increased deposition efficiency and operating factor of FCAW the weld deposition rate increases thus translating into increased productivity. The increase in productivity, in turn, reduces labor cost by reducing the man-hours required for the completion of any given weld. An added benefit gained by using FCAW is that it also significantly reduces the skill level required by the welder to produce welds of equal quality. When all of these benefits are combined FCAW yields significant cost savings opportunities by reducing labor and simultaneously improving productivity.

A Weibull Stress Approach Incorporating the Coupling Effect of Constraint and Plastic Strain in Cleavage Fracture Toughness Predictions

This work describes a micromechanics methodology based upon a local failure criterion incorporating the strong effects of plastic strain on cleavage fracture coupled with statistics of microcracks. A central objective is to gain some understanding on the role of plastic strain on cleavage fracture by means of a probabilistic fracture parameter and how it contributes to the cleavage failure probability. A parameter analysis is conducted to assess the general effects of plastic strain on fracture toughness correlations for conventional SE(B) specimens with varying crack size over specimen width ratios. Another objetive is to evaluate the effectiveness of the modified Weibull stress (σ̃w) model to correct effects of constraint loss in PCVN specimens which serve to determine the indexing temperature, T0, based on the Master Curve methodology. Fracture toughness testing conducted on an A285 Grade C pressure vessel steel provides the cleavage fracture resistance (Jc) data needed to estimate T0. Very detailed non-linear finite element analyses for 3-D models of plane-sided SE(B) and PCVN specimens provide the evolution of near-tip stress field with increased macroscopic load (in terms of the J-integral) to define the relationship between σ̃w and J. For the tested material, the Weibull stress methodology yields estimates for the reference temperature, T0, from small fracture specimens which are in good agreement with the corresponding estimates derived from testing of much larger crack configurations.

Critical Flaw Size Evaluation in Butt-Fusion Joints of HDPE Pipes

The integrity of high density polyethylene (HDPE) piping and fusion joints are a topic of interest to the nuclear industry, regulators, ASME code, and the plastics pipe industry. The ASME Code Case N-755-1 has been approved and addresses the use of HDPE in safety related applications. Over the last few years some of the concerns identified with the parent HDPE pipe material and the fusion joints have been addressed while others are still being resolved. One such unresolved concern is the effect of the fusion process on the integrity of the joint, specifically, the introduction of flaws during the fusion process. The potential impact of flaws in the fusion joint on the service life of the HDPE piping is being evaluated. The current study calculates stress intensity factors (SIF) for circumferential flaws and uses them to evaluate the potential structural integrity of HDPE fusion joints in pipes. The recent API 579-1/ASME FFS-1 standard provides SIF (KI) solutions to various semi-elliptical and full-circumferential (360°) surface cracks/flaws on the outer surface (OD) and the inner surface (ID). The API 579-1/ASME FFS-1 standard SIF tables and finite element analysis (FEA) of selected cases were used to develop simplified SIF relations for full-circumferential surface flaws that can be used for plastic pipes with diameters ranging from 101.6 mm (4 inch) through 914.4 mm (36 inch) and dimensional ratios (DRs) from 7 through 13. Further, the SIF of embedded flaws akin to lack-of-fusion regions was evaluated. The results from this study serve as precursors to understanding and advancing experimental methods to address important issues related to the critical tolerable flaw size in the butt-fusion joint material and were utilized to select the specimen tests and hydrostatic pipe tests used to evaluate various joining processes. Further, they will help with understanding the essential variables that control the long-term component integrity and structural performance of HDPE pipe joints in ASME Class 3 nuclear piping.

Validation Approaches for Weld Residual Stress Simulation

In assessment of stress corrosion cracking behavior of susceptible welded materials, the contribution of weld residual stress is a key input for stress intensity factor calculations, which in turn are used to determine anticipated crack growth and to plan for inspection or repair. Without accurate weld residual stress information, it is challenging to develop an optimal plan for plant management. Weld residual stress simulations, based on non-linear finite element computations, provide a means to estimate residual stresses in components. However, there is no established, consensus approach for weld residual stress model validation, which could be used to judge model quality, specifically with respect to the influence of residual stress output on plant management decisions. A consensus model validation approach would benefit a broad range of stakeholders in pressure vessel technology. The paper provides technical detail of example approaches for weld residual stress model validation, and applies these approaches to a set of weld residual stress model outputs that were developed in the context of an industry round robin. The set of outputs is from Phase 2a of the international round robin organized cooperatively by the U.S. Nuclear Regulatory Commission and the Electric Power Research Institute. Example validation approaches include comparisons of output from one model with output from other models, as well as comparisons of model output with data from residual stress measurements. The figures of merit used for comparisons range from simple (e.g., evaluation of mechanical section forces) to complex (e.g., comparison of predicted crack growth behavior). Applying a range of validation approaches provides information for use within the technical community, to support development of a consensus approach for weld residual stress model validation.

Process Optimization of Ultrasonic Shot Peening by Realistic Modeling of Beads Motion

In the nuclear industry surface mechanical treatments are used in order to improve the surface integrity of the component, which increases their lifetime regarding corrosion and fatigue damages. A good understanding of these processes and their consequences is required to ensure the efficiency and perpetuity of such mitigation treatment. This study focuses on the ultrasonic shot peening process. It consists in shooting at high speed small steel beads on the part to be treated by using a high frequency vibration device. Parameters such as the number and the size of beads, the input frequency and the dimensions of the chamber can induce large ranges of impact velocity and coverage. In order to help manufacturers to control the treatment applied on their components, a numerical model has been developed. It accounts for the shocks of the beads against the walls of the chamber, the peening head and between beads, describing their motions accurately. In this paper, we will introduce the numerical model developed to simulate the motions of beads in the peening chamber. Special attention will be taken to the determination of the restitution rates related to the different materials. Results of the model will be shown for different process parameter (e.g. the number of beads), and a thorough analysis of their effects on the workpiece will be presented, including a comparison with some experimental results.

Micromechanisms of Hydrogen-Assisted Cracking in Super Duplex Stainless Steel Investigated by Scanning Probe Microscopy

Understanding the micromechanisms of hydrogen-assisted fracture in multiphase metals is of great scientific and engineering importance. By using a combination of scanning electron microscopy (SEM), scanning tunneling microscopy (STM), atomic force microscopy (AFM) and magnetic force microscopy (MFM), the micromorphology of fracture surface and microcrack formation in hydrogen-precharged super duplex stainless steel 2507 are characterized from microscale to nanoscale. The results reveal that the fracture surfaces consist of quasi-brittle facets with riverlike patterns at the microscale, which exhibit rough irregular patterns or remarkable quasi-periodic corrugation patterns at the nanoscale that can be correlated with highly localized plastic deformation. The microcracks preferentially initiate and propagate in ferrite phase and are stopped or deflected by the boundaries of the austenite phase. The hydrogen-assisted cracking mechanisms in super duplex stainless steel are discussed according to the experimental results and hydrogen-enhanced localized plasticity theory.

3D Simulation of a Peripheral Adapter J-Groove Attachment Weld in a Vessel Head

In Pressurized Water Reactors, most of heavy components and pipes have a large thickness and their manufacturing processes often require multi-pass welding. Despite the stiffness of these components, the distortion issue may be important for operational requirements (e.g. misalignment) or controllability reasons (Non Destructive Examinations have to be achievable, therefore ovalization should be limited). These requirements may be difficult to achieve by simply adjusting welding processes. Indeed because of the complexity of mechanisms involved during a welding operation and the high number of influencing parameters, this process is still essentially based on the experience of the welder. Furthermore the experimental estimation of the stress and distortion level in the component remains a difficult task that is subject to errors even if techniques are currently improved to become more accurate. These are the reasons why AREVA has put a large effort to improve welding numerical simulations, in order to have a better understanding of the involved physical phenomena and also to predict the residual state through the structure. Computational welding mechanics is used to qualify the manufacturing processes in the very early phase of the welded component design. Within the framework of a R&D program whose main objective was to improve tools for the numerical simulation of welding regarding industrial needs, AREVA has decided to validate new methodologies based on 3D computation by comparison with measurements. For this validation task the chosen industrial demonstrator was a Control Rod Drive Mechanism (CRDM) Nozzle with a J-groove attachment weld to the vessel head. For such an application, operations of post-joining straightening have to be limited, if not prohibited, because of their cost or the impossibility to use them in front of a steel giant. The control of distortion during welding operations is a key issue for which simulation can be of great help. Regarding distortion issues, both accurate metal deposit sequence modeling and respect of the real welding parameters are mandatory, especially for multi-pass operation on such a complex geometry. The aim of this paper is to present the simulation of the distortion of a peripheral adapter J-groove attachment weld mock-up. This new full 3D simulation improves the result of the previous one based on lumped pass deposits. It is the result of a fruitful collaboration between AREVA and ESI-Group.

A Parametric Study of Rm/T and Weld Repair Effects on Through-Wall Axial and Hoop WRS Distributions in BWR Nozzle Dissimilar Metal Welds

Weld residual stress (WRS) distributions are an important input into fracture mechanics evaluations necessary to determine the residual lives of dissimilar metal welds (DMWs). Since the DMW geometry and the presence or absence, size, and location of weld repairs is nozzle specific, finite element WRS analysis is often used to predict through-wall weld residual stress distributions. It is important to note that despite small differences in plant specific geometry or weld location specific weld repair geometry there are substantial similarities between the configurations that have been evaluated in the numerous weld specific finite element WRS analyses documented in the literature. Important insight can be gained from parametric studies of simplified geometries in order to understand the significance of different parameters on the resulting WRS distributions. The results of such studies can allow engineers to focus resources on refining accuracy of critical inputs and to support simplified model development suitable for incorporation into design and fitness for service codes. This paper documents the results of various studies performed to validate the ability to use a simplified pipe-to-pipe model for simulating relative effects on through-wall WRS distributions of pipe and weld repair geometry, investigate the effect of pipe mean radius to wall thickness ratio, weld repair depth (ID and OD), and weld repair sequence. Fifteen cases are analyzed. The dimensions selected for each case span a range of wall thickness, Rm/t and depth of repair values representative of typical Boiling Water Reactor (BWR) nozzle DMWs. The results are used as input into a simplified WRS model presented in a separate paper [17].

Evaluation of Strength Design Criteria and Plastic Flow Criteria for Pressure Vessels

The present paper evaluates the traditional strength design criteria and recently developed plastic flow criteria used in the structural design and integrity assessment for pressure vessels. This includes (1) a brief review of the traditional strength criteria used in ASME Boiler and Pressure Vessel (B&PV) Code, (2) a discussion of the shortcoming of existing strength criteria when used to predict the burst pressure of pressure vessels, (3) an analysis of challenges, technical gaps and basic needs to improve the traditional strength design criteria, (4) a comparison of strength theory and flow theory for ductile pressure vessels, (5) an evaluation of available flow criteria and their shortcoming in prediction of failure pressure of pressure vessels, (6) an introduction of newly developed multi-axial flow criterion and its application to pressure vessels, and (7) a demonstration of experimental validations of the new flow criterion when used to predict the burst pressure of pressure vessels. On this basis, several recommendations are made for further study to improve the existing strength design and integrity assessment methods of pressure vessels.