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Sample records for residual welding stresses

  1. Residual stress by repair welds

    International Nuclear Information System (INIS)

    Mochizuki, Masahito; Toyoda, Masao

    2003-01-01

    Residual stress by repair welds is computed using the thermal elastic-plastic analysis with phase-transformation effect. Coupling phenomena of temperature, microstructure, and stress-strain fields are simulated in the finite-element analysis. Weld bond of a plate butt-welded joint is gouged and then deposited by weld metal in repair process. Heat source is synchronously moved with the deposition of the finite-element as the weld deposition. Microstructure is considered by using CCT diagram and the transformation behavior in the repair weld is also simulated. The effects of initial stress, heat input, and weld length on residual stress distribution are studied from the organic results of numerical analysis. Initial residual stress before repair weld has no influence on the residual stress after repair treatment near weld metal, because the initial stress near weld metal releases due to high temperature of repair weld and then stress by repair weld regenerates. Heat input has an effect for residual stress distribution, for not its magnitude but distribution zone. Weld length should be considered reducing the magnitude of residual stress in the edge of weld bead; short bead induces high tensile residual stress. (author)

  2. Weld Residual Stress in Corner Boxing Joints

    OpenAIRE

    Kazuyoshi, Matsuoka; Tokuharu, Yoshii; Ship Research Institute, Ministry of Transport; Ship Research Institute, Ministry of Transport

    1998-01-01

    Fatigue damage often occurs in corner boxing welded joints because of stress concentration and residual stress. The hot spot stress approach is applicable to stress concentration. However, the number of suitable methods for estimating residual stress in welded joints is limited. The purpose of this paper is to clarify the residual stress in corner boxing joints. The method of estimating residual stresses based on the inherent stress technique is presented. Residual stress measurements are per...

  3. Residual stresses in zircaloy welds

    International Nuclear Information System (INIS)

    Santisteban, J. R.; Fernandez, L; Vizcaino, P.; Banchik, A.D.; Samper, R; Martinez, R. L; Almer, J; Motta, A.T.; Colas, K.B; Kerr, M.; Daymond, M.R

    2009-01-01

    Welds in Zirconium-based alloys are susceptible to hydrogen embrittlement, as H enters the material due to dissociation of water. The yield strain for hydride cracking has a complex dependence on H concentration, stress state and texture. The large thermal gradients produced by the applied heat; drastically changes the texture of the material in the heat affected zone, enhancing the susceptibility to delayed hydride cracking. Normally hydrides tend to form as platelets that are parallel to the normal direction, but when welding plates, hydride platelets may form on cooling with their planes parallel to the weld and through the thickness of the plates. If, in addition to this there are significant tensile stresses, the susceptibility of the heat affected zone to delayed hydride cracking will be increased. Here we have measured the macroscopic and microscopic residual stressed that appear after PLASMA welding of two 6mm thick Zircaloy-4 plates. The measurements were based on neutron and synchrotron diffraction experiments performed at the Isis Facility, UK, and at Advanced Photon Source, USA, respectively. The experiments allowed assessing the effect of a post-weld heat treatment consisting of a steady increase in temperature from room temperature to 450oC over a period of 4.5 hours; followed by cooling with an equivalent cooling rate. Peak tensile stresses of (175± 10) MPa along the longitudinal direction were found in the as-welded specimen, which were moderately reduced to (150±10) MPa after the heat-treatment. The parent material showed intergranular stresses of (56±4) MPa, which disappeared on entering the heat-affected zone. In-situ experiments during themal cyclong of the material showed that these intergranular stresses result from the anisotropy of the thermal expansion coefficient of the hexagonal crystal lattice. [es

  4. Validation of welded joint residual stress simulation

    International Nuclear Information System (INIS)

    Computational mechanics is being increasingly applied to predict the state of residual stress in welded joints for nuclear power plant applications. Motives for undertaking such calculations include optimising the design of welded joints and weld procedures, assessing the effectiveness of mitigation processes, providing more realistic inputs to structural integrity assessments and underwriting safety cases for operating nuclear power plant. Fusion welding processes involve intense localised heating to melt the surfaces to be joined and introduction of molten weld filler metal. A complex residual stress field develops at the weld through solidification, differential thermal contraction, cyclic thermal plasticity, phase transformation and chemical diffusion processes. The calculation of weld residual stress involves detailed non-linear analyses where many assumptions and approximations have to be made. In consequence, the accuracy and reliability of solutions can be highly variable. This paper illustrates the degree of variability that can arise in weld residual stress simulation results and summarises the new R6 guidelines which aim to improve the reliability and accuracy of computational predictions. The requirements for validating weld simulations are reviewed where residual stresses are to be used in fracture mechanics analysis. This includes a discussion of how to obtain and interpret measurements from mock-ups, benchmark weldments and published data. Benchmark weldments are described that illustrate some of the issues and show how validation of numerical prediction of weld residual stress can be achieved. Finally, plans for developing the weld modelling guidelines and associated benchmarks are outlined

  5. Welding residual stress distributions for dissimilar metal nozzle butt welds in pressurized water reactors

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Ji Soo; Kim, Ju Hee; Bae, Hong Yeol; OH, Chang Young; Kim, Yun Jae [Korea Univ., Seoul (Korea, Republic of); Lee, Kyungsoo [Korea Electric Power Research Institute, Daejeon (Korea, Republic of); Song, Tae Kwang [Korea Institute of Nuclear Safety, Daejeon (Korea, Republic of)

    2012-02-15

    In pressurized water nuclear reactors, dissimilar metal welds are susceptible to primary water stress corrosion cracking. To access this problem, accurate estimation of welding residual stresses is important. This paper provides general welding residual stress profiles in dissimilar metal nozzle butt welds using finite element analysis. By introducing a simplified shape for dissimilar metal nozzle butt welds, changes in the welding residual stress distribution can be seen using a geometry variable. Based on the results, a welding residual stress profile for dissimilar metal nozzle butt welds is proposed that modifies the existing welding residual stress profile for austenitic pipe butt welds.

  6. Residual stress reduction in the penetration nozzle weld joint by overlay welding

    International Nuclear Information System (INIS)

    Jiang, Wenchun; Luo, Yun; Wang, B.Y.; Tu, S.T.; Gong, J.M.

    2014-01-01

    Highlights: • Residual stress reduction in penetration weld nozzle by overlay welding was studied. • The overlay weld can decrease the residual stress in the weld root. • Long overlay welding is proposed in the actual welding. • Overlay weld to decrease residual stress is more suitable for thin nozzle. - Abstract: Stress corrosion cracking (SCC) in the penetration nozzle weld joint endangers the structural reliability of pressure vessels in nuclear and chemical industries. How to decrease the residual stress is very critical to ensure the structure integrity. In this paper, a new method, which uses overlay welding on the inner surface of nozzle, is proposed to decrease the residual stresses in the penetration joint. Finite element simulation is used to study the change of weld residual stresses before and after overlay welding. It reveals that this method can mainly decrease the residual stress in the weld root. Before overlay welding, large tensile residual stresses are generated in the weld root. After overlay weld, the tensile hoop stress in weld root has been decreased about 45%, and the radial stress has been decreased to compressive stress, which is helpful to decrease the susceptibility to SCC. With the increase of overlay welding length, the residual stress in weld root has been greatly decreased, and thus the long overlay welding is proposed in the actual welding. It also finds that this method is more suitable for thin nozzle rather than thick nozzle

  7. Significance of residual stress on fatigue properties of welded pipes

    International Nuclear Information System (INIS)

    Ohta, A.; Maeda, Y.; Kanao, M.

    1984-01-01

    The mean stress effect on the fatigue properties of two kinds of welded pipes was investigated in cantilever bending. The fatigue strength changed with the mean stress on fillet welded pipes, but did not change on butt welded pipes. The fatigue crack initiated from the toe of weld on the outer surface of fillet welded pipes and from the undercut on the inner surface of butt welded pipes. The measurement of the fatigue crack propagation rate and the residual stress distribution through the thickness of pipe revealed that the difference in the fatigue properties between fillet and butt welded pipes arose from the weld-induced residual stress, tension on the inner surface and compression on the outer surface. It is suggested that the production of compressive residual stress along the inner surface would be an effective means for improving the fatigue strength of butt welded pipes. (author)

  8. Fatigue life estimation of welded components considering welding residual stress relaxation and its mean stress effect

    International Nuclear Information System (INIS)

    Han, Seung Ho; Han, Jeong Woo; Shin, Byung Chun; Kim, Jae Hoon

    2003-01-01

    The fatigue life of welded joints is sensitive to welding residual stress and complexity of their geometric shapes. To predict the fatigue life more reasonably, the effects of welding residual stress and its relaxation on their fatigue strengths should be considered quantitatively, which are often regarded to be equivalent to the effects of mean stresses by external loads. The hot-spot stress concept should be also adopted which can reduce the dependence of fatigue strengths for various welding details. Considering the factors mentioned above, a fatigue life prediction model using the modified Goodman's diagram was proposed. In this model, an equivalent stress was introduced which is composed of the mean stress based on the hot-spot stress concept and the relaxed welding residual stress. From the verification of the proposed model to real welding details, it is proved that this model can be applied to predict reasonably their fatigue lives

  9. Fatigue life estimation considering welding residual stress and hot-spot stress of welded components

    International Nuclear Information System (INIS)

    Han, S. H.; Lee, T. K.; Shin, B. C.

    2002-01-01

    The fatigue life of welded joints is sensitive to welding residual stress and complexity of their geometric shapes. To predict the fatigue life more reasonably, the effects of welding residual stress and its relaxation have to be considered quantitatively which are equivalent to mean stress by external loads. The hot-spot stress concept should be also adopted which can be reduce the dependence of fatigue strengths for various welding details. Considering the factors mentioned above, a fatigue life prediction model using the modified Goodman's diagram was proposed. In this model, an equivalent stress was introduced which are composed of the mean stress based on the hot-spot stress concept and the relaxed welding residual stress. From the verification of the proposed model to real welding details, it is confirmed that this model can be applied to predict reasonably their fatigue lives

  10. Residual stress measurements of welded stainless steel 304 plate using the HANARO residual stress instrument

    International Nuclear Information System (INIS)

    Mun, M. K.; Lee, C. H.; Em, V. T.

    2001-01-01

    In order to nondestructively measure in-depth residual stress distribution of the metallic materials, it is unique method to use neutron diffraction. In this paper the principles of residual stress measurements by neutron diffraction is described. The residual stress distribution of welded strainless steeel 304 plate using te HANARO residual stress instrument is also described

  11. Residual Stress Analysis of an Overlay Weld on a Repair Weld

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Kang Soo; Lee, Ho Jin; Lee, Bong Sang [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of); Jung, I. C.; Byeon, J. G.; Park, K. S. [Doosan Heavy Industries and Construction Co., Changwon (Korea, Republic of)

    2008-10-15

    In recent years, the dissimilar metal, Alloy 82/182 welds used to connect stainless steel piping and low alloy steel or carbon steel components in nuclear reactor piping system have experienced the cracking due to primary water stress corrosion(PWSCC). It is well known that one reason of the cracking is the residual stress by the weld. But, it is difficult to estimate the weld residual stress exactly due to many parameters of a welding. In this paper, the analysis of 3 FEM models is performed to estimate the weld residual stress on the dissimilar metal weld exactly.

  12. Residual stress analysis of an overlay weld on a dissimilar metal weld

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Kang Soo; Lee, Ho Jin; Lee, Bong Sang (Korea Atomic Energy Research Institute, Daejeon (Korea)); Jung, I.C.; Byeon, J.G.; Park, K.S. (Doosan Heavy Industries and Construction Co., Changwon (Korea)), e-mail: kskim5@kaeri.re.kr

    2009-07-01

    In recent years, a dissimilar metal, Alloy 82/182 welds used to connect stainless steel piping and low alloy steel or carbon steel components in nuclear reactor piping system have experienced a cracking due to a primary water stress corrosion (PWSCC). It is well known that one reason for the cracking is the residual stress by the weld. But, it is difficult to estimate the weld residual stress exactly due to many parameters of a welding. In this paper, the analysis of 3 FEM models is performed to estimate the weld residual stress on a dissimilar metal weld exactly

  13. Comparison of Welding Residual Stresses of Hybrid Laser-Arc Welding and Submerged Arc Welding in Offshore Steel Structures

    DEFF Research Database (Denmark)

    Andreassen, Michael Joachim; Yu, Zhenzhen; Liu, Stephen

    2016-01-01

    In the offshore industry, welding-induced distortion and tensile residual stresses have become a major concern in relation to the structural integrity of a welded structure. Particularly, the continuous increase in size of welded plates and joints needs special attention concerning welding induced...... are hybrid laser-arc welding (HLAW) and submerged arc welding (SAW). Both welding methods are applied for a full penetration butt-weld of 10 mm thick plates made of thermomechanically hot-rolled, low-carbon, fine-grain S355ML grade steel used in offshore steel structures. The welding residual stress state...

  14. Effects of post weld heat treatment and weld overlay on the residual stress and mechanical properties in dissimilar metal weld

    International Nuclear Information System (INIS)

    Campos, Wagner R.C.; Ribeiro, Vladimir S.; Vilela, Alisson H.F.; Almeida, Camila R.O.; Rabello, Emerson G.

    2017-01-01

    The object of this work is a dissimilar metal weld (DMW) pipe joint between carbon steel (A-106 Gr B) and stainless steel (A-312 TP316L) pipes and filler metals of Nickel alloy (82/182), which find wide application in the field of chemical, oil, petroleum industries, fossil fuel and nuclear power plant. A lot of the failures that have occurred in dissimilar metal welded are affected greatly by residual stresses. Residual stress is often a cause of premature failure of critical components under normal operation of welded components. Several methods have been tested and developed for removing the tensile residual stresses. The aim of the methods is to reduce the tensile stress state or to create compressive stresses at a predefined area, such as the inner surface of a welded pipe joint. Post weld heat treatment (PWHT) and weld overlay (WOL) are two of the residual stress mitigation methods which reduce the tensile residual stress, create compressive stresses and arrest crack initiation and crack growth. The technique used to substantially minimized or eliminated this failure development in the root weld is the post weld heat treatments (stress relief heat treatment) or the weld overlay. In this work was studied the effectiveness in reducing internal residual stress in dissimilar metal welded pipe joints subjected to post weld heat treatment and weld overlay, measurement by hole-drilling strain-gage method of stress relaxation. Also held was mechanical characterization of the welded pipe joint itself. (author)

  15. Effects of post weld heat treatment and weld overlay on the residual stress and mechanical properties in dissimilar metal weld

    Energy Technology Data Exchange (ETDEWEB)

    Campos, Wagner R.C.; Ribeiro, Vladimir S.; Vilela, Alisson H.F.; Almeida, Camila R.O.; Rabello, Emerson G., E-mail: wrcc@cdtn.br, E-mail: camilarezende.cr@gmail.com, E-mail: egr@cdtn.br, E-mail: vladimirsoler@hotmail.com, E-mail: ahfv02@outlook.com [Centro de Desenvolvimento da Tecnologia Nuclear (CDTN/CNEN-MG), Belo Horizonte, MG (Brazil)

    2017-07-01

    The object of this work is a dissimilar metal weld (DMW) pipe joint between carbon steel (A-106 Gr B) and stainless steel (A-312 TP316L) pipes and filler metals of Nickel alloy (82/182), which find wide application in the field of chemical, oil, petroleum industries, fossil fuel and nuclear power plant. A lot of the failures that have occurred in dissimilar metal welded are affected greatly by residual stresses. Residual stress is often a cause of premature failure of critical components under normal operation of welded components. Several methods have been tested and developed for removing the tensile residual stresses. The aim of the methods is to reduce the tensile stress state or to create compressive stresses at a predefined area, such as the inner surface of a welded pipe joint. Post weld heat treatment (PWHT) and weld overlay (WOL) are two of the residual stress mitigation methods which reduce the tensile residual stress, create compressive stresses and arrest crack initiation and crack growth. The technique used to substantially minimized or eliminated this failure development in the root weld is the post weld heat treatments (stress relief heat treatment) or the weld overlay. In this work was studied the effectiveness in reducing internal residual stress in dissimilar metal welded pipe joints subjected to post weld heat treatment and weld overlay, measurement by hole-drilling strain-gage method of stress relaxation. Also held was mechanical characterization of the welded pipe joint itself. (author)

  16. Evaluation of residual stresses in dissimilar weld joints

    International Nuclear Information System (INIS)

    Bonaventure, A.; Ayrault, D.; Montay, G.; Klosek, V.

    2011-01-01

    Dissimilar metal joints between pipes of ferritic and austenitic steels are present in primary coolant circuit of pressurized water reactors. Over the last years in particular in USA and Japan, stress corrosion cracks, often associated with weld repairs, have been observed for some dissimilar welds made with an Inconel filler metal. The integrity of this type of components is thus a major safety issue. In this context, the goal of this work is to evaluate the welding residual stresses field for a dissimilar weld joint. A representative bi-metallic tubular weld joint was fabricated and residual stresses profiles in the different weld zones were evaluated by means of the hole drilling and neutron diffraction methods. (authors)

  17. Residual stress measurement of welding area by neutron diffraction method

    International Nuclear Information System (INIS)

    Suzuki, Tamaki; Sugiyama, Masaaki; Oikawa, Hatsuhiko; Nose, Tetsuro; Imafuku, Muneyuki; Tomota, Yo; Suzuki, Hiroshi; Moriai, Atsushi

    2010-01-01

    Resistance spot welding technique is extensively applied to join the body steel sheets in the manufacturing process for the automobile industry. It is known that the fatigue crack initiates occasionally inside of the spot-welded zone in this material, which is a serious issue of the fatigue life. Although this phenomenon is supposed to be related to internal residual stress, the actual residual stress distribution inside of the spot-welded zone is not clear up to now. In this study, a neutron diffraction residual stress measurement technique with well-defined sub-mm 3 square gauge volume is applied in order to clarify the internal three dimensional residual stress distribution just below the spot-welded part of the steel sheets. (author)

  18. Neutron diffraction studies of laser welding residual stresses

    Science.gov (United States)

    Petrov, Peter I.; Bokuchava, Gizo D.; Papushkin, Igor V.; Genchev, Gancho; Doynov, Nikolay; Michailov, Vesselin G.; Ormanova, Maria A.

    2016-01-01

    The residual stress and microstrain distribution induced by laser beam welding of the low-alloyed C45 steel plate was investigated using high-resolution time-of-flight (TOF) neutron diffraction. The neutron diffraction experiments were performed on FSD diffractometer at the IBR-2 pulsed reactor in FLNP JINR (Dubna, Russia). The experiments have shown that the residual stress distribution across weld seam exhibit typical alternating sign character as it was observed in our previous studies. The residual stress level is varying in the range from -60 MPa to 450 MPa. At the same time, the microstrain level exhibits sharp maxima at weld seam position with maximal level of 4.8·10-3. The obtained experimental results are in good agreement with FEM calculations according to the STAAZ model. The provided numerical model validated with measured data enables to study the influence of different conditions and process parameters on the development of residual welding stresses.

  19. Reduction of Residual Stresses and Distortion in Girth Welded Pipes.

    Science.gov (United States)

    1987-06-01

    2.10).,1. R*4 $DATA 000402 027340 ( 6000) (3000) VAL L* Vec $iATA 000116 000132 ( 45.) (9.10) Sib routies, Furc’t :ors, atemerit ... Processo r- De ...Science in Mechanical Engineering. ABSTRACT Conventionally, welding control has been used to assure that the quality of the weld itself is maintained...to control and reduce these tensile residual stresses. [4] 8 Determination of residual stresses is complex. it requires an understanding in

  20. Effect of constraint condition and internal medium on residual stress under overlay welding for dissimilar metal welding

    Energy Technology Data Exchange (ETDEWEB)

    Song, Tae Kwang; Kim, Yun Jae [Korea Univ., Seoul (Korea, Republic of); Lee, Kyoung Soo; Park, Chi Yong [Korea Electric Power Research Institute, Daejeon (Korea, Republic of); Kim, Jong Sung [Korea Power Engineering Company, Inc., Yongin (Korea, Republic of); Kim, Jin Weon [Chosun Univ., Gwangju (Korea, Republic of)

    2007-07-01

    In nuclear power plants, residual stress of dissimilar metal weld propagates cracks in the weld metal which is susceptible to stress corrosion cracking. Overlay welding is a process widely used to mitigate residual stress replacing inside tensile stress by compression stress. However, according to the result of this study the effect of overlay welding on residual stress depends on both internal medium and constraint condition. The purpose of this study is to maximize the positive effect of overlay welding by finite element analyses.

  1. Residual stresses associated with welds in austenitic steel

    International Nuclear Information System (INIS)

    Fidler, R.

    1978-01-01

    Two exploratory welds have been made with AISI 316 austenitic steel and Armex GT electrodes by the manual metal-arc process, and residual stress measurements made in the as-welded condition and after various periods of stress relief. The results show that substantial stress relief occurs at temperatures of 850 0 and 750 0 C after 1 hr, but is not complete. The stress distributions are compared with those obtained from ferritic welds and the effect of differences in thermal expansion coefficients is examined using finite element analysis. (author)

  2. Effect of preemptive weld overlay sequence on residual stress distribution for dissimilar metal weld of Kori nuclear power plant pressurizer

    Energy Technology Data Exchange (ETDEWEB)

    Bae, Hong Yeol; Song, Tae Kwang; Chun, Yun Bae; Oh, Chang Young; Kim, Yun Jae [Korea Univ., Seoul (Korea, Republic of); Lee, Kyoung Soo; Park, Chi Yong [Korea Electric Power Research Institute, Daejeon (Korea, Republic of)

    2008-07-01

    Weld overlay is one of the residual stress mitigation method which arrest crack. An overlay weld sued in this manner is termed a Preemptive Weld OverLay(PWOL). PWOL was good for distribution of residual stress of Dissimilar Metal Weld(DMW) by previous research. Because range of overlay welding is wide relatively, residual stress distribution on PWR is affected by welding sequence. In order to examine the effect of welding sequence, PWOL was applied to a specific DMW of KORI nuclear power plant by finite element analysis method. As a result, the welding direction that from nozzle to pipe is better good for residual stress distribution on PWR.

  3. Residual stress analysis of an Overlay weld and a repair weld on the dissimilar Butt weld

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Kang Soo, E-mail: kskim5@kaeri.re.k [Korea Atomic Energy Research Institute, 150, Dukjin-dong, Daejeon 305-353 (Korea, Republic of); Lee, Ho Jin; Lee, Bong Sang [Korea Atomic Energy Research Institute, 150, Dukjin-dong, Daejeon 305-353 (Korea, Republic of); Jung, In Chul; Park, Kwang Soo [Doosan Heavy Industries and Construction Co., 555 Gwigok Dong, Changwon 641-792 (Korea, Republic of)

    2009-12-15

    Both the experiment and FE analysis were performed to estimate the residual stresses at the parts of the dissimilar metal welds. The specimen of the dissimilar Butt welds was manufactured, and the residual stresses of this specimen were measured by the X-ray method and a Hole Drilling Technique. The values measured by two experimental methods showed a big deviation at the SUS 316L plate. Consequently, the experimental methods to estimate the residual stresses are not a superior method. The Butt FEM Model on this specimen was developed and analyzed by the ABAQUS Code. The results of the FE analysis were compared with those of the experimental methods. As a whole, the values of the Butt FEM Model showed a trend which was in agreement with the experimental values and the values of FE analysis were found reasonable. The Repair FEM Model and the Overlay FEM Model were developed and analyzed by the ABAQUS Code. The values of these results were also found reasonable data even if the experimental methods be not performed. Therefore, the residual stresses for the dissimilar metal welds can be estimated by an analysis with an appropriate FEM Model without the experimental methods.

  4. Residual stress analysis of an Overlay weld and a repair weld on the dissimilar Butt weld

    International Nuclear Information System (INIS)

    Kim, Kang Soo; Lee, Ho Jin; Lee, Bong Sang; Jung, In Chul; Park, Kwang Soo

    2009-01-01

    Both the experiment and FE analysis were performed to estimate the residual stresses at the parts of the dissimilar metal welds. The specimen of the dissimilar Butt welds was manufactured, and the residual stresses of this specimen were measured by the X-ray method and a Hole Drilling Technique. The values measured by two experimental methods showed a big deviation at the SUS 316L plate. Consequently, the experimental methods to estimate the residual stresses are not a superior method. The Butt FEM Model on this specimen was developed and analyzed by the ABAQUS Code. The results of the FE analysis were compared with those of the experimental methods. As a whole, the values of the Butt FEM Model showed a trend which was in agreement with the experimental values and the values of FE analysis were found reasonable. The Repair FEM Model and the Overlay FEM Model were developed and analyzed by the ABAQUS Code. The values of these results were also found reasonable data even if the experimental methods be not performed. Therefore, the residual stresses for the dissimilar metal welds can be estimated by an analysis with an appropriate FEM Model without the experimental methods.

  5. Measurement of residual stresses in welded sample of dissimilar materials

    International Nuclear Information System (INIS)

    Mansur, Tanius Rodrigues; Gomes, Paulo de Tarso Vida; Scaldaferri, Denis Henrique Bianchi; Martins, Geraldo Antonio Scoralick; Atanazio Filho, Nelson do Nascimento

    2008-01-01

    The welding of dissimilar metals has several applications in the industry. Especially in the nuclear industry, this joint type, common between carbon steel and stainless steel, it is always reason of analysis and special cares tends in view the need to maintain the integrity of the equipment. Residual stresses are introduced in the material as a result of processes as welding, machining, sanding and polishing that can to produce deformation in the proximities of the surface of the material. Residual compressive stresses can be introduced in the material through the jetting process (bombardment of the surface for small glass spheres, dry sand or steel). That procedure allows a fine subsurface layer to suffer yielding, compressing the superficial layer and reducing the formation of areas of concentration of traction stresses, increasing the resistance of the material to the fatigue. The welding process introduces residual stresses due to the geometry resulting from the fusion of the material welded and of the heterogeneous cooling. Besides the microstructural alteration and chemical composition of the material in the affected area for the heat, introduced by the welding, it is also had the effect of the discontinuity of the passes and the formation of bubbles and emptiness that can contribute to the cracks nucleation, reducing the resistance to the fatigue. In the great majority of the times residual stresses are harmful and there are many documented cases which US these stresses went predominant factors for the failure for fatigue. A particularly dangerous aspect of the residual stresses is that their presence is not usually observed, what usually happens with an applied load to the structure. The knowledge of the surface residual stresses is important to predict the emergence of failure when the component or structure is requested. In nuclear power plants it is common to welding of piping of stainless steels with mouthpieces of carbon steel of pressure vases of

  6. Simulation of Weld Mechanical Behavior to Include Welding-Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes

    Science.gov (United States)

    2015-11-01

    Memorandum Simulation of Weld Mechanical Behavior to Include Welding-Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes...Weld Mechanical Behavior to Include Welding-Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes by Charles R. Fisher...Welding- Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes 5a. CONTRACT NUMBER N/A 5b. GRANT NUMBER N/A 5c

  7. Residual stress relief in MAG welded joints of dissimilar steels

    International Nuclear Information System (INIS)

    Seodek, P.; Brozda, J.; Wang, L.; Withers, P.J.

    2003-01-01

    This paper addresses the relief of residual stress in welded joints between austenitic and non-alloyed ferritic-pearlitic steels. A series of similar and dissimilar steel joints based on the 18G2A (ferritic-pearlitic) and 1H18N10T (austenitic) steels were produced, some of which were stress relieved by annealing and some by mechanical prestressing. For the as-welded and stress relieved test joints the residual stresses were measured by trepanning. To aid the interpretation of these results, 2D plane stress finite element analysis has been performed to simulate the residual stress relieving methods. Analysis of the results has shown that thermal stress relieving of welded joints between dissimilar steels is not effective and may even increase residual stresses, due to the considerable difference in thermal expansion of the joined steels. It was found that, for the loads imposed, the effectiveness of the mechanical stress relieving of dissimilar steel welded joints was much lower than that of similar steel joints

  8. Improvement and Validation of Weld Residual Stress Modelling Procedure

    International Nuclear Information System (INIS)

    Zang, Weilin; Gunnars, Jens; Dong, Pingsha; Hong, Jeong K.

    2009-06-01

    The objective of this work is to identify and evaluate improvements for the residual stress modelling procedure currently used in Sweden. There is a growing demand to eliminate any unnecessary conservatism involved in residual stress assumptions. The study was focused on the development and validation of an improved weld residual stress modelling procedure, by taking advantage of the recent advances in residual stress modelling and stress measurement techniques. The major changes applied in the new weld residual stress modelling procedure are: - Improved procedure for heat source calibration based on use of analytical solutions. - Use of an isotropic hardening model where mixed hardening data is not available. - Use of an annealing model for improved simulation of strain relaxation in re-heated material. The new modelling procedure is demonstrated to capture the main characteristics of the through thickness stress distributions by validation to experimental measurements. Three austenitic stainless steel butt-welds cases are analysed, covering a large range of pipe geometries. From the cases it is evident that there can be large differences between the residual stresses predicted using the new procedure, and the earlier procedure or handbook recommendations. Previously recommended profiles could give misleading fracture assessment results. The stress profiles according to the new procedure agree well with the measured data. If data is available then a mixed hardening model should be used

  9. Weld residual stress predictions in reactor vessel head penetrations

    Energy Technology Data Exchange (ETDEWEB)

    Suanno, Rodolfo L.M.; Ferrari, Lucio D.B. [ELETROBRAS Termonuclear S.A. - ELETRONUCLEAR, Rio de Janeiro, RJ (Brazil). Stress Analysis Department], e-mail: rsuanno@eletronuclear.gov.br; Teughels, Anne; Malekian, Christian [Tractebel Engineering, Brussels (Belgium). Reliability Nuclear Department], e-mail: anne.teughels@tractebel.com

    2009-07-01

    The penetrations in the early Pressurized Water Reactors Vessels are characterized by Alloy 600 tubes, welded by Alloy 182/82. The Alloy 600 tubes have been shown to be susceptible to PWSCC (Primary Water Stress Corrosion Cracking) which may lead to crack forming. The cracking mechanism is driven mainly by the welding residual stress and, in a second place, by the operational stress in the weld region. It is therefore of big interest to quantify the weld residual stress field correctly. In this paper the weld residual stress field is calculated by finite elements using a sequentially coupled approach, which is well known in literature. It includes a transient thermal analysis simulating the heating during the multipass welding, followed by a transient thermo-mechanical analysis for the determination of the stresses involved with it. The welding consists of a sequence of weld beads, each of which is deposited in its entirety, at once, instead of gradually. Central as well as eccentric sidehill nozzles on the vessel head are analyzed in the paper. For the former a 2- dimensional axisymmetrical finite element model is used, whereas for the latter a 3-dimensional model is set up. Different positions on the vessel head are compared and the influence of the sidehill effect is illustrated. In the framework of a common project for Angra 1, Tractebel Engineering (Belgium) and ELETRONUCLEAR (Nuclear Utility, Brazil) had the opportunity to compare their analysis method, which they applied to the Belgian and the Brazilian nuclear reactors, respectively. The global approach in both cases is very similar but is applied to different configurations, specific for each plant. In the article the results of both cases are compared. (author)

  10. Residual stress in repair welds measured with neutron diffraction with and without post weld heat treatment

    International Nuclear Information System (INIS)

    Price, J.W.H.; Paradowska, A.M.; Finlayson, T.

    2010-01-01

    In welding, residual stresses (RS) are formed in the structure as the result of differential contractions which occur as the weld metal solidifies and cools to ambient temperature. The tensile stresses can have significant effects on the susceptibility of a material to degradation mechanisms such as fatigue, corrosion, fracture resistance, and creep. Welding repairs have increasingly become a structural integrity concern for aging pressure vessel and piping components. Both the repair procedure and the subsequent safety assessment, such as BS7910 and R6 require a better understanding of the welding effect on structural components. The use of a neutron beam as a non-destructive method of measuring residual stress due to repair welding has been explored. Two types of full penetration butt weld repairs on 25 mm ferritic steel were examined. From the findings of this research in terms of residual stress, temper bead welding repair may not be better than stringer bead welding. Post-weld heat treatment may be still advisable for temper bead weld repairs on ferritic steel.

  11. Quantification of Residual Stresses in External Attachment Welding Applications

    DEFF Research Database (Denmark)

    Alhajri, R.; Liu, S.; Yu, Z.

    2017-01-01

    It is uncertain whether postweld heat treatment (PWHT) should be required for external attachment welds in petrochemical industry applications where stress corrosion cracking (SCC) is a possibility. An industrial criterion established by NACE SP0472 indicates that PWHT is not required if residual...... welding (GMAW) process to deposit single beadonplate welds with ER70S6 wire on ASTM516 grade 70 pressure vessel steel plates of 6.3, 12.7, and 19 mm thicknesses. Microstructural analysis, temperature, and distortion measurements of weldments were performed to qualify the FEA modeling results. In addition...

  12. Influence of Hardening Model on Weld Residual Stress Distribution

    International Nuclear Information System (INIS)

    Mullins, Jonathan; Gunnars, Jens

    2009-06-01

    This study is the third stage of a project sponsored by the Swedish Radiation Safety Authority (SSM) to improve the weld residual stress modelling procedures currently used in Sweden. The aim of this study was to determine which material hardening model gave the best agreement with experimentally measured weld residual stress distributions. Two girth weld geometries were considered: 19mm and 65mm thick girth welds with Rin/t ratios of 10.5 and 2.8, respectively. The FE solver ABAQUS Standard v6.5 was used for analysis. As a preliminary step some improvements were made to the welding simulation procedure used in part one of the project. First, monotonic stress strain curves and a mixed isotropic/kinematic hardening model were sourced from the literature for 316 stainless steel. Second, more detailed information was obtained regarding the geometry and welding sequence for the Case 1 weld (compared with phase 1 of this project). Following the preliminary step, welding simulations were conducted using isotropic, kinematic and mixed hardening models. The isotropic hardening model gave the best overall agreement with experimental measurements; it is therefore recommended for future use in welding simulations. The mixed hardening model gave good agreement for predictions of the hoop stress but tended to under estimate the magnitude of the axial stress. It must be noted that two different sources of data were used for the isotropic and mixed models in this study and this may have contributed to the discrepancy in predictions. When defining a mixed hardening model it is difficult to delineate the relative contributions of isotropic and kinematic hardening and for the model used it may be that a greater isotropic hardening component should have been specified. The kinematic hardening model consistently underestimated the magnitude of both the axial and hoop stress and is not recommended for use. Two sensitivity studies were also conducted. In the first the effect of using a

  13. Residual and operating stresses in welded Alloy 600 penetrations

    International Nuclear Information System (INIS)

    Hunt, E.S.; Gross, D.J.; Pathania, R.

    1995-01-01

    An elastic-plastic finite element model has been developed for calculating residual and operating stresses in Alloy 600 penetrations which are installed in pressure vessel shells by J-groove welds. The welding process is simulated by multiple passes of heat input with heat transfer into the adjacent parts during welding and cooling. Analysis results are presented for CRDM nozzles, pressurizer instrument nozzles and pressurizer heater sleeves. The effect of several key variables such as nozzle material yield strength, angle of the nozzle relative to the vessel shell, weld size, presence of counterbores, etc. are explored. Results of the modelling are correlated with field and laboratory data. Application of the stress analysis results to PWSCC predictive modeling is discussed. (author). 6 refs, 12 figs, 2 tabs

  14. Effect of Weld Schedule on the Residual Stress Distribution of Boron Steel Spot Welds

    Science.gov (United States)

    Raath, N. D.; Norman, D.; McGregor, I.; Dashwood, R.; Hughes, D. J.

    2017-06-01

    Press-hardened boron steel has been utilized in anti-intrusion systems in automobiles, providing high strength and weight-saving potential through gage reduction. Boron steel spot welds exhibit a soft heat-affected zone which is surrounded by a hard nugget and outlying base material. This soft zone reduces the strength of the weld and makes it susceptible to failure. Additionally, different welding regimes lead to significantly different hardness distributions, making failure prediction difficult. Boron steel sheets, welded with fixed and adaptive schedules, were characterized. These are the first experimentally determined residual stress distributions for boron steel resistance spot welds which have been reported. Residual strains were measured using neutron diffraction, and the hardness distributions were measured on the same welds. Additionally, similar measurements were performed on spot welded DP600 steel as a reference material. A correspondence between residual stress and hardness profiles was observed for all welds. A significant difference in material properties was observed between the fixed schedule and adaptively welded boron steel samples, which could potentially lead to a difference in failure loads between the two boron steel welds.

  15. Evaluation of Residual Stress Measurements Before and After Post-Weld Heat Treatment in the Weld Repairs

    Science.gov (United States)

    Pardowska, Anna M.; Price, John W. H.; Finlayson, Trevor R.; Ibrahim, R.

    2010-11-01

    Welding repairs are increasingly a structural integrity concern for aging pressure vessel and piping components. It has been demonstrated that the residual stress distribution near repair welds can be drastically different from that of the original weld. Residual stresses have a significant effect on the lifetime performance of a weld, and a reduction of these stresses is normally desirable. The aim of this paper is to investigate residual stresses in various weld repair arrangements using the non-destructive neutron diffraction technique. This research is focused on characterization of the residual stress distribution: (i) in the original weld; (ii) in a shallow toe weld repair; and (iii) after conventional post-weld heat treatment. The focus of the measurements is on the values of the subsurface strain/stress variations across the weld.

  16. Residual stresses and their mechanisms of production at circumferential weld by heat-sink welding

    International Nuclear Information System (INIS)

    Ueda, Yukio; Nakacho, Keiji; Ohkubo, Katsumi; Shimizu, Tsubasa.

    1983-01-01

    In the previous report, the authors showed effectiveness of the heat-sink welding (water cooling) to accomplish this end by conducting theoretical analysis and an experiment on residual stresses in the 4B pipe of SUS 304 by the conventional welding and the heat-sink welding at a certain standard heat-input condition. In this research, different pipe sizes and varied heat-input are applied. The welding residual stresses by the conventional welding and the heat-sink welding are obtained by the theoretical analysis and their production mechanisms are clarified. Hence the influence of the above changes of conditions on effectiveness of the heat-sink welding is investigated. The main results are summarized as follow. (1) In case of this pipes such as 2B and 4B pipes, it is important to minimize heat-input per one pass (especially for latter half passes) in order to improve the effectiveness of the heat-sink welding. The effectiveness can be predicted either by theoretical analysis of the temperature distribution history with consideration of the characteristic of heat transfer under spray-watering or by experimental measurement. (2) In case of 24B pipes, thick pipes, it is desirable to minimize heat-input for the first half passes, by which the heat-sink welding becomes more effective. In addition, no matter whether the conventional welding or the heat-sink welding, it is important to prevent angular distorsion which produces tensile axial stresses on the inner surface of the pipe in the weld zone. Possible measures to meet these requirements are to apply restraining jigs, to minimize the section area of the groove (ex. application of the narrow gap arc welding), and to change continuous welding to skip one. (J.P.N.)

  17. Residual stress measurement of large scaled welded pipe using neutron diffraction method. Effect of SCC crack propagation and repair weld on residual stress distribution

    International Nuclear Information System (INIS)

    Suzuki, Hiroshi; Katsuyama, Jinya; Tobita, Tohru; Morii, Yukio

    2011-01-01

    The RESA-1 neutron engineering diffractometer in the JRR-3 (Japan Research Reactor No.3) at the Japan Atomic Energy Agency, which is used for stress measurements, was upgraded to realize residual stress measurements of large scaled mechanical components. A series of residual stress measurements was made to obtain through-thickness residual stress distributions in a Type 304 stainless steel butt-welded pipe of 500A-sch.80 using the upgraded RESA-1 diffractometer. We evaluated effects of crack propagation such as stress corrosion cracking (SCC) and a part-circumference repair weld on the residual stress distributions induced by girth welding. Measured residual stress distributions near original girth weld revealed good agreement with typical results shown in some previous works using finite element method, deep hole drilling as well as neutron diffraction. After introducing a mock crack with 10 mm depth in the heat affected zone on the inside wall of the pipe by electro discharge machining, the axial residual stresses were found to be released in the part of the mock crack. However, changes in the through-wall bending stress component and the self-equilibrated stress component were negligible and hence the axial residual stress distribution in the ligament was remained in the original residual stresses near girth weld without the mock crack. Furthermore, changes in hoop and radial residual stress were also small. The residual stress distributions after a part repair welding on the outer circumference of the girth weld were significantly different from residual stress distributions near the original girth weld. The through-thickness average axial residual stress was increased due to increase of the tensile membrane stress and mitigation of the bending stress after repair welding. Throughout above studies, we evidenced that the neutron diffraction technique is useful and powerful tool for measuring residual stress distributions in large as well as thick mechanical

  18. Effects of shot peening on the residual stress of welded SS400 steel

    International Nuclear Information System (INIS)

    Lee, Jong Man; Kim, Tae Hyung; Cheong, Seong Kyun; Lee, Seung Ho

    2002-01-01

    The fatigue life of structures is usually determined by welding zone. The tensile residual stress, which is induced by welding, reduces the fatigue life and fatigue strength of welded structures. If we remove the tensile residual stress or induce the compressive residual stress, the fatigue life of welded structures will be improved. The change of hardness and compressive residual stress of welded zone after shot peening was investigated in this paper. The results show that the hardness was increased by shot peening. The residual stress was reduced by shot peening

  19. Evaluation of stress intensity factors due to welding residual stresses for circumferential cracked pipes

    International Nuclear Information System (INIS)

    Oh, Chang-Young; Kim, Yun-Jae; Oh, Young-Jin; Kim, Jong-Sung; Song, Tae-Kwang; Kim, Yong-Beum

    2013-01-01

    To investigate the applicability of existing methods to estimate stress intensity factors due to welding residual stresses, comparisons with finite element (FE) solutions are made for two types of generic welding residual stress profiles, generated by simulating repair welds. It is found that fitting residual stresses over the crack depth using third-order polynomials gives good estimates of stress intensity factors but fitting over the entire thickness can result in inaccurate estimates even with fourth-order polynomials. Noting that welding residual stresses are often determined from FE analyses, linearization of residual stresses to estimate stress intensity factors is proposed. Comparison with FE solutions shows good agreements. -- Highlights: ► Applicability of K estimation methods is investigated for welding residual stresses. ► Two types of generic residual stress profiles with repair welds are considered. ► Fitting residual stresses over the crack depth gives good estimates of K. ► A method to estimate K by linearising residual stress profiles is proposed

  20. Residual Stress Evaluation of Weld Inlay Process on Reactor Vessel Nozzles

    Energy Technology Data Exchange (ETDEWEB)

    Cho, Kihyun; Cho, Hong Seok [KEPCO KPS, Naju (Korea, Republic of)

    2015-10-15

    Weld overlay, weld inlay and stress improvement are mitigation technologies for butt joints. Weld overlay is done on pressurizer nozzles which are the highest potential locations occurring PWSCC due to high temperature in Korea. Reactor vessel nozzles are other big safety concerns for butt joints. Weld overlay and stress improvement should be so difficult to apply to those locations because space is too limited. Weld inlay should be one of the solutions. KEPCO KPS has developed laser welding system and process for reactor nozzles. Welding residual stress analysis is necessary for flaw evaluation. United States nuclear regulatory commission has calculated GTAW(Gas Tungsten Arc Welding) residual stress using ABAQUS. To confirm effectiveness of weld inlay process, welding residual stress analysis was performed. and difference between GTAW and LASER welding process was compared. Evaluation of weld inlay process using ANSYS and ABAQUS is performed. All of the both results are similar. The residual stress generated after weld inlay was on range of 450-500 MPa. Welding residual stresses are differently generated by GTAW and LASER welding. But regardless of welding process type, residual tensile stress is generated on inside surface.

  1. Residual Stress Evaluation of Weld Inlay Process on Reactor Vessel Nozzles

    International Nuclear Information System (INIS)

    Cho, Kihyun; Cho, Hong Seok

    2015-01-01

    Weld overlay, weld inlay and stress improvement are mitigation technologies for butt joints. Weld overlay is done on pressurizer nozzles which are the highest potential locations occurring PWSCC due to high temperature in Korea. Reactor vessel nozzles are other big safety concerns for butt joints. Weld overlay and stress improvement should be so difficult to apply to those locations because space is too limited. Weld inlay should be one of the solutions. KEPCO KPS has developed laser welding system and process for reactor nozzles. Welding residual stress analysis is necessary for flaw evaluation. United States nuclear regulatory commission has calculated GTAW(Gas Tungsten Arc Welding) residual stress using ABAQUS. To confirm effectiveness of weld inlay process, welding residual stress analysis was performed. and difference between GTAW and LASER welding process was compared. Evaluation of weld inlay process using ANSYS and ABAQUS is performed. All of the both results are similar. The residual stress generated after weld inlay was on range of 450-500 MPa. Welding residual stresses are differently generated by GTAW and LASER welding. But regardless of welding process type, residual tensile stress is generated on inside surface

  2. Comparison of residual stress distributions of similar and dissimilar thick butt-weld plates

    International Nuclear Information System (INIS)

    Suzuki, Hiroshi; Katsuyama, Jinya; Morii, Yukio

    2012-01-01

    Residual stress distributions of 35 mm thick dissimilar metal butt-weld between A533B ferritic steel and Type 304 austenitic stainless steel (304SS) with Ni alloy welds and similar metal butt-weld of 304SS were measured using neutron diffraction. Effects of differences in thermal expansion coefficients (CTEs) and material strengths on the weld residual stress distributions were discussed by comparison of the residual stress distributions between the similar and dissimilar metal butt-welds. Residual stresses in the similar metal butt-weld exhibited typical distributions found in a thick butt-weld and they were distributed symmetrically on either side of the weld line. Meanwhile, asymmetric residual stress distributions were observed near the root of the dissimilar metal butt-weld, which was caused by differences in CTEs and yield strengths among both parent materials and weld metals. Transverse residual stress distribution of the dissimilar metal butt-weld was similar trend to that of the similar metal butt-weld, since effect of difference in CTEs were negligible, while magnitude of the transverse residual stress near the root depended on the yield strengths of each metal. In contrast, the normal and longitudinal residual stresses in the dissimilar metal butt-weld distributed asymmetrically on either side of weld line due to influence of differences in CTEs. (author)

  3. Prediction of residual stress distributions due to surface machining and welding and crack growth simulation under residual stress distribution

    International Nuclear Information System (INIS)

    Ihara, Ryohei; Katsuyama, JInya; Onizawa, Kunio; Hashimoto, Tadafumi; Mikami, Yoshiki; Mochizuki, Masahito

    2011-01-01

    Research highlights: → Residual stress distributions due to welding and machining are evaluated by XRD and FEM. → Residual stress due to machining shows higher tensile stress than welding near the surface. → Crack growth analysis is performed using calculated residual stress. → Crack growth result is affected machining rather than welding. → Machining is an important factor for crack growth. - Abstract: In nuclear power plants, stress corrosion cracking (SCC) has been observed near the weld zone of the core shroud and primary loop recirculation (PLR) pipes made of low-carbon austenitic stainless steel Type 316L. The joining process of pipes usually includes surface machining and welding. Both processes induce residual stresses, and residual stresses are thus important factors in the occurrence and propagation of SCC. In this study, the finite element method (FEM) was used to estimate residual stress distributions generated by butt welding and surface machining. The thermoelastic-plastic analysis was performed for the welding simulation, and the thermo-mechanical coupled analysis based on the Johnson-Cook material model was performed for the surface machining simulation. In addition, a crack growth analysis based on the stress intensity factor (SIF) calculation was performed using the calculated residual stress distributions that are generated by welding and surface machining. The surface machining analysis showed that tensile residual stress due to surface machining only exists approximately 0.2 mm from the machined surface, and the surface residual stress increases with cutting speed. The crack growth analysis showed that the crack depth is affected by both surface machining and welding, and the crack length is more affected by surface machining than by welding.

  4. Control of welding residual stress for ensuring integrity against fatigue and stress-corrosion cracking

    International Nuclear Information System (INIS)

    Mochizuki, Masahito

    2007-01-01

    The availability of several techniques for residual stress control is discussed in this paper. The effectiveness of these techniques in protecting from fatigue and stress-corrosion cracking is verified by numerical analysis and actual experiment. In-process control during welding for residual stress reduction is easier to apply than using post-weld treatment. As an example, control of the welding pass sequence for multi-pass welding is applied to cruciform joints and butt-joints with an X-shaped groove. However, residual stress improvement is confirmed for post-weld processes. Water jet peening is useful for obtaining a compressive residual stress on the surface, and the tolerance against both fatigue and stress-corrosion cracking is verified. Because cladding with a corrosion-resistant material is also effective for preventing stress-corrosion cracking from a metallurgical perspective, the residual stress at the interface of the base metal is carefully considered. The residual stress of the base metal near the clad edge is confirmed to be within the tolerance of crack generation. Controlling methods both during and after welding processes are found to be effective for ensuring the integrity of welded components

  5. Simulation of Weld Mechanical Behavior to Include Welding Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes

    Science.gov (United States)

    2015-11-01

    data .  scaleFactor: Scale factor to convert SYSWELD units to units in Abaqus analysis for field of interest. A help description can be obtained by...Memorandum Simulation of Weld Mechanical Behavior to Include Welding-Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes...Weld Mechanical Behavior to Include Welding-Induced Residual Stress and Distortion: Coupling of SYSWELD and Abaqus Codes by Charles R. Fisher

  6. Reduction method for residual stress of welded joint using random vibration

    International Nuclear Information System (INIS)

    Aoki, Shigeru; Nishimura, Tadashi; Hiroi, Tetsumaro

    2005-01-01

    Welded joints are used for construction of many structures. Residual stress is induced near the bead caused by locally given heat. Tensile residual stress on the surface may reduce fatigue strength. In this paper, a new method for reduction of residual stress using vibration during welding is proposed. As vibrational load, random vibration, white noise and filtered white noise are used. Two thin plates are butt-welded. Residual stress is measured with a paralleled beam X-ray diffractometer with scintillation counter after removing quenched scale chemically. It is concluded that tensile residual stress near the bead is reduced by using random vibration during welding

  7. Finite element analysis of residual stress in the welded zone of a ...

    Indian Academy of Sciences (India)

    Unknown

    Abstract. The distribution of the residual stress in the weld joint of HQ130 grade high strength steel was in- vestigated by means of finite element method (FEM) using ANSYS software. Welding was carried out using gas shielded arc welding with a heat input of 16 kJ/cm. The FEM analysis on the weld joint reveals that there.

  8. Measurement of residual stress in a friction welded joint by using neutron diffraction

    International Nuclear Information System (INIS)

    Okido, Shinobu; Morii, Yukio; Hayashi, Makoto; Minakawa, Nobuaki

    2001-01-01

    The mechanism that produces residual stress near the boundary of two metals connected by friction welding was investigated by neutron diffraction. This investigation showed that the residual stress near the boundary of friction welding was compressive (about 300 MPa) at the surface and tensile (about 200 MPa) at the center of the welded specimen. These results indicate that the residual stress was produced by the heat history during cooling after the upsetting process. (author)

  9. Residual stress characterization of welds using x-ray diffraction techniques

    International Nuclear Information System (INIS)

    Pineault, J.A.; Brauss, M.E.

    1996-01-01

    Neglect of residual stresses created during processes lead to stress corrosion cracking, distortion, fatigue cracking, premature failures in components, and instances of over design. Automated residual stress mapping and truly portable equipment have now made the characterization of residual stresses using x-ray diffraction (XRI) practical. The nondestructive nature of the x-ray diffraction technique has made the tile residual stress characterization of welds a useful tool for process optimization and failure analysis, particularly since components can be measured before and after welding and post welding processes. This paper illustrates the importance of residual stress characterization in welds and presents examples where x-ray diffraction techniques were applied in the characterization of various kinds of welds. arc welds, TIG welds, resistance welds, laser welds and electron beam welds. Numerous techniques are available to help manage potentially harmfull residual stresses created during the welding process thus, the effects of a few example post weld processes such as grinding, heat treating and shot peening are also addressed

  10. Neutron Diffraction Evaluation of Near Surface Residual Stresses at Welds in 1300 MPa Yield Strength Steel

    Directory of Open Access Journals (Sweden)

    Ebrahim Harati

    2017-05-01

    Full Text Available Evaluation of residual stress in the weld toe region is of critical importance. In this paper, the residual stress distribution both near the surface and in depth around the weld toe was investigated using neutron diffraction, complemented with X-ray diffraction. Measurements were done on a 1300 MPa yield strength steel welded using a Low Transformation Temperature (LTT consumable. Near surface residual stresses, as close as 39 µm below the surface, were measured using neutron diffraction and evaluated by applying a near surface data correction technique. Very steep surface stress gradients within 0.5 mm of the surface were found both at the weld toe and 2 mm into the heat affected zone (HAZ. Neutron results showed that the LTT consumable was capable of inducing near surface compressive residual stresses in all directions at the weld toe. It is concluded that there are very steep stress gradients both transverse to the weld toe line and in the depth direction, at the weld toe in LTT welds. Residual stress in the base material a few millimeters from the weld toe can be very different from the stress at the weld toe. Care must, therefore, be exercised when relating the residual stress to fatigue strength in LTT welds.

  11. Neutron Diffraction Evaluation of Near Surface Residual Stresses at Welds in 1300 MPa Yield Strength Steel.

    Science.gov (United States)

    Harati, Ebrahim; Karlsson, Leif; Svensson, Lars-Erik; Pirling, Thilo; Dalaei, Kamellia

    2017-05-29

    Evaluation of residual stress in the weld toe region is of critical importance. In this paper, the residual stress distribution both near the surface and in depth around the weld toe was investigated using neutron diffraction, complemented with X-ray diffraction. Measurements were done on a 1300 MPa yield strength steel welded using a Low Transformation Temperature (LTT) consumable. Near surface residual stresses, as close as 39 µm below the surface, were measured using neutron diffraction and evaluated by applying a near surface data correction technique. Very steep surface stress gradients within 0.5 mm of the surface were found both at the weld toe and 2 mm into the heat affected zone (HAZ). Neutron results showed that the LTT consumable was capable of inducing near surface compressive residual stresses in all directions at the weld toe. It is concluded that there are very steep stress gradients both transverse to the weld toe line and in the depth direction, at the weld toe in LTT welds. Residual stress in the base material a few millimeters from the weld toe can be very different from the stress at the weld toe. Care must, therefore, be exercised when relating the residual stress to fatigue strength in LTT welds.

  12. Variation behavior of residual stress distribution by manufacturing processes in welded pipes of austenitic stainless steel

    International Nuclear Information System (INIS)

    Ihara, Ryohei; Hashimoto, Tadafumi; Mochizuki, Masahito

    2012-01-01

    Stress corrosion cracking (SCC) has been observed near heat affected zone (HAZ) of primary loop recirculation pipes made of low-carbon austenitic stainless steel type 316L in the nuclear power plants. For the non-sensitization material, residual stress is the important factor of SCC, and it is generated by machining and welding. In the actual plants, welding is conducted after machining as manufacturing processes of welded pipes. It could be considered that residual stress generated by machining is varied by welding as a posterior process. This paper presents residual stress variation due to manufacturing processes of pipes using X-ray diffraction method. Residual stress distribution due to welding after machining had a local maximum stress in HAZ. Moreover, this value was higher than residual stress generated by welding or machining. Vickers hardness also had a local maximum hardness in HAZ. In order to clarify hardness variation, crystal orientation analysis with EBSD method was performed. Recovery and recrystallization were occurred by welding heat near the weld metal. These lead hardness decrease. The local maximum region showed no microstructure evolution. In this region, machined layer was remained. Therefore, the local maximum hardness was generated at machined layer. The local maximum stress was caused by the superposition effect of residual stress distributions due to machining and welding. Moreover, these local maximum residual stress and hardness are exceeded critical value of SCC initiation. In order to clarify the effect of residual stress on SCC initiation, evaluation including manufacturing processes is important. (author)

  13. The Effect of Welding-Pass Grouping on the Prediction Accuracy of Residual Stress in Multipass Butt Welding

    Directory of Open Access Journals (Sweden)

    Jeongung Park

    2017-01-01

    Full Text Available The residual stress analysis of a thick welded structure requires a lot of time and computer memory, which are different from those in thin welded structure analysis. This study investigated the effect of residual stress due to welding-pass grouping as a way to reduce the analysis time in multipass thick butt welding joint. For this purpose, the parametric analysis which changes the number of grouping passes was conducted in the multipass butt weld of a structure with a thickness of 25 mm and 70 mm. In addition, the residual stress by thermal elastoplastic FE analysis is compared with the results by the neutron diffraction method for verifying the reliability of the FE analysis. The welding sequence is considered in order to predict the residual stress more accurately when using welding-pass grouping method. The results of the welding-pass grouping model and half model occurred between the results of the left/right of the full model. If the total number of welding-pass grouping is less than half of that of welding pass, a large difference with real residual stress is found. Therefore, the total number of the welding-pass grouping should not be reduced to more than half.

  14. Experimental and Numerical Studies on Residual Stress in Wide Butt Welds

    Directory of Open Access Journals (Sweden)

    Yang Ding

    2017-01-01

    Full Text Available The presence of residual stress in steel members can significantly compromise the stiffness and fatigue life of steel structural components. This influence becomes more serious for the wide butt welds in the construction of large-sized steel members due to the different residual stress distribution from the normal size butt welds. This paper experimentally studied the residual stress in the wide butt welds through an 8-experiment test program. High residual stress was produced during the wide butt welding and this stress was observed to be even higher than the yield strength of the steel. Moreover, this residual stress in the steel plate was firstly compressive and then transferred into tensile stress with the increase in the distance away from the butt weld line. The magnitude of the residual stress increased with the increase in the width of the welding seams. This paper also developed a finite element model by SYSWELD to simulate the residual stress produced by the wide butt welding. The accuracy of the FE simulation was checked by the reported test results. In order to reduce the residual stress, the ultrasonic peening method was adopted. The analysis results indicated that ultrasonic peening method effectively reduced the residual stress caused by the wide butt welding during the construction.

  15. Residual stress distribution in steel butt welds measured using neutron and synchrotron diffraction.

    Science.gov (United States)

    Paradowska, A M; Price, J W H; Finlayson, T R; Lienert, U; Walls, P; Ibrahim, R

    2009-03-25

    70 keV synchrotron radiation and thermal neutrons have been employed to investigate the residual stress characteristics in a fully restrained, steel, butt weld. The focus is on the values of the subsurface and through-thickness strain/stress variation in the middle of the weld. The advantages and limitations of the techniques have been addressed, in relation to the gauge volume, the stress-free reference sample and positioning. The measurement of residual stress around the weld achieved in this work significantly improves the resolution at which residual stress in welded components has been determined.

  16. Neutron diffraction analysis of residual strain/stress distribution in the vicinity of high strength welds

    Directory of Open Access Journals (Sweden)

    Hamák I.

    2010-06-01

    Full Text Available Residual stresses resulting from non homogeneous heat distribution during welding process belong to most significant factor influencing behavior of welded structures. These stresses are responsible for defect occurrence during welding and they are also responsible for crack initiation and propagation at the either static or dynamic load. The significant effect of weld metal chemical composition as well as the effect of fatigue load and local plastic deformation on residual stress distribution and fatigue life have been recognized for high strength steels welds. The changes in residual stress distribution have then positive effect on cold cracking behavior and also on fatigue properties of the welds [1-3]. Several experimental methods, both destructive and non-destructive, such as hole drilling method, X-ray diffraction, neutron diffraction and others, have been used to examine residual stress distribution in all three significant orientations in the vicinity of the welds. The present contribution summarizes the results of neutron diffraction measurements of residual stress distribution in the vicinity of single-pass high-strength-steel welds having different chemical composition as well as the influence of fatigue load and local plastic deformation. It has been observed that the chemical composition of the weld metal has a significant influence on the stress distribution around the weld. Similarly, by aplying both cyclic load or pre-stress load on the specimens, stress relaxation was observed even in the region of approximately 40 mm far from the weld toe.

  17. Nondestructive control of residual stresses during welding and recharge processes

    International Nuclear Information System (INIS)

    Suarez, J.C.; Fernandez, L.M.; Cruz, C.; Merino, F.; Aragon, B.

    1993-01-01

    In this work, the stress state of material during welding and recharge processes is controlled with the help of Barkhausen effect. The changes, occurred in the longitudinal and transversal stress profile are show during deposition of welding rings. It is proved that the stress state of the base-material depends on the amount of recharge layers, deposited on it

  18. Finite element analysis of residual stress in the welded zone of a ...

    Indian Academy of Sciences (India)

    Unknown

    cracks, the thermal stress in the weld joint has to be minimized by controlling the weld heat input. Keywords. ... The determination of critical residual stress that initiates ... Factors influencing the for- mation and propagation of weld cracks were analysed and supporting microstructural studies were carried out. 2. Experimental.

  19. Plastic strain and residual stress distributions in an AISI 304 stainless steel BWR pipe weld

    Science.gov (United States)

    Saukkonen, Tapio; Aalto, Miikka; Virkkunen, Iikka; Ehrnstén, Ulla; Hänninen, Hannu

    In AISI 304 stainless steel pipe welds weld shrinkage causes large variations in residual plastic strain in different parts of the weld metal and heat-affected zone (HAZ). The amount of strain was analyzed by EBSD quantitatively by comparing the intra-grain misorientations to the calibration curve. Highest degrees of plastic strain (10...20%) were detected in the HAZ close to the root area of a prototypical BWR plant weld. Strain in the weld metal varies in the different directions of solidification, being high in the weld bead boundaries and near the fusion lines. Preliminary studies of the effects of mechanical and elastic anisotropy of the weld metal microstructure on the grain size level were performed by EBSD and nanoindentation. The residual stress distribution in the same weld cross-section was determined by a contour method. The residual strain and stress distributions are superimposed and EAC susceptibility of various areas of the pipe weld is evaluated and discussed.

  20. The effect of initial stress induced during the steel manufacturing process on the welding residual stress in multi-pass butt welding

    Directory of Open Access Journals (Sweden)

    Jeong-ung Park

    2018-03-01

    Full Text Available A residual stress generated in the steel structure is broadly categorized into initial residual stress during manufacturing steel material, welding residual stress caused by welding, and heat treatment residual stress by heat treatment. Initial residual stresses induced during the manufacturing process is combined with welding residual stress or heat treatment residual stress, and remained as a final residual stress. Because such final residual stress affects the safety and strength of the structure, it is of utmost importance to measure or predict the magnitude of residual stress, and to apply this point on the design of the structure. In this study, the initial residual stress of steel structures having thicknesses of 25 mm and 70 mm during manufacturing was measured in order to investigate initial residual stress (hereinafter, referred to as initial stress. In addition, thermal elastic plastic FEM analysis was performed with this initial condition, and the effect of initial stress on the welding residual stress was investigated. Further, the reliability of the FE analysis result, considering the initial stress and welding residual stress for the steel structures having two thicknesses, was validated by comparing it with the measured results. In the vicinity of the weld joint, the initial stress is released and finally controlled by the weld residual stress. On the other hand, the farther away from the weld joint, the greater the influence of the initial stress. The range in which the initial stress affects the weld residual stress was not changed by the initial stress. However, in the region where the initial stress occurs in the compressive stress, the magnitude of the weld residual compressive stress varies with the compression or tension of the initial stress. The effect of initial stress on the maximum compression residual stress was far larger when initial stress was considered in case of a thickness of 25 mm with a value of 180

  1. Residual stresses analysis of friction stir welding using one-way FSI simulation

    International Nuclear Information System (INIS)

    Kang, Sung Wook; Jang, Beom Seon; Song, Ha Cheol

    2015-01-01

    When certain mechanisms, such as plastic deformations and temperature gradients, occur and are released in a structure, stresses remain because of the shape of the structure and external constraints. These stresses are referred to as residual stresses. The base material locally expands during heating in the welding process. When the welding is completed and cooled to room temperature, the residual stresses are left at nearly the yield strength level. In the case of friction stir welding, the maximum temperature is 80% to 90% of the melting point of the materials. Thus, the residual stresses in the welding process are smaller than those in other fusion welding processes; these stresses have not been considered previously. However, friction stir welding residual stresses are sometimes measured at approximately 70% or above. These residual stresses significantly affect fatigue behavior and lifetime. The present study investigates the residual stress distributions in various welding conditions and shapes of friction stir welding. In addition, the asymmetric feature is considered in temperature and residual stress distribution. Heat transfer analysis is conducted using the commercial computational fluid dynamics program Fluent, and results are used in the finite element structural analysis with the ANSYS Multiphysics software. The calculated residual stresses are compared with experimental values using the X-ray diffraction method.

  2. Effect of preemptive weld overlay on residual stress mitigation for dissimilar metal weld of nuclear power plant pressurizer

    Energy Technology Data Exchange (ETDEWEB)

    Song, Tae Kwang; Bae, Hong Yeol; Chun, Yun Bae; Oh, Chang Young; Kim, Yun Jae [Korea University, Seoul (Korea, Republic of); Lee, Kyoung Soo; Park, Chi Yong [Korea Electric Power Research Institute, Daejeon (Korea, Republic of)

    2008-10-15

    Weld overlay is one of the residual stress mitigation methods which arrest crack initiation and crack growth. Therefore weld overlay can be applied to the region where cracking is likely to be. An overlay weld used in this manner is termed a Preemptive Weld OverLay(PWOL). In Pressurized Water Reactor(PWR) dissimilar metal weld is susceptible region for Primary Water Stress Corrosion Cracking(PWSCC). In order to examine the effect of PWOL on residual stress mitigation, PWOL was applied to a specific dissimilar metal weld of Kori nuclear power plant by finite element analysis method. As a result, strong compressive residual stress was made in PWSCC susceptible region and PWOL was proved effective preemptive repair method for weldment.

  3. Prediction of Welding Deformation and Residual Stress of Stiffened Plates Based on Experiments

    Science.gov (United States)

    Bai, R. X.; Guo, Z. F.; Lei, Z. K.

    2017-12-01

    Thermo-elastic-plastic (TEP) method is a method that can accurately predict welding deformation and residual stresses, but the premise is to select the appropriate heat source parameters. Aiming at the two welded joints in the stiffened plate studied in this paper, the welding experiments of simple components were carried out respectively, and the corresponding welding deformation and residual stresses were measured. Based on the welding experiment, the corresponding TEP model was established, and the corresponding heat source parameters were obtained according to the experimental data. The comparison between the experimental results and the numerical results shows that the obtained heat source parameters can well predict the welding deformation and residual stress of the welded structure. And then, the obtained heat source parameters were applied to the TEP model of the stiffened plate. The prediction results show that the T-type fillet welds of the stiffened plate can reduce the angular deformation caused by the butt welds to a certain extent. In addition, we can also find that the heat of the subsequent welds can reduce the residual stresses at the completed welds. This method not only can save a lot of experimental costs and time, but also can accurately predict the welding deformation and residual stresses.

  4. Reduction method for residual stress of welded joint using harmonic vibrational load

    International Nuclear Information System (INIS)

    Aoki, Shigeru; Nishimura, Tadashi; Hiroi, Tetsumaro; Hirai, Seiji

    2007-01-01

    Welding is widely used for construction of many structures. Since welding is a process using locally given heat, residual stress is generated near the bead. Tensile residual stress degrades fatigue strength. Some reduction methods of residual stress have been presented and, for example, heat treatment and shot peening are practically used. However, those methods need special tools and are time consuming. In this paper, a new method for reduction of residual stress using harmonic vibrational load during welding is proposed. The proposed method is examined experimentally for some conditions. Two thin plates are supported on the supporting device and butt-welded using an automatic CO 2 gas shielded arc welding machine. Residual stress in the direction of the bead is measured by using a paralleled beam X-ray diffractometer with scintillation counter after removing quenched scale chemically. First, the welding of rolled steel for general structure for some excitation frequencies is examined. Specimens are welded along the groove on both sides. For all frequencies, tensile residual stress near the bead is significantly reduced. Second, welding of the specimen made of high tensile strength steel is examined. In this case, tensile residual stress near the bead is also reduced. Finally, the proposed method is examined by an analytical method. An analytical model which consists of mass and preloaded springs with elasto-plastic characteristic is used. Reduction of residual stress is demonstrated using this model

  5. Effect of preemptive weld overlay on residual stress of repaired weldment in surge nozzle

    Energy Technology Data Exchange (ETDEWEB)

    Oh, Chang Young; Song, Tae Kwang; Bae, Hong Yeol; Chun, Yun Bae; Kim, Yun Jae [Korea Univ., Seoul (Korea, Republic of); Lee, Kyoung Soo; Park, Chi Yong [Korea Electric Power Research Institute, Daejeon (Korea, Republic of)

    2008-07-01

    In the welding process, weldments usually include repair weld during the manufacturing process. Repair welds is supposed to cause strong tensile residual stress. Moreover weldments, usually made by Alloy 82/182, is susceptible to PWSCC. Therefore, mitigation of welding residual stress in weldments is important for reliable operating. PWOL is one of the methods for mitigation and verified for over twenty years. In this paper, residual stress distribution of repaired weldments and the effect of PWOL on mitigation is examined for surge nozzle.

  6. Effects of residual stress on fatigue strength of small diameter welded pipe joint

    International Nuclear Information System (INIS)

    Yamashita, Tetsuo; Hattori, Takahiro; Nomoto, Toshiharu; Iida, Kunihiro; Sato, Masanobu

    1996-01-01

    A power plant consists of many welded components, therefore, it is essential in establishing the reliability of the power plant to maintain the reliability of all welded components. The fatigue failure caused by mechanical vibrations of small diameter welded joints, which is represented by socket welded joints, is one of the major causes of trouble for the welded parts of the power plant. Here, bending fatigue tests were conducted to investigate the fatigue strength of small diameter socket welded pipe joints. In the most cases of large diameter socket joints, a fatigue crack started from the root of the fillet weld though the stress amplitude at the root was smaller than that at the toe of fillet weld. Additionally, the fatigue strength was affected by the weld bead sequence. The residual stress was considered to be one of the important parameters governing fatigue strength, therefore, its effects were investigated. In several types of pipe joints, the local stress and residual stress distributions were calculated by finite element analysis. The residual stresses were compressive at the toe and tensile at the root of the socket welded joints. Based on these results, the effects of residual stresses on the fatigue strength are discussed for small diameter welded pipe joints in the present work

  7. Study of residual stresses in CT test specimens welded by electron beam

    Science.gov (United States)

    Papushkin, I. V.; Kaisheva, D.; Bokuchava, G. D.; Angelov, V.; Petrov, P.

    2018-03-01

    The paper reports result of residual stress distribution studies in CT specimens reconstituted by electron beam welding (EBW). The main aim of the study is evaluation of the applicability of the welding technique for CT specimens’ reconstitution. Thus, the temperature distribution during electron beam welding of a CT specimen was calculated using Green’s functions and the residual stress distribution was determined experimentally using neutron diffraction. Time-of-flight neutron diffraction experiments were performed on a Fourier stress diffractometer at the IBR-2 fast pulsed reactor in FLNP JINR (Dubna, Russia). The neutron diffraction data estimates yielded a maximal stress level of ±180 MPa in the welded joint.

  8. Application of welding simulation to block joints in shipbuilding and assessment of welding-induced residual stresses and distortions

    Directory of Open Access Journals (Sweden)

    Wolfgang Fricke

    2014-06-01

    Full Text Available During ship design, welding-induced distortions are roughly estimated as a function of the size of the component as well as the welding process and residual stresses are assumed to be locally in the range of the yield stress. Existing welding simulation methods are very complex and time-consuming and therefore not applicable to large structures like ships. Simplified methods for the estimation of welding effects were and still are subject of several research projects, but mostly concerning smaller structures. The main goal of this paper is the application of a multi-layer welding simulation to the block joint of a ship structure. When welding block joints, high constraints occur due to the ship structure which are assumed to result in accordingly high residual stresses. Constraints measured during construction were realized in a test plant for small-scale welding specimens in order to investigate their and other effects on the residual stresses. Associated welding simulations were successfully performed with fine-mesh finite element models. Further analyses showed that a courser mesh was also able to reproduce the welding-induced reaction forces and hence the residual stresses after some calibration. Based on the coarse modeling it was possible to perform the welding simulation at a block joint in order to investigate the influence of the resulting residual stresses on the behavior of the real structure, showing quite interesting stress distributions. Finally it is discussed whether smaller and idealized models of definite areas of the block joint can be used to achieve the same results offering possibilities to consider residual stresses in the design process.

  9. Validation of Weld Residual Stress Modeling in the NRC International Round Robin Study

    International Nuclear Information System (INIS)

    Mullins, Jonathan; Gunnars, Jens

    2013-01-01

    Weld residual stresses (WRS) have a large influence on the behavior of cracks growing under normal operation loads and on the leakage flow from a through-wall crack. Accurate prediction on weld residual stresses is important to make proper decisions when cracks in weld joints are detected. During the latest years, there has been a strong development in both analytical procedures to numerically determine WRS and experimental measurements of WRS. The USNRC (United States Nuclear Regulatory Commission) has formed a program for validation of WRS predictions through comparison of numerically calculated residual stress fields in dissimilar welds measured by different methods. The present report describes the results of the project with special focus on the contribution from Inspecta Technology. Objectives: The principal objective of the project is to compare different WRS predictions for a dissimilar pipe weld with careful measurements on a mock-up weld. The results of the project will make it possible to make recommendations on computational procedures for WRS in dissimilar metal welds. Results: It is concluded that numerical analysis of weld residual stresses using the finite element method is very useful for the estimation of weld residual stresses in complex geometries and dissimilar metal welds. The validation study increases the understanding of uncertainties associated with different modeling approaches and helps to identify the most sensitive parameters

  10. Effects of stop–start features on residual stresses in a multipass austenitic stainless steel weld

    International Nuclear Information System (INIS)

    Turski, M.; Francis, J.A.; Hurrell, P.R.; Bate, S.K.; Hiller, S.; Withers, P.J.

    2012-01-01

    In this article we describe experiments that characterise and quantify the localised perturbations in residual stress associated with both ramped and abrupt stop–start features in a multipass weld. Residual stress distributions in AISI Grade 304L/308L stainless steel groove-welded specimens, containing weld interruptions that were introduced in a controlled manner, have been characterised using both neutron diffraction and the incremental deep hole drilling method. The extent to which the localised stresses associated with the interruptions were annealed by overlayed passes was also assessed. The results suggest that, regardless of the type of interruption, there can be significant localised increases in residual stress if the stop–start feature is left exposed. If further weld passes are deposited, then the localised increases in stress are likely to persist if the interruption was abrupt, whereas for a ramped interruption they may be dissipated. - Highlights: ► In this study the residual stress-field surrounding weld interruptions was measured. ► Localised stresses were found to increase at weld interruptions. ► Both ramped and abrupt weld interruptions were investigated. ► After subsequent weld passes, localised stresses persisted for abrupt interruptions. ► After subsequent weld passes, localised stresses dissipated for ramped interruptions.

  11. Residual stress investigation of copper plate and canister EB-Welds Complementary Results

    International Nuclear Information System (INIS)

    Gripenberg, H.

    2009-03-01

    The residual stresses in copper as induced by EB-welding were studied by specimens where the weld had two configurations: either a linear or a circumferential weld. This report contains the residual stress measurements of two plates, containing linear welds, and the full-scale copper lid specimen to which a hollow cylinder section had been joined by a circumferential EB-weld. The residual stress state of the EB-welded copper specimens was investigated by X-ray diffraction (XRD), hole drilling (HD) ring core (RC) and contour method (CM). Three specimens, canister XK010 and plates X251 and X252, were subjected to a thorough study aiming at quantitative determination of the residual stress state in and around the EB-welds using XRD for surface and HD and RC for spatial stress analysis. The CM maps one stress component over a whole cross section. The surface residual stresses measured by XRD represent the machined condition of the copper material. The XRD study showed that the stress changes towards compression close to the weld in the hollow cylinder, which indicates shrinkage in the hoop direction. According to the same analogy, the shrinkage in the axial direction is much smaller. The HD measurements showed that the stress state in the base material is bi-axial and, in terms of von Mises stress, 50 MPa for the plates and 20 MPa for the cylinder part of the canister. The stress state in the EB-welds of all specimens differs clearly from the stress state in the base material being more tensile, with higher magnitudes of von Mises stress in the plate than in the canister welds. The HD and RC results were obtained using linear elastic theory. The RC measurements showed that the maximum principal stress in the BM is close to zero near the surface and it becomes slightly tensile, 10 MPa, deeper under the surface. Welding pushed the general stress state towards tension with the maximum principal stress reaching 50 MPa, deeper than 5 mm below the surface in the weld. The

  12. Tensile Residual Stress Mitigation Using Low Temperature Phase Transformation Filler Wire in Welded Armor Plates

    Energy Technology Data Exchange (ETDEWEB)

    Feng, Zhili [ORNL; Bunn, Jeffrey R [ORNL; Tzelepis, Demetrios A [ORNL; Payzant, E Andrew [ORNL; Yu, Xinghua [ORNL

    2016-01-01

    Hydrogen induced cracking (HIC) has been a persistent issue in welding of high-strength steels. Mitigating residual stresses is one of the most efficient ways to control HIC. The current study develops a proactive in-process weld residual stress mitigation technique, which manipulates the thermal expansion and contraction sequence in the weldments during welding process. When the steel weld is cooled after welding, martensitic transformation will occur at a temperature below 400 C. Volume expansion in the weld due to the martensitic transformation will reduce tensile stresses in the weld and heat affected zone and in some cases produce compressive residual stresses in the weld. Based on this concept, a customized filler wire which undergoes a martensitic phase transformation during cooling was developed. The new filler wire shows significant improvement in terms of reducing the tendency of HIC in high strength steels. Bulk residual stress mapping using neutron diffraction revealed reduced tensile and compressive residual stresses in the welds made by the new filler wire.

  13. Residual Stress Distribution in Carbon Steel Pipe Welded Joint Measured by Neutron Diffraction

    OpenAIRE

    Makoto, HAYASHI; Masayuki, ISHIWATA; Yukio, MORII; Nobuaki, MINAKAWA; ROOT, John H.; Mechanical Engineering Research Laboratory, Hitachi, Ltd.,; Nuclear Engineering Division, Hitachi Ltd.,; Tokai Establishment, Japan Atomic Energy Research Institute; Tokai Establishment, Japan Atomic Energy Research Institute; National Research Council of Canada

    2000-01-01

    In order to estimate crack growth behavior of fatigue and stress corrosion cracking in pipes, the residual stress distribution near the pipe weld region has to be measured through the wall thickness.Since the penetration depth of neutron is deep enough to pass through the thick pipe wall, the neutron diffraction technique for the residual stress measurement is effective for this purpose.At the first step the residual stress distribution near the weld region in a butt-welded carbon steel pipe ...

  14. Evaluation of residual stress distribution in austenitic stainless steel pipe butt-welded joint

    International Nuclear Information System (INIS)

    Maekawa, Akira; Noda, Michiyasu; Takahashi, Shigeru; Oumaya, Toru; Serizawa, Hisashi; Murakawa, Hidekazu

    2009-01-01

    This paper reports measured and estimated results of residual stress distributions of butt-welded austenitic stainless steel pipe in order to improve estimation accuracy of welding residual stress. Neutron diffraction and strain gauge method were employed for the measurement of the welding residual stress and its detailed distributions on inner and outer surface of the pipe as well as the distributions within the pipe wall were obtained. Finite element method was employed for the estimation. Transient and residual stresses in 3D butt-welded joint model were computed by employing Iterative Substructure Method and also commercial FEM code ABAQUS for a reference. The measured and estimated distributions presented typical characteristic of straight butt-welded pipe which had decreasing trend along the axial direction and bending type distributions through wall of the pipe. Both results were compared and the accuracy of measurement and estimation was discussed. (author)

  15. Verification of residual stresses in flash-butt-weld rails using neutron diffraction

    Science.gov (United States)

    Tawfik, David; Kirstein, Oliver; Mutton, Peter John; Chiu, Wing Kong

    2006-11-01

    Residual stresses developed during flash-butt welding may play a crucial role in prolonging the fatigue life of the welded tracks under service loading conditions. The finished welds typically exhibit high levels of tensile residual stresses in the web region of the weld. Moreover, the surface condition of the web may contain shear drag or other defects resulting from the shearing process which may lead to the initiation and propagation of fatigue cracks in a horizontal split web failure mode under high axle loads. However, a comprehensive understanding into the residual stress behaviour throughout the complex weld geometry remains unclear and is considered necessary to establish the correct localised post-weld heat treatment modifications intended to lower tensile residual stresses. This investigation used the neutron diffraction technique to analyse residual stresses in an AS60 flash-butt-welded rail cooled under normal operating conditions. The findings will ultimately contribute to developing modifications to the flash-butt-welding procedure to lower tensile residual stresses which may then improve rail performance under high axle load.

  16. Evaluation of residual stresses for the multipass welds of 316L stainless steel pipe

    International Nuclear Information System (INIS)

    Kim, S. H.; Joo, Y. S.; Lee, J. H.

    2003-01-01

    It is necessary to evaluate the influence of the residual stress and distortion in the design and fabrication of welded structure and the sound welded structure can be maintained by this consideration. Multipass welds of the 316L stainless steel have been widely employed in the pipes of Liquid Metal Reactor. In this study, the residual stresses in the 316L stainless steel pipe welds were calculated by the finite element method using ANSYS code. Also, the residual stresses both on the surface and in the interior of the thickness were measured by HRPD(High Resolution Powder Diffractometer) instrumented in HANARO Reactor. The residual stresses were measured for each 18 points in small(t/d=0.075) and large pipe specimens (t/d=0.034). The experimental and calculated results were compared and the characteristics of the distribution of the residual stress discussed

  17. Residual stress characterization of steel TIG welds by neutron diffraction and by residual magnetic stray field mappings

    Science.gov (United States)

    Stegemann, Robert; Cabeza, Sandra; Lyamkin, Viktor; Bruno, Giovanni; Pittner, Andreas; Wimpory, Robert; Boin, Mirko; Kreutzbruck, Marc

    2017-03-01

    The residual stress distribution of tungsten inert gas welded S235JRC+C plates was determined by means of neutron diffraction (ND). Large longitudinal residual stresses with maxima around 600 MPa were found. With these results as reference, the evaluation of residual stress with high spatial resolution GMR (giant magneto resistance) sensors was discussed. The experiments performed indicate a correlation between changes in residual stresses (ND) and the normal component of local residual magnetic stray fields (GMR). Spatial variations in the magnetic field strength perpendicular to the welds are in the order of the magnetic field of the earth.

  18. Research on fatigue behavior and residual stress of large-scale cruciform welding joint with groove

    International Nuclear Information System (INIS)

    Zhao, Xiaohui; Liu, Yu; Liu, Yong; Gao, Yuan

    2014-01-01

    Highlights: • The fatigue behavior of the large-scale cruciform welding joint with groove was studied. • The longitudinal residual stress of the large-scale cruciform welding joint was tested by contour method. • The fatigue fracture mechanism of the large-scale cruciform welding joint with groove was analyzed. - Abstract: Fatigue fracture behavior of the 30 mm thick Q460C-Z steel cruciform welded joint with groove was investigated. The fatigue test results indicated that fatigue strength of 30 mm thick Q460C-Z steel cruciform welded joint with groove can reach fatigue level of 80 MPa (FAT80). Fatigue crack source of the failure specimen initiated from weld toe. Meanwhile, the microcrack was also found in the fusion zones of the fatigue failure specimen, which was caused by weld quality and weld metal integrity resulting from the multi-pass welds. Two-dimensional map of the longitudinal residual stress of 30 mm thick Q460C-Z steel cruciform welded joint with groove was obtained by using the contour method. The stress nephogram of Two-dimensional map indicated that longitudinal residual stress in the welding center is the largest

  19. Residual Stress Distribution In Heat Affected Zone Of Welded Steel By Means Of Neutron Diffraction Method

    International Nuclear Information System (INIS)

    Fajar, Andika; Prasuad; Gunawan; Muslich, M. Rifai

    1996-01-01

    Three dimensional residual stress distribution in the heat affected zone of 10 mm thick welded steel by means of neutron diffraction technique has been measured. The results showed that the residual stress was distributed near the welded metal, namely within about 46,25 mm. The major tensile stresses occurred in the X-direction, and they attained a level greater than 2000 MPa through the position far away fram the weld. The tensile stresses in the Y and Z- directions lied between 500 and 1500 MPa, The results also suggest that the stress in the surface was greater than that in the middle of the sample

  20. Surface residual stress evaluation in double-electrode butt welded steel plates

    International Nuclear Information System (INIS)

    Estefen, S.F.; Gurova, T.; Castello, X.; Leontiev, A.

    2010-01-01

    Surface residual stress evaluation for double-electrode welding was studied. The stresses were monitored after each operational step: positioning, implementing of constraints, welding and constraints removal. The measurements were performed at the deposited metal, heat affected zone, base metal close to the weld joint and along the plate using the X-ray diffraction method. It was observed differences in the stress evaluations for double-electrode welding which resulted in lower bending distortions and higher values of surface residual stresses, compared with single-electrode welding. This behavior is associated with the stress distribution just after the welding processes in both heat affected zone and base metal close to the fillet for double-electrode welding. The main results from the laboratorial tests indicated lower values of the bending distortions for double-electrode welding compared with the single-electrode. In relation to the residual stress, the double-electrode welding generated, in general, higher stress values in both longitudinal and transversal directions.

  1. Distortion and residual stresses in laser beam weld shaft-hub joints

    Science.gov (United States)

    Buschenhenke, F.; Hofmann, M.; Seefeld, T.; Vollertsen, F.

    In laser beam welding, a serious challenge is to control the distortion during the process. Understanding the whole process chain in view of different distortion potentials applied in each processing step provides the ability to control the distortion of the welded components. Every manufacturing step induces residual stresses in the component which can be released by the heat of the welding process, while further residual stresses are introduced into the welded parts upon cooling. The laser beam sources of the new generation permit a high power welding process and high beam quality at the same time. These laser beams are capable of producing deep and narrow seams. Thus the thermal strains of the joined parts are expected to be minimized. Especially axial welded shaft-hub joints show an irregular distribution of bending deformation, which is caused by the self-influencing welding gap. This work deals with the investigation of different laser beam sources and their effect on the welding distortion in axial welded shafthub joints made of steel (20MnCr5). The aim of the work done was to achieve minimal distortion after the welding process. To characterize the influences on the distortion behaviour of the welded parts, residual stresses have been determined by neutron diffraction.

  2. Laser welding of 9Cr FMS: insights from residual stress measurements and computations

    International Nuclear Information System (INIS)

    Kumar, Santosh; Awasthi, Reena; Dey, G.K.

    2016-01-01

    Ferritic/Martensitic Steels (FMS) with 8-12 wt. %Cr, 1-2 wt. % Mo/W, 0.1 wt. % C and microalloying additions of ∼ 0.2 wt. % V and ∼ 0.06 wt. % Nb/Ta have emerged as the structural materials for next generation power plants and nuclear reactors. In recent times, laser and electron beam welding of these steels have drawn considerable interest owing to low heat input associated with these processes and the ensuring benefits like lower distortions, narrow fusion zone and heat affected zone, to name a few. Residual stresses are invariably associated with any weld joint due to thermo-metallurgical dilation of the material in the vicinity of the joint. These stresses can be measured experimentally as well as computed by modelling and simulation. Recent work on residual stress measurements by neutron diffraction in laser welded joints in 9Cr FMS and computations of the same, by finite element modelling and simulation, have provided a fresh insight into evolution of stresses during welding and character of the resulting residual stress-field. A brief introduction of laser welding, residual stress measurements by neutron diffraction, modelling and simulation of laser welding is presented and this is followed by a discussion on some interesting insights obtained from the measurements and computations of residual stresses in laser welded 9Cr FMS plates. (author)

  3. Optimisation of process parameters in friction stir welding based on residual stress analysis: a feasibility study

    DEFF Research Database (Denmark)

    Tutum, Cem Celal; Hattel, Jesper Henri

    2010-01-01

    The present paper considers the optimisation of process parameters in friction stir welding (FSW). More specifically, the choices of rotational speed and traverse welding speed have been investigated using genetic algorithms. The welding process is simulated in a transient, two......-dimensional sequentially coupled thermomechanical model in ANSYS. This model is then used in an optimisation case where the two objectives are the minimisation of the peak residual stresses and the maximisation of the welding speed. The results indicate that the objectives for the considered case are conflicting......, and this is presented as a Pareto optimal front. Moreover, a higher welding speed for a fixed rotational speed results, in general, in slightly higher stress levels in the tension zone, whereas a higher rotational speed for a fixed welding speed yields somewhat lower peak residual stress, however, a wider tension zone...

  4. Neutron diffraction analysis of residual stresses near unannealed welds in anhydrous ammonia nurse tanks.

    Science.gov (United States)

    Becker, A T; Chumbley, L S; Goettee, D; Russell, A M

    2014-01-01

    Neutron diffraction analysis was employed to measure residual stresses near welds in used anhydrous ammonia nurse tanks. Tensile residual stresses contribute to stress corrosion cracking of nurse tanks, which can cause tanks to release toxic ammonia vapor. The analysis showed that tensile residual stresses were present in the tanks measured, and the magnitudes of these stresses approached the yield strength of the steel. Implications for agricultural safety and health are discussed.

  5. Characterization of Residual Stress Effects on Fatigue Crack Growth of a Friction Stir Welded Aluminum Alloy

    Science.gov (United States)

    Newman, John A.; Smith, Stephen W.; Seshadri, Banavara R.; James, Mark A.; Brazill, Richard L.; Schultz, Robert W.; Donald, J. Keith; Blair, Amy

    2015-01-01

    An on-line compliance-based method to account for residual stress effects in stress-intensity factor and fatigue crack growth property determinations has been evaluated. Residual stress intensity factor results determined from specimens containing friction stir weld induced residual stresses are presented, and the on-line method results were found to be in excellent agreement with residual stress-intensity factor data obtained using the cut compliance method. Variable stress-intensity factor tests were designed to demonstrate that a simple superposition model, summing the applied stress-intensity factor with the residual stress-intensity factor, can be used to determine the total crack-tip stress-intensity factor. Finite element, VCCT (virtual crack closure technique), and J-integral analysis methods have been used to characterize weld-induced residual stress using thermal expansion/contraction in the form of an equivalent delta T (change in local temperature during welding) to simulate the welding process. This equivalent delta T was established and applied to analyze different specimen configurations to predict residual stress distributions and associated residual stress-intensity factor values. The predictions were found to agree well with experimental results obtained using the crack- and cut-compliance methods.

  6. Effect of processing conditions on residual stress distributions by bead-on-plate welding after surface machining

    International Nuclear Information System (INIS)

    Ihara, Ryohei; Mochizuki, Masahito

    2014-01-01

    Residual stress is important factor for stress corrosion cracking (SCC) that has been observed near the welded zone in nuclear power plants. Especially, surface residual stress is significant for SCC initiation. In the joining processes of pipes, butt welding is conducted after surface machining. Residual stress is generated by both processes, and residual stress distribution due to surface machining is varied by the subsequent butt welding. In previous paper, authors reported that residual stress distribution generated by bead on plate welding after surface machining has a local maximum residual stress near the weld metal. The local maximum residual stress shows approximately 900 MPa that exceeds the stress threshold for SCC initiation. Therefore, for the safety improvement of nuclear power plants, a study on the local maximum residual stress is important. In this study, the effect of surface machining and welding conditions on residual stress distribution generated by welding after surface machining was investigated. Surface machining using lathe machine and bead on plate welding with tungsten inert gas (TIG) arc under various conditions were conducted for plate specimens made of SUS316L. Then, residual stress distributions were measured by X-ray diffraction method (XRD). As a result, residual stress distributions have the local maximum residual stress near the weld metal in all specimens. The values of the local maximum residual stresses are almost the same. The location of the local maximum residual stress is varied by welding condition. It could be consider that the local maximum residual stress is generated by same generation mechanism as welding residual stress in surface machined layer that has high yield stress. (author)

  7. FEM Analysis and Measurement of Residual Stress by Neutron Diffraction on the Dissimilar Overlay Weld Pipe

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Kang Soo; Lee, Ho Jin; Woo, Wan Chuck; Seong, Baek Seok [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of); Byeon, Jin Gwi; Park, Kwang Soo; Jung, In Chul [Doosan Heavy Industries and Construction Co., Changwon (Korea, Republic of)

    2010-10-15

    Much research has been done to estimate the residual stress on a dissimilar metal weld. There are many methods to estimate the weld residual stress and FEM (Finite Element Method) is generally used due to the advantage of the parametric study. And the X-ray method and a Hole Drilling technique for an experimental method are also usually used. The aim of this paper is to develop the appropriate FEM model to estimate the residual stresses of the dissimilar overlay weld pipe. For this, firstly, the specimen of the dissimilar overlay weld pipe was manufactured. The SA 508 Gr3 nozzle, the SA 182 safe end and SA376 pipe were welded by the Alloy 182. And the overlay weld by the Alloy 52M was performed. The residual stress of this specimen was measured by using the Neutron Diffraction device in the HANARO (High-flux Advanced Neutron Application ReactOr) research reactor, KAERI (Korea Atomic Energy Research Institute). Secondly, FEM Model on the dissimilar overlay weld pipe was made and analyzed by the ABAQUS Code (ABAQUS, 2004). Thermal analysis and stress analysis were performed, and the residual stress was calculated. Thirdly, the results of the FEM analysis were compared with those of the experimental methods

  8. Residual Stresses Due to Circumferential Girth Welding of Austenitic Stainless Steel Pipes

    Science.gov (United States)

    Tarak, Farzan

    Welding, as a joining method in fabrication of engineering products and structural elements, has a direct influence on thermo-mechanical behavior of components in numerous structural applications. Since these thermo-mechanical behaviors have a major role in the life of welding components, predicting thermo-mechanical effects of welding is a major factor in designing of welding components. One of the major of these effects is generation of residual stresses due to welding. These residual stresses are not the causes of failure in the components solely, but they will add to external loads and stresses in operating time. Since, experimental methods are time consuming and expensive, computational simulation of welding process is an effective method to calculate these residual stresses. This investigation focuses on the evaluation of residual stresses and distortions due to circumferential girth welding of austenitic stainless steel pipes using the commercial finite element software ESI Visual-Environment and SYSWELDRTM to simulate welding process. Of particular importance is the comparison of results from three different types of mechanics models: 1) Axisymmetric, 2) Shell, and 3) Full 3-D.

  9. Residual stress characterization of steel TIG welds by neutron diffraction and by residual magnetic stray field mappings

    International Nuclear Information System (INIS)

    Stegemann, Robert; Cabeza, Sandra; Lyamkin, Viktor; Bruno, Giovanni; Pittner, Andreas; Wimpory, Robert; Boin, Mirko; Kreutzbruck, Marc

    2017-01-01

    The residual stress distribution of tungsten inert gas welded S235JRC+C plates was determined by means of neutron diffraction (ND). Large longitudinal residual stresses with maxima around 600 MPa were found. With these results as reference, the evaluation of residual stress with high spatial resolution GMR (giant magneto resistance) sensors was discussed. The experiments performed indicate a correlation between changes in residual stresses (ND) and the normal component of local residual magnetic stray fields (GMR). Spatial variations in the magnetic field strength perpendicular to the welds are in the order of the magnetic field of the earth. - Highlights: • Comparison of magnetic microstructure with neutron diffraction stress analysis. • High spatial resolution magnetic stray field images of hypereutectoid TIG welds. • Spatial variations of the stray fields are below the magnetic field of the earth. • GMR spin valve gradiometer arrays adapted for the evaluation of magnetic microstructures. • Magnetic stray fields are closely linked to microstructure of the material.

  10. Residual stress characterization of steel TIG welds by neutron diffraction and by residual magnetic stray field mappings

    Energy Technology Data Exchange (ETDEWEB)

    Stegemann, Robert, E-mail: Robert.Stegemann@bam.de [Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, 12200 Berlin (Germany); Cabeza, Sandra; Lyamkin, Viktor; Bruno, Giovanni; Pittner, Andreas [Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, 12200 Berlin (Germany); Wimpory, Robert; Boin, Mirko [HZB Helmholtz-Zentrum Berlin, Hahn-Meitner-Platz 1, 14109 Berlin (Germany); Kreutzbruck, Marc [Bundesanstalt für Materialforschung und -prüfung (BAM), Unter den Eichen 87, 12200 Berlin (Germany); IKT, University of Stuttgart, Pfaffenwaldring 32, 70569 Stuttgart (Germany)

    2017-03-15

    The residual stress distribution of tungsten inert gas welded S235JRC+C plates was determined by means of neutron diffraction (ND). Large longitudinal residual stresses with maxima around 600 MPa were found. With these results as reference, the evaluation of residual stress with high spatial resolution GMR (giant magneto resistance) sensors was discussed. The experiments performed indicate a correlation between changes in residual stresses (ND) and the normal component of local residual magnetic stray fields (GMR). Spatial variations in the magnetic field strength perpendicular to the welds are in the order of the magnetic field of the earth. - Highlights: • Comparison of magnetic microstructure with neutron diffraction stress analysis. • High spatial resolution magnetic stray field images of hypereutectoid TIG welds. • Spatial variations of the stray fields are below the magnetic field of the earth. • GMR spin valve gradiometer arrays adapted for the evaluation of magnetic microstructures. • Magnetic stray fields are closely linked to microstructure of the material.

  11. Residual stress distribution in ferritic to austenitic steel joints made by laser welding,

    OpenAIRE

    Iordachescu, Mihaela; Ruiz Hervías, Jesús; Luzin, V.; Scutelnicu, Elena; Valiente Cancho, Andrés; Ocaña Moreno, José Luis

    2013-01-01

    In this study, autogenous laser welding was used to join thin plates of low carbon ferritic and austenitic stainless steel. Due to the differences in the thermo-physical properties of base metals, this kind of weld exhibits a complex microstructure, which frequently leads to an overall loss of joint quality. Four welded samples were prepared by using different sets of processing parameters, with the aim of minimizing the induced residual stress field. The dissimilar austenitic-ferritic joints...

  12. On residual stress prescriptions for fitness for service assessment of pipe girth welds

    International Nuclear Information System (INIS)

    Dong, Pingsha; Song, Shaopin; Zhang, Jinmiao; Kim, Myung H.

    2014-01-01

    This paper aims to provide a detailed assessment of some of the existing residual stress profiles stipulated in widely used fitness-for-service assessment codes and standards, such as BS 7910 Appendix Q and API 579 RP Annex E, by taking advantage of some comprehensive residual stress studies that have recently become available. After presenting a case study on which residual stress measurements are available for validating finite element based residual stress analysis procedure, residual stress profiles stipulated in BS 7910 for pipe girth welds are selected for detailed evaluation by comparing residual stress distribution characteristics shown in parametric finite element results. A shell theory based full-field residual stress profile estimation scheme is then presented to illustrate how an improved estimation of residual stress profiles can be achieved in light of some of the deficiencies in BS 7910 and API 579 identified in this study. - Highlights: • Critically assessed girth weld residual stress profiles in major FFS Codes and Standards. • Identified deficiencies in relating to pipe geometry, heat input, and axial distance from weld. • Presented a shell theory based scheme for prescribing full-field residual stress profiles

  13. Through-Thickness Measurements of Residual Stresses in an Overlay Dissimilar Weld Pipe using Neutron Diffraction

    Energy Technology Data Exchange (ETDEWEB)

    Woo, Wan Chuck; EM, Vyacheslav; Lee, Ho Jin; Kim, Kang Soo; Kang, Mi Hyun; Joo, Jong Dae; Seong, Baek Seok [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of); Byeon, Jin Gwi; Park, Kwang Soo [Doosan Heavy Industries and Construction Co., Changwon (Korea, Republic of)

    2010-10-15

    The distribution of residual stresses in dissimilar material joints has been extensively studied because of the wide applications of the dissimilar welds in many inevitable complex design structures. Especially the cracking of dissimilar welding has been a long standing issue of importance in many components of the power generation industries such as nuclear power plant, boiling pressure system, and steam generators. In particular, several failure analysis and direct observations have shown that critical fractures have frequently occurred in one side of the dissimilar welded parts. For example, the heat-affected zone on the ferrite steel side is known to critical in many dissimilar welding pipes when ferrite (low carbon steel) and austenite (stainless) steels are joined. The main cause of the residual stresses can be attributed to the mismatch in the coefficient of thermal expansion between the dissimilar metals (ferrite and austenite). Additional cladding over circumferential welds is known to reinforce the mechanical property due to the beneficial compressive residual stress imposed on the weld and heat-affected zone. However, science-based quantitative measurement of the through thickness residual stress distribution is very limited in literature. The deep penetration capability of neutrons into most metallic materials makes neutron diffraction a powerful tool to investigate and map the residual stresses of materials throughout the thickness and across the weld. Furthermore, the unique volume averaged bulk characteristic of materials and mapping capability in three dimensions are suitable for the engineering purpose. Thus, the neutron-diffraction measurement method has been selected as the most useful method for the study of the residual stresses in various dissimilar metal welded structures. The purpose of this study is to measure the distribution of the residual stresses in a complex dissimilar joining with overlay in the weld pipe. Specifically, we measured

  14. Effects of weld residual stresses on crack-opening area analysis of pipes for LBB applications

    International Nuclear Information System (INIS)

    Dong, P.; Rahman, S.; Wilkowski, G.

    1997-01-01

    This paper summarizes four different studies undertaken to evaluate the effects of weld residual stresses on the crack-opening behavior of a circumferential through-wall crack in the center of a girth weld. The effect of weld residual stress on the crack-opening-area and leak-rate analyses of a pipe is not well understood. There are no simple analyses to account for these effects, and, therefore, they are frequently neglected. The four studies involved the following efforts: (1) Full-field thermoplastic finite element residual stress analyses of a crack in the center of a girth weld, (2) A comparison of the crack-opening displacements from a full-field thermoplastic residual stress analysis with a crack-face pressure elastic stress analysis to determine the residual stress effects on the crack-opening displacement, (3) The effects of hydrostatic testing on the residual stresses and the resulting crack-opening displacement, and (4) The effect of residual stresses on crack-opening displacement with different normal operating stresses

  15. Effects of weld residual stresses on crack-opening area analysis of pipes for LBB applications

    Energy Technology Data Exchange (ETDEWEB)

    Dong, P.; Rahman, S.; Wilkowski, G. [and others

    1997-04-01

    This paper summarizes four different studies undertaken to evaluate the effects of weld residual stresses on the crack-opening behavior of a circumferential through-wall crack in the center of a girth weld. The effect of weld residual stress on the crack-opening-area and leak-rate analyses of a pipe is not well understood. There are no simple analyses to account for these effects, and, therefore, they are frequently neglected. The four studies involved the following efforts: (1) Full-field thermoplastic finite element residual stress analyses of a crack in the center of a girth weld, (2) A comparison of the crack-opening displacements from a full-field thermoplastic residual stress analysis with a crack-face pressure elastic stress analysis to determine the residual stress effects on the crack-opening displacement, (3) The effects of hydrostatic testing on the residual stresses and the resulting crack-opening displacement, and (4) The effect of residual stresses on crack-opening displacement with different normal operating stresses.

  16. Estimation of residual stress in welding of dissimilar metals at nuclear power plants using cascaded support vetor regression

    Energy Technology Data Exchange (ETDEWEB)

    Koo, Young Do; Yoo, Kwae Hwan; Na, Man Gyun [Dept. of Nuclear Engineering, Chosun University, Gwangju (Korea, Republic of)

    2017-06-15

    Residual stress is a critical element in determining the integrity of parts and the lifetime of welded structures. It is necessary to estimate the residual stress of a welding zone because residual stress is a major reason for the generation of primary water stress corrosion cracking in nuclear power plants. That is, it is necessary to estimate the distribution of the residual stress in welding of dissimilar metals under manifold welding conditions. In this study, a cascaded support vector regression (CSVR) model was presented to estimate the residual stress of a welding zone. The CSVR model was serially and consecutively structured in terms of SVR modules. Using numerical data obtained from finite element analysis by a subtractive clustering method, learning data that explained the characteristic behavior of the residual stress of a welding zone were selected to optimize the proposed model. The results suggest that the CSVR model yielded a better estimation performance when compared with a classic SVR model.

  17. Estimation of residual stress in welding of dissimilar metals at nuclear power plants using cascaded support vector regression

    Directory of Open Access Journals (Sweden)

    Young Do Koo

    2017-06-01

    Full Text Available Residual stress is a critical element in determining the integrity of parts and the lifetime of welded structures. It is necessary to estimate the residual stress of a welding zone because residual stress is a major reason for the generation of primary water stress corrosion cracking in nuclear power plants. That is, it is necessary to estimate the distribution of the residual stress in welding of dissimilar metals under manifold welding conditions. In this study, a cascaded support vector regression (CSVR model was presented to estimate the residual stress of a welding zone. The CSVR model was serially and consecutively structured in terms of SVR modules. Using numerical data obtained from finite element analysis by a subtractive clustering method, learning data that explained the characteristic behavior of the residual stress of a welding zone were selected to optimize the proposed model. The results suggest that the CSVR model yielded a better estimation performance when compared with a classic SVR model.

  18. Residual stress measurements in the dissimilar metal weld in pressurizer safety nozzle of nuclear power plant

    Energy Technology Data Exchange (ETDEWEB)

    Campos, Wagner R.C.; Rabello, Emerson G.; Mansur, Tanius R.; Scaldaferri, Denis H.B.; Paula, Raphael G., E-mail: wrcc@cdtn.br, E-mail: egr@cdtn.br, E-mail: tanius@cdtn.br, E-mail: dhbs@cdtn.br, E-mail: tanius@cdtn.br, E-mail: raphaelmecanica@gmail.com [Centro de Desenvolvimento da Tecnologia Nuclear (CDTN/CNEN-MG), Belo Horizonte, MG (Brazil); Souto, Joao P.R.S.; Carvalho Junior, Ideir T., E-mail: joprocha@yahoo.com.br, E-mail: ideir_engenharia@yahoo.com.br [Universidade Federal de Minas Gerais (UFMG), Belo Horizonte, MG (Brazil). Dept. de Engenharia Metalurgica

    2013-07-01

    Weld residual stresses have a large influence on the behavior of cracking that could possibly occur under normal operation of components. In case of an unfavorable environment, both stainless steel and nickel-based weld materials can be susceptible to stress-corrosion cracking (SCC). Stress corrosion cracks were found in dissimilar metal welds of some pressurized water reactor (PWR) nuclear plants. In the nuclear reactor primary circuit the presence of tensile residual stress and corrosive environment leads to so-called Primary Water Stress Corrosion Cracking (PWSCC). The PWSCC is a major safety concern in the nuclear power industry worldwide. PWSCC usually occurs on the inner surface of weld regions which come into contact with pressurized high temperature water coolant. However, it is very difficult to measure the residual stress on the inner surfaces of pipes or nozzles because of inaccessibility. A mock-up of weld parts of a pressurizer safety nozzle was fabricated. The mock-up was composed of three parts: an ASTM A508 C13 nozzle, an ASTM A276 F316L stainless steel safe-end, an AISI 316L stainless steel pipe and different filler metals of nickel alloy 82/182 and AISI 316L. This work presents the results of measurements of residual strain from the outer surface of the mock-up welded in base metals and filler metals by hole-drilling strain-gage method of stress relaxation. (author)

  19. Residual stress measurements in the dissimilar metal weld in pressurizer safety nozzle of nuclear power plant

    International Nuclear Information System (INIS)

    Campos, Wagner R.C.; Rabello, Emerson G.; Mansur, Tanius R.; Scaldaferri, Denis H.B.; Paula, Raphael G.; Souto, Joao P.R.S.; Carvalho Junior, Ideir T.

    2013-01-01

    Weld residual stresses have a large influence on the behavior of cracking that could possibly occur under normal operation of components. In case of an unfavorable environment, both stainless steel and nickel-based weld materials can be susceptible to stress-corrosion cracking (SCC). Stress corrosion cracks were found in dissimilar metal welds of some pressurized water reactor (PWR) nuclear plants. In the nuclear reactor primary circuit the presence of tensile residual stress and corrosive environment leads to so-called Primary Water Stress Corrosion Cracking (PWSCC). The PWSCC is a major safety concern in the nuclear power industry worldwide. PWSCC usually occurs on the inner surface of weld regions which come into contact with pressurized high temperature water coolant. However, it is very difficult to measure the residual stress on the inner surfaces of pipes or nozzles because of inaccessibility. A mock-up of weld parts of a pressurizer safety nozzle was fabricated. The mock-up was composed of three parts: an ASTM A508 C13 nozzle, an ASTM A276 F316L stainless steel safe-end, an AISI 316L stainless steel pipe and different filler metals of nickel alloy 82/182 and AISI 316L. This work presents the results of measurements of residual strain from the outer surface of the mock-up welded in base metals and filler metals by hole-drilling strain-gage method of stress relaxation. (author)

  20. Nondestructive Testing of Residual Stress on the Welded Part of Butt-welded A36 Plates Using Electronic Speckle Pattern Interferometry

    Directory of Open Access Journals (Sweden)

    Kyeongsuk Kim

    2016-02-01

    Full Text Available Most manufacturing processes, including welding, create residual stresses. Residual stresses can reduce material strength and cause fractures. For estimating the reliability and aging of a welded structure, residual stresses should be evaluated as precisely as possible. Optical techniques such as holographic interferometry, electronic speckle pattern interferometry (ESPI, Moire interferometry, and shearography are noncontact means of measuring residual stresses. Among optical techniques, ESPI is typically used as a nondestructive measurement technique of in-plane displacement, such as stress and strain, and out-of-plane displacement, such as vibration and bending. In this study, ESPI was used to measure the residual stress on the welded part of butt-welded American Society for Testing and Materials (ASTM A36 specimens with CO2 welding. Four types of specimens, base metal specimen (BSP, tensile specimen including welded part (TSP, compression specimen including welded part (CSP, and annealed tensile specimen including welded part (ATSP, were tested. BSP was used to obtain the elastic modulus of a base metal. TSP and CSP were used to compare residual stresses under tensile and compressive loading conditions. ATSP was used to confirm the effect of heat treatment. Residual stresses on the welded parts of specimens were obtained from the phase map images obtained by ESPI. The results confirmed that residual stresses of welded parts can be measured by ESPI.

  1. Residual stress distribution in carbon steel pipe welded joint measured by neutron diffraction

    International Nuclear Information System (INIS)

    Hayashi, Makoto; Ishiwata, Masayuki; Morii, Yukio; Minakawa, Nobuaki

    2000-01-01

    In order to estimate crack growth behavior of fatigue and stress corrosion cracking in pipes, the residual stress distribution near the pipe weld region has to be measured through the wall thickness. Since the penetration depth of neutron is deep enough to pass through the thick pipe wall, the neutron diffraction technique for the residual stress measurement is effective for this purpose. At the first step the residual stress distribution near the weld region in a butt-welded carbon steel pipe was measured by the neutron diffraction. Significant stresses extended only to a distance of 30 mm from the center of the weld. The major tensile stresses occurred in the hoop direction in the fusion and heat affected zones of the weldment, and they attained a level greater than 200 MPa through the thickness. While the axial residual stress at the inside surface was 50 MPa, the stress at the outside surface was -100 MPa. The comparison of residual stress distributions measured by the neutron diffraction, the X-ray diffraction and the strain gauge method reveals that the neutron diffraction is the most effective for measuring the residual stress inside the structural components. (author)

  2. An Evaluation on the Residual Stresses Induced by EFR Welding of CEDM Nozzle

    Energy Technology Data Exchange (ETDEWEB)

    Lee, Sang Ho; Park, Gi Yeol; Kim, Tae Ryong [KEPCO International Nuclear Graduate School, Ulsan (Korea, Republic of)

    2015-10-15

    In this paper, carried out the welding analysis to use the SYSWELD as welding interpretation code based on the reactor upper head nozzle. In this paper, evaluated the residual stress in CEDM nozzle by EFR through the SYSWELD which is the welding interpretation code. The conclusion are same as below. 1) When comparing with Hoop Stress and Axial Stress by J-Groove and EFR, after welding residual stress by EFR is lower than after J-Groove. 2) After EFR, it was confirmed that the tensile stress is reduced after increasing over the point3. The PWSCC of Dissimilar Metal Zone of reactor can degrade the integrity of the main device in nuclear power plant, and according to the power plant stopped for inspection, it can cause an enormous amount of lost sales when the crack is occurred. Various methods have been developed to reduce residual stress to prevent the PWSCC like Weld Overlay (WOL), Mechanical Stress Improvement Process (Msp), Laser Peening, Inlay Weld, etc. Among them, Wol is the most commonly used welding method in nuclear power plant. When performing a Wol, structure rigidity will be increase, and residual stress of welding zone will be changed into compressive stress from the tensile stress. This has the advantage that improved resistance to PWSCC. The most commonly used material in nuclear power plant is Inconel 600. Inconel 600 consist of a Ni-Cr-Fe and it has 14-17% of Cr content, 10% of Fe content and susceptible to PWSCC. The more Cr content is more stronger against PWSCC. Inconel 690 which has 2 times more Cr content than Inconel 600 has very strong resistance to PWSCC than Inconel 600. Embedded Flaw Repair (EFR) has been developed in Westinghouse by 1994. The welding metal with high corrosion resistance is embedded on the surface of component, and could protect cracking part from the PWSCC. It is permanent repair method that isolates the flaw from the environment, eliminating further crack propagation due to PWSCC. EFR method is that at least three layers

  3. An Evaluation on the Residual Stresses Induced by EFR Welding of CEDM Nozzle

    International Nuclear Information System (INIS)

    Lee, Sang Ho; Park, Gi Yeol; Kim, Tae Ryong

    2015-01-01

    In this paper, carried out the welding analysis to use the SYSWELD as welding interpretation code based on the reactor upper head nozzle. In this paper, evaluated the residual stress in CEDM nozzle by EFR through the SYSWELD which is the welding interpretation code. The conclusion are same as below. 1) When comparing with Hoop Stress and Axial Stress by J-Groove and EFR, after welding residual stress by EFR is lower than after J-Groove. 2) After EFR, it was confirmed that the tensile stress is reduced after increasing over the point3. The PWSCC of Dissimilar Metal Zone of reactor can degrade the integrity of the main device in nuclear power plant, and according to the power plant stopped for inspection, it can cause an enormous amount of lost sales when the crack is occurred. Various methods have been developed to reduce residual stress to prevent the PWSCC like Weld Overlay (WOL), Mechanical Stress Improvement Process (Msp), Laser Peening, Inlay Weld, etc. Among them, Wol is the most commonly used welding method in nuclear power plant. When performing a Wol, structure rigidity will be increase, and residual stress of welding zone will be changed into compressive stress from the tensile stress. This has the advantage that improved resistance to PWSCC. The most commonly used material in nuclear power plant is Inconel 600. Inconel 600 consist of a Ni-Cr-Fe and it has 14-17% of Cr content, 10% of Fe content and susceptible to PWSCC. The more Cr content is more stronger against PWSCC. Inconel 690 which has 2 times more Cr content than Inconel 600 has very strong resistance to PWSCC than Inconel 600. Embedded Flaw Repair (EFR) has been developed in Westinghouse by 1994. The welding metal with high corrosion resistance is embedded on the surface of component, and could protect cracking part from the PWSCC. It is permanent repair method that isolates the flaw from the environment, eliminating further crack propagation due to PWSCC. EFR method is that at least three layers

  4. The Effect of Weld Residual Stress on Life of Used Nuclear Fuel Dry Storage Canisters

    Energy Technology Data Exchange (ETDEWEB)

    Ronald G. Ballinger; Sara E. Ferry; Bradley P. Black; Sebastien P. Teysseyre

    2013-08-01

    With the elimination of Yucca Mountain as the long-term storage facility for spent nuclear fuel in the United States, a number of other storage options are being explored. Currently, used fuel is stored in dry-storage cask systems constructed of steel and concrete. It is likely that used fuel will continue to be stored at existing open-air storage sites for up to 100 years. This raises the possibility that the storage casks will be exposed to a salt-containing environment for the duration of their time in interim storage. Austenitic stainless steels, which are used to construct the canisters, are susceptible to stress corrosion cracking (SCC) in chloride-containing environments if a continuous aqueous film can be maintained on the surface and the material is under stress. Because steel sensitization in the canister welds is typically avoided by avoiding post-weld heat treatments, high residual stresses are present in the welds. While the environment history will play a key role in establishing the chemical conditions for cracking, weld residual stresses will have a strong influence on both crack initiation and propagation. It is often assumed for modeling purposes that weld residual stresses are tensile, high and constant through the weld. However, due to the strong dependence of crack growth rate on stress, this assumption may be overly conservative. In particular, the residual stresses become negative (compressive) at certain points in the weld. The ultimate goal of this research project is to develop a probabilistic model with quantified uncertainties for SCC failure in the dry storage casks. In this paper, the results of a study of the residual stresses, and their postulated effects on SCC behavior, in actual canister welds are presented. Progress on the development of the model is reported.

  5. Effect of Ultrasonic Peening and Accelerated Corrosion Exposure on the Residual Stress Distribution in Welded Marine Steel

    Science.gov (United States)

    Ahmad, Bilal; Fitzpatrick, Michael E.

    2015-03-01

    Specimens of DH36 marine steel were prepared with welded attachments. Residual stress measurements were made on the samples as-welded, following an ultrasonic peening treatment, and following accelerated corrosion exposure after ultrasonic peening. Neutron diffraction and the contour method were used for determining the residual stress profiles. The welding introduces tensile near-surface residual stress, approaching the material yield strength, and the ultrasonic peening overlays this with a compressive residual stress. Material removal by corrosion decreases the peak surface compressive stress slightly, by removal of a layer of stressed material, but does not cause significant redistribution of the residual stress profile.

  6. Effects of tooling on the residual stress distribution in an inertia weld

    International Nuclear Information System (INIS)

    Pang, J.W.L.; Preuss, M.; Withers, P.J.; Baxter, G.J.; Small, C.

    2003-01-01

    Neutron diffraction residual strain measurements have been made on a tubular structure formed by joining two nickel-based superalloy RR1000 parts by inertia welding. Residual strains in the radial, hoop and axial directions of the tube cross-section have been measured. The corresponding residual stress field has been calculated accounting for the stress-free lattice parameter variations in the region close to the weld line. Tensile residual stresses were observed near the inner diameter of the tube with magnitudes of the order of +500, +1100 and +1300 MPa in the radial, axial and hoop directions, respectively. By comparison near the outer diameter (OD) of the weld the corresponding stresses are of the order of -200, -1000 and 150 MPa. The final stress state reflects the influence of the gripping fixture tooling and thermal gradients during inertia welding. Additional X-ray (at the surface) and hole-drilling (at the near surface) measurements show a steep residual stress gradient in the near surface region. Tensile hoop and axial machining stresses at the surface indicate the potential for improving the inertia weld tooling and the machining parameters used when removing the flash

  7. Investigation of residual stress in laser welding between carbon steel AISI 1010 and stainless AISI 304

    International Nuclear Information System (INIS)

    Mirim, Denilson de Camargo

    2011-01-01

    The dissimilar materials union has the residual stress formation as one of the most critical problems, which occurs mainly because these materials have both different thermal expansion coefficients and thermal conductivities. In this study, it was investigated the laser welding technique between steels, AISI 1010 and AISI 304. The materials were joined by butt autogenous welding with a continuous Nd:YAG laser. The main objective was to identify the welding parameters influence by the residual stresses analysis in the heat affected zone (HAZ). It was executed a factorial design with three-factor at two levels with a replica, which were varied power, welding speed and focal position of the laser beam. Residual stress measurements by the diffraction of X-rays were performed on the sample surface, to study their variation as a function of the parameters investigated. The blind hole method was also used to evaluate the residual stress along the samples depth, up to depth of 1mm. Besides residual stress measurement, weld seams were evaluated by optical and scanned electron microscopy, which were aimed to determine the weld geometry and changes in the microstructure. It was also made Vickers hardness measurements to evaluate the extent of HAZ. To evaluate the mechanical properties of the union were performed tensile and fatigue test. The MINITAB 15 software was used to analyze the residual stresses obtained by the blind hole method at different depths of the HAZ. It was also used statistical regression based on both the influences different and the combination of this input factors, in the residual stress of union. The results indicate that the models can satisfactorily predict the responses and provide users a guide to better define the welding parameters. (author)

  8. Effect of Welding Processes on the Microstructure, Mechanical Properties and Residual Stresses of Plain 9Cr-1Mo Steel Weld Joints

    Science.gov (United States)

    Nagaraju, S.; Vasantharaja, P.; Brahadees, G.; Vasudevan, M.; Mahadevan, S.

    2017-12-01

    9Cr-1Mo steel designated as P9 is widely used in the construction of power plants and high-temperature applications. It is chosen for fabricating hexcan fuel subassembly wrapper components of fast breeder reactors. Arc welding processes are generally used for fabricating 9Cr-1Mo steel weld joints. A-TIG welding process is increasingly being adopted by the industries. In the present study, shielded metal arc (SMA), tungsten inert gas (TIG) and A-TIG welding processes are used for fabricating the 9Cr-1Mo steel weld joints of 10 mm thickness. Effect of the above welding processes on the microstructure evolution, mechanical properties and residual stresses of the weld joints has been studied in detail. All the three weld joints exhibited comparable strength and ductility values. 9Cr-1Mo steel weld joint fabricated by SMAW process exhibited lower impact toughness values caused by coarser grain size and inclusions. 9Cr-1Mo steel weld joint fabricated by TIG welding exhibited higher toughness due to finer grain size, while the weld joint fabricated by A-TIG welding process exhibited adequate toughness values. SMA steel weld joint exhibited compressive residual stresses in the weld metal and HAZ, while TIG and A-TIG weld joint exhibited tensile residual stresses in the weld metal and HAZ.

  9. Application of the bead flush method to welded pipes to evaluate residual stresses nondestructively

    International Nuclear Information System (INIS)

    Nakamura, H.; Yamamoto, M.

    2002-01-01

    To assess the structural integrity of welded structures during the design and in-service inspection, it is important to evaluate welding residual stresses. Recently, the design process of structures has shifted from 'the design by rule' to 'the design by analysis' using the FEM (finite element method) codes. As the design process advances, analytical processes have formed a link in the chain of manufacturing and in-service inspection procedures. Under this circumstance, authors have proposed a new method called 'the Bead Flush Method', to evaluate the welding residual stresses by utilizing the FEM data constructed during the structural design. In this method, eigenstrains as sources of residual stresses are calculated from released elastic strains after removal of reinforcement of the weld by applying the inverse analysis. Then, residual stresses as well as displacements at any location concerned are evaluated by imposing eigenstrains as initial strains in the FEM analysis. Mechanical properties required through this analysis are the elastic constants at room temperature. No further properties, such as temperature dependencies of the yield strength and the thermal coefficient, are needed. By now, we have confirmed its utility for welded plates by computer simulations and experiments. In this study, further development of this method for application to welded pipes was attempted. Despite its relatively simple shape of pipes (axe symmetrical) compared with welded plates (3-dimentional), welded pipe problems are more complicated than those of welded plates from a view point of the inverse analysis. As a first step, a basic formulization was attempted to overcome this difficulty and future problems to be solved were made clear. Then computer simulations of the bead flush method conducted for a thin walled welded pipe confirmed its utility. Refs. 2 (author)

  10. Residual Stresses in Inertia-Friction-Welded Dissimilar High-Strength Steels

    Science.gov (United States)

    Moat, R. J.; Hughes, D. J.; Steuwer, A.; Iqbal, N.; Preuss, M.; Bray, S. E.; Rawson, M.

    2009-09-01

    The welding of dissimilar alloys is seen increasingly as a way forward to improve efficiencies in modern aeroengines, because it allows one to tailor varying material property demands across a component. Dissimilar inertia friction welding (IFW) of two high-strength steels, Aermet 100 and S/CMV, has been identified as a possible joint for rotating gas turbine components and the resulting welds are investigated in this article. In order to understand the impact of the welding process and predict the life expectancy of such structures, a detailed understanding of the residual stress fields present in the welded component is needed. By combining energy-dispersive synchrotron X-ray diffraction (EDSXRD) and neutron diffraction, it has been possible to map the variations in lattice spacing of the ferritic phase on both sides of two tubular Aermet 100-S/CMV inertia friction welds (as-welded and postweld heat-treated condition) with a wall thickness of 37 mm. Laboratory-based XRD measurements were required to take into account the variation in the strain-free d-spacing across the weld region. It was found that, in the heat-affected zone (HAZ) slightly away from the weld line, residual stress fields showed tensile stresses increasing most dramatically in the hoop direction toward the weld line. Closer to the weld line, in the plastically affected zone, a sharp drop in the residual stresses was observed on both sides, although more dramatically in the S/CMV. In addition to residual stress mapping, synchrotron XRD measurements were carried out to map microstructural changes in thin slices cut from the welds. By studying the diffraction peak asymmetry of the 200- α diffraction peak, it was possible to demonstrate that a martensitic phase transformation in the S/CMV is responsible for the significant stress reduction close to the weld line. The postweld heat treatment (PWHT) chosen to avoid any overaging of the Aermet 100 and to temper the S/CMV martensite resulted in little

  11. Sensitivity Analysis for Residual Stress on DVI (Direct Vessel Injection) Nozzle Welded Joint

    Energy Technology Data Exchange (ETDEWEB)

    Noh, Byeong Wook; Chung, Sung Ho; Lee, Jung Hun; Kim, Oak Sug [DOOSAN Heavy Industries and Construction Co. LTD, Reactor Design Team, 555 Guygok-dong Changwon (Korea, Republic of)

    2008-07-01

    Generally, any welding process produces high compressive or tensile residual stresses in the heat affected zone depending on the method, shape and procedures of the weldment. In particular, the tensile residual stresses have a considerable effect on the material strength, fatigue strength and corrosion cracking. For this reason, it is important that some knowledge of the internal stress state be deduced either from measurements or from modeling predictions. In this study, the residual stresses after a multi-pass welding process for DVI nozzle welding joint were evaluated by a numerical simulation method. The welding joint considered three weld joint angles of 40 deg., 6 deg. and 2 deg. Computations were made using a 2-D finite element model based on the simulation of cooling from the heat treatment temperature to room temperature with two cooling conditions at the inside surface. In these results, it is shown that the residual stress increased at the inner surface, when water cooling was applied to the inner surface, and axial compressive residual stress increased at the inner surface when the joint angle was decreased. (authors)

  12. Surface preparation for residual stress measurement of an accelerated corrosion tested welded marine steel

    International Nuclear Information System (INIS)

    Ahmad, Bilal; Fitzpatrick, Michael E.

    2015-01-01

    Residual stress measurement is often required for the assessment of structural integrity of components. Measurement of residual stress in corrosion tested specimens is challenging owing to the difficulty of accessing the surface because of the rust layer. This study explored the potential methods for the surface preparation of an ultrasonically-peened and accelerated corrosion tested DH36 marine steel fillet welded specimen to ease the way for subsequent residual stress measurement using neutron diffraction and the contour method. We find that hydroblasting introduces compressive residual stress at the surface that will alter the surface stress to be measured

  13. The inclusion of weld residual stress in fracture margin assessments of embrittled nuclear reactor pressure vessels

    International Nuclear Information System (INIS)

    Dickson, T.L.; Bass, B.R.; McAfee, W.J.

    1998-01-01

    Analyses were performed to determine the impact of weld residual stresses in a reactor pressure vessel (RPV) on (1) the generation of pressure temperature (P-T) curves required for maintaining specified fracture prevention margins during nuclear plant startup and shutdown, and (2) the conditional probability of vessel failure due to pressurized thermal shock (PTS) loading. The through wall residual stress distribution in an axially oriented weld was derived using measurements taken from a shell segment of a canceled RPV and finite element thermal stress analyses. The P-T curve derived from the best estimate load analysis and a t / 8 deep flaw, based on K Ic , was less limiting than the one derived from the current methodology prescribed in the ASME Boiler and Pressure Vessel Code. The inclusion of the weld residual stresses increased the conditional probability of cleavage fracture due to PTS loading by a factor ranging from 2 to 4

  14. Evaluation of residual stresses in welded part using hard synchrotron x-rays

    International Nuclear Information System (INIS)

    Suzuki, Kenji; Shobu, Takahisa; Shiro, Ayumi; Zhang Shuoyuan

    2013-01-01

    The spiral slit-system and DSTM (diffraction spot trace method) are under development in order to evaluate internal stresses of materials with coarse grains. The spiral slit-system was improved so that the length of the gauge volume is independent of the diffraction angle. The bending stress in the specimen with coarse grains was measured in order to confirm performance of this advanced spiral slit-system. The distribution of the measured bending stress coincided with the applied bending stress. As a result, it was proved that the combination of the advanced spiral slit-system and the DSTM is useful for the internal stress measurement of materials with coarse grains. The welded specimen of a Mg-alloy plate was prepared by melt-run with TIG welding. The residual stress map in the cross-section of the specimen was made using the DSTM. On the other hand, the residual stresses of the welded specimen were simulated by a finite element method. Although the measured residual stresses were similar to the simulated results, the residual stresses due to extrusion were measured also using the DSTM. The DSTM is an excellent technique for the stress measurement of weld parts. (author)

  15. Residual stress distribution in carbon steel pipe welded joints measured by neutron diffraction

    International Nuclear Information System (INIS)

    Hayashi, Makoto; Ishiwata, Masayuki; Morii, Yukio; Minakawa, Nobuaki.

    1996-01-01

    Three dimensional residual stress distributions in a 4 inch diameter carbon steel pipe welded joint were measured by neutron diffraction technique. The results showed that the residual stress distributed near the weld metal, namely within about 30mm. The major tensile stresses occurred in the hoop direction in the fusion and heat affected zones of the weldment, and they attained a level greater than 200 MPa throughout the pipe wall thickness. While the axial residual stress at the inside surface was 40 MPa, the stress at the outside surface was -100 MPa. These residual stress distributions were compared with those measured by the X-ray diffraction technique and strain gauge method, and they agreed with each other. (author)

  16. Characterization of Mechanical Properties and Residual Stress in API 5L X80 Steel Welded Joints

    Science.gov (United States)

    de Sousa Lins, Amilton; de Souza, Luís Felipe Guimarães; Fonseca, Maria Cindra

    2018-01-01

    The use of high-strength and low-alloy steels, high design factors and increasingly stringent safety requirements have increased the operating pressure levels and, consequently, the need for further studies to avoid and prevent premature pipe failure. To evaluate the possibility of improving productivity in manual arc welding of this type of steel, this work characterizes the mechanical properties and residual stresses in API 5L X80 steel welded joints using the SMAW and FCAW processes. The residual stresses were analyzed using x-ray diffraction with the sin2 ψ method at the top and root of the welded joints in the longitudinal and transverse directions of the weld bead. The mechanical properties of the welded joints by both processes were characterized in terms of tensile strength, impact toughness and Vickers microhardness in the welded and shot peening conditions. A predominantly compressive residual stress was found, and shot peening increased the tensile strength and impact toughness in both welded joints.

  17. Residual stresses measurement by neutron diffraction and theoretical estimation in a single weld bead

    International Nuclear Information System (INIS)

    Price, John W.H.; Paradowska, Anna; Joshi, Suraj; Finlayson, Trevor

    2006-01-01

    Welding residual stresses are important in pressure vessel and structural applications. However, residual stress remains the single largest unknown in industrial damage situations. They are difficult to measure or theoretically estimate and are often significant when compared with the in-service stresses on which they superimpose. High residual stresses lead to loss of performance in corrosion, fatigue and fracture. In this research, a measurement of residual stress by the neutron diffraction technique is compared to an analysis of the same geometry by theoretical finite element procedures. The results indicate good agreement but scope for further understanding of the details of modelling the welding heat source, heat transfer and variation of material properties with temperature

  18. Characterising electron beam welded dissimilar metal joints to study residual stress relaxation from specimen extraction

    International Nuclear Information System (INIS)

    Abburi Venkata, K.; Truman, C.E.; Smith, D.J.; Bhaduri, A.K.

    2016-01-01

    Nuclear power plants require dissimilar metal weld joints to connect the primary steam generator made from ferritic steel to the intermediate heat exchanger made from austenitic steel. Such joints are complex because of the mismatch in the thermal and the mechanical properties of the materials used in the joint. Electron Beam (EB) welding is emerging as a promising technique to manufacture dissimilar joints providing a great many advantages over conventional welding techniques, in terms of low heat input, high heat intensity, narrow fusion and heat affected zones, deeper penetration and increased welding speeds. However before this method can be considered for implementation in an actual plant, it is essential for a careful and a comprehensive outlining of the joint characteristics and the apparent effects on performance during service. In the present study, an EB welded joint was manufactured using austenitic AISI 316LN stainless steel and a ferritic-martensitic P91 steel, without the addition of filler material. Neutron diffraction measurement was conducted on the welded plate to measure the residual stress distribution across the weld as well as through the thickness of the plate. A finite element analysis was conducted on a two-dimensional cross-sectional model using ABAQUS code to simulate the welding process and predict the residual stresses, implementing the effects of solid-state phase transformation experienced by P91 steel. The predicted residual stresses were transferred to a 3D finite element model of the plate to simulate the machining and extraction of a C(T) blank specimen from the welded plate and the extent of stress relaxation is studied.

  19. REAL STRUCTURE AND RESIDUAL STRESSES IN ADVANCED WELDS DETERMINED BY X-RAY AND NEUTRON DIFFRACTION

    Directory of Open Access Journals (Sweden)

    Karel Trojan

    2017-07-01

    Full Text Available The paper outlines the capability of X-ray diffraction (XRD for evaluation of real structure changes and residual stresses (RS on cross-section of advanced thick welds due to the welding of ferromagnetic plates. The results of neutron diffraction describe a three-dimensional state of RS and also verify previous assumptions of RS redistribution as a result of the surface preparation for determination 2D maps measured by XRD.

  20. Residual Stresses in Thick Bi-metallic Fusion Welds: A Neutron Diffraction Study

    OpenAIRE

    Ohms, C.

    2013-01-01

    Welding is applied in many industrial sectors to join components, and has become an important manufacturing process because it enables the fabrication of structures that could not otherwise be constructed. Weld regions have inhomogeneous microstructures and are more susceptible to crack initiation and crack propagation than the surrounding base material regions. Residual stresses are also formed, which superimpose with applied loads, resulting in a reduction of the maximum applied load a comp...

  1. Through-Thickness Residual Stress Profiles in Austenitic Stainless Steel Welds: A Combined Experimental and Prediction Study

    Science.gov (United States)

    Mathew, J.; Moat, R. J.; Paddea, S.; Francis, J. A.; Fitzpatrick, M. E.; Bouchard, P. J.

    2017-12-01

    Economic and safe management of nuclear plant components relies on accurate prediction of welding-induced residual stresses. In this study, the distribution of residual stress through the thickness of austenitic stainless steel welds has been measured using neutron diffraction and the contour method. The measured data are used to validate residual stress profiles predicted by an artificial neural network approach (ANN) as a function of welding heat input and geometry. Maximum tensile stresses with magnitude close to the yield strength of the material were observed near the weld cap in both axial and hoop direction of the welds. Significant scatter of more than 200 MPa was found within the residual stress measurements at the weld center line and are associated with the geometry and welding conditions of individual weld passes. The ANN prediction is developed in an attempt to effectively quantify this phenomenon of `innate scatter' and to learn the non-linear patterns in the weld residual stress profiles. Furthermore, the efficacy of the ANN method for defining through-thickness residual stress profiles in welds for application in structural integrity assessments is evaluated.

  2. Study on the residual stress relaxation in girth-welded steel pipes under bending load using diffraction methods

    International Nuclear Information System (INIS)

    Hempel, Nico; Nitschke-Pagel, Thomas; Dilger, Klaus

    2017-01-01

    This research is dedicated to the experimental investigation of the residual stress relaxation in girth-welded pipes due to quasi-static bending loads. Ferritic-pearlitic steel pipes are welded with two passes, resulting in a characteristic residual stress state with high tensile residual stresses at the weld root. Also, four-point bending is applied to generate axial load stress causing changes in the residual stress state. These are determined both on the outer and inner surfaces of the pipes, as well as in the pipe wall, using X-ray and neutron diffraction. Focusing on the effect of tensile load stress, it is revealed that not only the tensile residual stresses are reduced due to exceeding the yield stress, but also the compressive residual stresses for equilibrium reasons. Furthermore, residual stress relaxation occurs both parallel and perpendicular to the applied load stress.

  3. Effect of residual stress on fatigue crack propagation at 200 C in a welded joint austenitic stainless steel - ferritic steel

    International Nuclear Information System (INIS)

    Zahouane, A.I.; Gauthier, J.P.; Petrequin, P.

    1988-01-01

    Fatigue resistance of heterogeneous welded joints between austenitic stainless steels and ferritic steels is evaluated for reactor components and more particularly effect of residual stress on fatigue crack propagation in a heterogeneous welded joint. Residual stress is measured by the hole method in which a hole is drilled through the center of a strain gage glued the surface of the materials. In the non uniform stress field a transmissibility function is used for residual stress calculation. High compression residual stress in the ferritic metal near the interface ferritic steel/weld slow down fatigue crack propagation. 5 tabs., 15 figs., 19 refs [fr

  4. Optimization of the Process Parameters for Controlling Residual Stress and Distortion in Friction Stir Welding

    DEFF Research Database (Denmark)

    Tutum, Cem Celal; Schmidt, Henrik Nikolaj Blicher; Hattel, Jesper Henri

    2008-01-01

    In the present paper, numerical optimization of the process parameters, i.e. tool rotation speed and traverse speed, aiming minimization of the two conflicting objectives, i.e. the residual stresses and welding time, subjected to process-specific thermal constraints in friction stir welding......, is investigated. The welding process is simulated in 2-dimensions with a sequentially coupled transient thermo-mechanical model using ANSYS. The numerical optimization problem is implemented in modeFRONTIER and solved using the Multi-Objective Genetic Algorithm (MOGA-II). An engineering-wise evaluation or ranking...

  5. Effect of geometric construction on residual stress distribution in designing a nuclear rotor joined by multipass narrow gap welding

    International Nuclear Information System (INIS)

    Tan, Long; Zhang, Linjie; Zhang, Jianxun; Zhuang, Dong

    2014-01-01

    Highlights: • The internal stress of the pipe is measured using local material removal method. • Bottom protrusion at weld seam can release the stress and mitigate stress evolution. The through-wall axial stress is bending type under the effect of the rotor discs. • The impact of geometric construction on the stress evolution begins after pass 15. - Abstract: The purpose of this study is to investigate the effect of geometric construction on the distribution of residual stresses before and after heat treatment in designing a nuclear welded rotor. The local material removal method was used to measure internal residual stress of the experimental pipe after post weld heat treatment. Three finite element models were employed as follows: a model of experimental pipe, a model with a bottom protrusion existed at the weld region, and a model of two rotor discs butt-welded with a bottom protrusion at the weld region. Investigated results showed that the bottom protrusion existed at the weld region can decrease the residual stress and mitigate the stress evolution significantly on the inner surface. Under the binding effect of the rotor discs, the axial stress of inner surface region is compressive stress; the through-wall axial stress at the weld center line can be deemed to a bending type; both the hoop stress and axial stress at the weld center line on the inner surface are compressive. The impact of geometric construction on the stress evolution at the root bead begins after pass 15 deposited

  6. Analysis of residual stress relief mechanisms in post-weld heat treatment

    International Nuclear Information System (INIS)

    Dong, Pingsha; Song, Shaopin; Zhang, Jinmiao

    2014-01-01

    This paper presents a recent study on weld residual stress relief mechanisms associated with furnace-based uniform post-weld heat treatment (PWHT). Both finite element and analytical methods are used to quantitatively examine how plastic deformation and creep relaxation contribute to residual stress relief process at different stages of PWHT process. The key contribution of this work to an improved understanding of furnace based uniform PWHT can be summarized as follows: (1)Plastic deformation induced stress relief during PWHT can be analytically expressed by the change in material elastic deformation capacity (or elastic deformation limit) measured in terms of material yield strength to Young's modulus ratio, which has a rather limited role in overall residual stress relief during furnace based uniform PWHT. (2)The most dominant stress relief mechanism is creep strain induced stress relaxation, as expected. However, a rapid creep strain development accompanied by a rapid residual stress reduction during heating stage before reaching PWHT temperature is shown to contribute to most of the stress relief seen in overall PWHT process, suggesting PWHT hold time can be significantly reduced as far as residual stress relief is concerned. (3)A simple engineering scheme for estimating residual stress reduction is proposed based on this study by relating material type, PWHT temperature, and component wall thickness. - Highlights: • The paper clarified effects of plastic deformation and creep relaxation on weld residual stress relief during uniform PWHT. • Creep strain development is far more important than plastic strain, mostly completed even before hold time starts. • Plastic strain development is insignificant and be analytically described by a material elastic deformation capacity parameter. • An engineering estimation scheme is proposed for determining residual stress reduction resulted from furnace based PWHT

  7. In situ neutron diffraction measurement of residual stress relaxation in a welded steel pipe during heat treatment

    International Nuclear Information System (INIS)

    Chen, B.; Skouras, A.; Wang, Y.Q.; Kelleher, J.F.; Zhang, S.Y.; Smith, D.J.; Flewitt, P.E.J.; Pavier, M.J.

    2014-01-01

    Many previous studies have presented results on the relaxation of residual stress in a welded component as a result of postweld heat treatment. Techniques such as neutron diffraction and deep hole drilling have been used to measure the residual stress after the heat treatment and compare this with the residual stress for the component in the as-welded condition. The work described in this paper is novel: neutron diffraction is used to measure the relaxation of residual stress continuously as the heat treatment is being carried out. Residual stresses are measured in a butt-welded ferritic steel pipe as the pipe is heat treated to 650 °C and then cooled to room temperature. The results identify those parts of the heat treatment that lead to significant stress relaxation and the mechanisms responsible for this relaxation. The techniques developed during this work allow future heat treatments to be optimised to achieve the low levels of residual stress in welded components

  8. On the evolution of local material properties and residual stress in a three-pass SA508 steel weld

    OpenAIRE

    Mark, A. F.; Francis, J. A.; Dai, H.; Turski, M.; Hurrell, P. R.; Bate, S. K.; Kornmeier, J. R.; Withers, P. J.

    2012-01-01

    In multi-pass welds, the development of residual stress generally depends on the response of the weld metal, heat-affected zone (HAZ) and nearby parent material to complex thermo-mechanical cycles. Here, the evolution of local material properties and residual stress was investigated for each of these zones during the manufacture of a three-pass groove weld in SA508 steel. Residual stress distributions were measured by neutron diffraction for a sample in which only one weld bead had been depos...

  9. Effect of welding processes and joint configuration on the residual stresses and distortion in type 316 LN stainless steel weld joints

    International Nuclear Information System (INIS)

    Vasantharaja, P.; Vasudevan, M.; Palanichamy, P.

    2012-01-01

    Fabrication by welding introduces significant residual stresses in the welded structure/component due to non-uniform heat distribution during heating and cooling cycle. To control, reduce, or beneficially redistribute the residual stresses in weld joints, the stress distribution needs to be known. In the present study, weld joints of 16 mm thick 316LN stainless steel were made by multi-pass TIG, A-TIG welding and combination of TIG and A-TIG welding processes with various joint configurations. While V-groove edge preparation was required for making multi-pass TIG weld joint, square-edge preparation was sufficient for making A-TIG weld joint. Ultrasonic nondestructive technique based on the critically refracted longitudinal waves (LCR waves) has been used for the quantitative surface/sub-surface residual stress measurements in the weld joints. Distortion measurements were carried out before and after welding using height gauge. A-TIG weld joint was found to exhibit significant reduction in tensile residual stresses and distortion in comparison to that of other joints. (author)

  10. Residual stress measurements on a stress relieved Zircaloy-4 weld by neutron diffraction

    Energy Technology Data Exchange (ETDEWEB)

    Carr, D.G. [Australian Nuclear Science and Technology Organisation, PMB 1 Menai 2234, NSW (Australia)]. E-mail: dgc@ansto.gov.au; Ripley, M.I. [Australian Nuclear Science and Technology Organisation, PMB 1 Menai 2234, NSW (Australia); Brown, D.W. [Los Alamos National Laboratory, Los Alamos, NM 87545 (United States); Vogel, S.C. [Los Alamos National Laboratory, Los Alamos, NM 87545 (United States); Holden, T.M. [Northern Stress Technologies, Deep River, Ont., K0J 1P0 (Canada)

    2006-12-15

    The macroscopic stress distribution across an annealed Zircaloy-4 gas tungsten arc weld was measured by neutron time-of-flight diffraction at the SMARTS diffractometer at Los Alamos National Laboratory. The stresses after annealing are about 40% lower than those in the same weld prior to heat treatment. The intergranular strains in the reference coupons, which give the macroscopic stress free lattice spacings, are consistent with the difference in cooling the strongly textured plate and the weakly textured weld.

  11. Analysis of residual stress in metal-inert-gas-welded Al-2024 using neutron and synchrotron X-ray diffraction

    International Nuclear Information System (INIS)

    Ganguly, S.; Stelmukh, V.; Edwards, L.; Fitzpatrick, M.E.

    2008-01-01

    A combination of neutron and synchrotron X-ray diffraction was used to measure and map the full three-dimensional state of residual stress across the cross-section in coupon samples of metal-inert-gas (MIG)-welded 2024 aluminium alloy. Samples were analysed both as-welded and following a post-welding skim which served to remove the weld flash and reduce the plate thickness. The profile of the residual stress and its evolution following skimming has been accurately characterized. The longitudinal direction shows the highest residual stress, approaching 300 MPa in tension. The skimming treatment did not change the peak stress, but the overall profile of stress was altered: this is slightly unexpected as machining away stressed material would generally be expected to reduce the peak residual stress. The results are discussed in terms of the generation of stress during welding and its evolution during skimming. Finally a comparison is made with the stress generated in the as-welded and skimmed conditions of a variable polarity plasma arc (VPPA)-welded specimen of similar dimensions, to show the effects of different weld processes on the residual stress generated. The stress measurement in the VPPA sample was carried out under near identical experimental conditions

  12. Neutron diffraction residual stress measurements on girth-welded 304 stainless steel pipes with weld metal deposited up to half and full pipe wall thickness

    International Nuclear Information System (INIS)

    Haigh, R.D.; Hutchings, M.T.; James, J.A.; Ganguly, S.; Mizuno, R.; Ogawa, K.; Okido, S.; Paradowska, A.M.; Fitzpatrick, M.E.

    2013-01-01

    The residual stress distribution has been measured in two girth-welded austenitic stainless steel pipe weldments using time-of-flight neutron diffraction. One had weld filler metal deposited up to half the pipe wall thickness, and one had weld metal deposited up to full pipe wall thickness. The aim of the work is to evaluate the evolution in residual stress profile on filling the weld, on which there is little experimental data, and where the selection of the correct hardening model used in finite element modelling can benefit greatly from an understanding of the intermediate residual stresses partway through the welding operation. The measured residual stresses are compared with those calculated by finite element modelling and measured using X-ray diffraction. The results show a change in the measured hoop stress at the weld toe from tension to compression between the half- and fully-filled weld. The finite element results show an overprediction of the residual stress, which may be a consequence of the simple isotropic hardening model applied. The results have implications for the likely occurrence of stress corrosion cracking in this important type of pipe-to-pipe weldment. Highlights: ► 304 steel girth welded with weld metal to half and full pipe wall thickness. ► Residual stresses measured by neutron and X-ray diffraction, and modelled by FE. ► Weld toe residual σ hoop changes from tensile to compressive from half to fully-filled. ► FE model for the fully-filled weld gives higher stress levels than those measured. ► Discrepancy is attributed to the isotropic hardening model used.

  13. Uncertainty Quantification and Comparison of Weld Residual Stress Measurements and Predictions.

    Energy Technology Data Exchange (ETDEWEB)

    Lewis, John R. [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States); Brooks, Dusty Marie [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

    2016-10-01

    In pressurized water reactors, the prevention, detection, and repair of cracks within dissimilar metal welds is essential to ensure proper plant functionality and safety. Weld residual stresses, which are difficult to model and cannot be directly measured, contribute to the formation and growth of cracks due to primary water stress corrosion cracking. Additionally, the uncertainty in weld residual stress measurements and modeling predictions is not well understood, further complicating the prediction of crack evolution. The purpose of this document is to develop methodology to quantify the uncertainty associated with weld residual stress that can be applied to modeling predictions and experimental measurements. Ultimately, the results can be used to assess the current state of uncertainty and to build confidence in both modeling and experimental procedures. The methodology consists of statistically modeling the variation in the weld residual stress profiles using functional data analysis techniques. Uncertainty is quantified using statistical bounds (e.g. confidence and tolerance bounds) constructed with a semi-parametric bootstrap procedure. Such bounds describe the range in which quantities of interest, such as means, are expected to lie as evidenced by the data. The methodology is extended to provide direct comparisons between experimental measurements and modeling predictions by constructing statistical confidence bounds for the average difference between the two quantities. The statistical bounds on the average difference can be used to assess the level of agreement between measurements and predictions. The methodology is applied to experimental measurements of residual stress obtained using two strain relief measurement methods and predictions from seven finite element models developed by different organizations during a round robin study.

  14. Weld repair practices without post weld heat treatment for ferritic alloys and their consequences on residual stresses: A review

    International Nuclear Information System (INIS)

    Aloraier, A.; Al-Mazrouee, A.; Price, J.W.H.; Shehata, T.

    2010-01-01

    The use of the half-bead, temper bead welding (TBW), and cold repair techniques is proving to reduce the cost of repairs and extend the life of aged components in power plants, petrochemical and hydrocarbon processing industries. It has been a significant area of interest for more than twenty years. A critical factor in this context is residual stress. The presence of residual stresses can lead to cracking which ultimately results in structural failure. This paper reviews the half-bead, TBW, and cold repair technique practices and their consequences on residual stresses within the nuclear, power, refinery and petrochemical industries and some of the contributions made by our group of researchers in this area. This paper reviews recent work by the Monash University group. We report our work on TBW residual stresses when measured using neutron diffraction which shows very little reduction in residual stresses over normally completed welds. The use of automatic FCAW has been explored in our group and is reported.

  15. A review of inducing compressive residual stress - shot peening; on structural metal and welded connection

    Science.gov (United States)

    Kanchidurai, S.; Krishanan, P. A.; Baskar, K.; Saravana Raja Mohan, K.

    2017-07-01

    Shot peening treatment (SPT) is a significant mechanical method to enhance the surface of the material by inducing compressive residual stress on the layer. This study provides a review of prominent improvement in fatigue life on high strength aluminium alloy, steel and welded connection by SPT. Compressive residual stress measurement and its factors data are extracted from assorted literature, optimized peening process commented in this paper, also different types of mechanical peening methods and its effectiveness are mentioned. Fatigue life improvement is focused commented to welded structural connections. The extracted results shows significant changes in the surface layer of metals, aluminium alloy 15 - 250% of fatigue life improvement, steel plain members 6-200% of fatigue life improvement, welded connections 50-75% of fatigue life improvement and significant improvement in mechanical properties like roughness reduction, wear, hardness, tensile strength, corrosion and scuffing.

  16. Non-destructive measurement of residual stresses in nuclear welds by means of neutron diffraction

    International Nuclear Information System (INIS)

    Ohms, C.; Youtsos, A.G.; Idsert, P. v.d.

    2001-01-01

    Non-destructive measurement of welding stresses in structural components remains a challenging task. One out of very few techniques applicable to such problems is the neutron diffraction technique, which is closely related to the well-established X-ray diffraction. Whereas the latter provides for non-destructive measurement of surface stresses only, neutron diffraction enables the engineer to obtain in- depth measurements of residual stress. At the High Flux Reactor (HFR) of the Joint Research Centre (JRC), Petten, a new residual stress diffractometer has been installed capable of handling components up to 1000 kg - the Large Component Neutron Diffraction Facility (LCNDF). It has facilitated residual stress measurements in various weldments, including steel piping welds for nuclear applications. In this paper the principles of the technique are outlined and major elements of testing equipment and procedures are presented. Particularities to be taken into account especially in testing of austenitic steel welds are explained. Finally test results obtained on two thick steel nuclear piping welds are presented. (orig.)

  17. Numerical investigation on residual stress distribution and evolution during multipass narrow gap welding of thick-walled stainless steel pipes

    International Nuclear Information System (INIS)

    Liu, C.; Zhang, J.X.; Xue, C.B.

    2011-01-01

    Research highlights: → We performed pass-by-pass simulation of stresses for welding of thick-walled pipes. → The distributions and evolution of the residual stresses are demonstrated. → After the groove is filled to a height, the through-wall stress is almost unchanged. - Abstracts: The detailed pass-by-pass finite element (FE) simulation is presented to investigate the residual stresses in narrow gap multipass welding of pipes with a wall thickness of 70 mm and 73 weld passes. The simulated residual stress on the outer surface is validated with the experimental one. The distribution and evolution of the through-wall residual stresses are demonstrated. The investigated results show that the residual stresses on the outer and inner surfaces are tensile in the weld zone and its vicinity. The through-wall axial residual stresses at the weld center line and the HAZ line demonstrate a distribution of bending type. The through-wall hoop residual stress within the weld is mostly tensile. After the groove is filled to a certain height, the peak tensile stresses and the stress distribution patterns for both axial and hoop stresses remain almost unchanged.

  18. Residual stress improvement for pipe weld by means of induction heating pre-flawed pipe

    International Nuclear Information System (INIS)

    Umemoto, T.; Yoshida, K.; Okamoto, A.

    1980-01-01

    The intergranular stress corrosion cracking (IGSCC) has been found in type 304 stainless steel piping of several BWR plants. It is already well known that IGSCC is most likely to occur when three essential factors, material sensitization, high tensile stress and corrosive environment, are present. If the welding residual stress is sufficiently high (200 to approximately 400 MPa) in the inside piping surface near the welded joint, then it may be one of the biggest contributors to IGSCC. If the residual stress is reduced or reversed by some way, the IGSCC will be effectively mitigated. In this paper a method to improve the residual stress named IHSI (Induction Heating Stress Improvement) is explained. IHSI aims to improve the condition of residual stress in the inside pipe surface using the thermal stress induced by the temperature difference in pipe wall, that is produced when the pipe is heated from the outside surface by an induction heating coil and cooled on the inside surface by water simultaneously. This method becomes more attractive when it can be successfully applied to in-service piping which might have some pre-flaw. In order to verify the validity of IHSI for such piping, some experiments and calculations using finite element method were conducted. These results are mainly discussed in this paper from the view-points of residual stress, flaw behaviour during IHSI and material deterioration. (author)

  19. Neutron diffraction residual stress measurements in a 316L stainless steel bead-on-plate weld specimen

    International Nuclear Information System (INIS)

    Pratihar, S.; Turski, M.; Edwards, L.; Bouchard, P.J.

    2009-01-01

    The distribution of residual stress in three orthogonal directions has been measured within a Type 316L austenitic stainless steel bead-on-plate weld specimen. Neutron diffraction was employed using the ENGIN-X instrument, located at the ISIS spallation facility of the Rutherford Appleton Laboratory, UK. A stress-free lattice parameter reference value was determined from a small cube, extracted from a far corner of the plate. A high magnitude of tensile residual stress was found along the weld bead in the longitudinal and transverse directions. The distributions of stress along through-thickness lines at the weld bead nominal start and stop locations and at the mid-length position showed an almost identical stress variation. However, a map of measured residual strain in the transverse direction beneath the weld bead revealed a concentration of strain located several millimetres before the nominal weld stop position where through-wall stress profiles were measured

  20. Neutron diffraction measurements of residual stresses in a 50 mm thick weld

    International Nuclear Information System (INIS)

    Woo, Wanchuck; Em, Vyacheslav; Mikula, Pavel; An, Gyu-Baek; Seong, Baek-Seok

    2011-01-01

    Research highlights: → Determined residual stresses through the thickness of the 50 mm thick weld. → Two-dimensional mapping of the longitudinal stress. Observed significant stresses along the heat-affected zone. → Measured the maximum stress of 460 MPa at 40 mm below from the top surface. - Abstract: Residual stresses were determined through the thickness of a 50 mm thick ferrite steel weld plate using neutron diffraction. Whereas the limiting penetration depth for iron-based alloys is about 25 mm in the most typical neutron diffractometers, we significantly enhanced the penetration depth up to 50 mm with 2 mm spatial resolution by using the neutron wavelength of 2.39 A. The selected wavelength minimizes the total neutron cross-section and beam attenuation, thereby, maximizes the neutron fluxes at depth. Two-dimensional mapping of the residual stresses shows that significant amounts of the tensile longitudinal stresses (over 90% of yield strength) were developed along the heat-affected zone of the weld.

  1. Repair weld induced residual stresses in thick-walled steel pressure vessels

    Energy Technology Data Exchange (ETDEWEB)

    Smith, G.C.; Holz, P.P.

    1978-06-01

    If a flaw requiring corrective action were to be found in an operating nuclear pressure vessel, there would be considerable safety and economic implications. Should such a flaw be found, one possible corrective action would be an in situ repair weld. A repair of this type would presumably involve grinding away material in a region encompassing the flaw and then filling the resulting cavity with weld metal. Thermal stress relieving under those conditions could lead to serious difficulties associated with thermal expansion and warpage and would therefore most likely be avoided. Such a departure from normal procedure raises questions relating to residual stresses and material toughness levels which would have to be assessed before a repair could be recommended or approved. The residual stress measurements reported are intended to provide baseline information to aid in an assessment should such a repair ever have to be seriously considered.

  2. Residual stress determination in an overlay dissimilar welded pipe by neutron diffraction

    Energy Technology Data Exchange (ETDEWEB)

    Woo, Wan Chuck [ORNL; Em, Vyacheslav [Korea Atomic Energy Research Institute; Hubbard, Camden R [ORNL; Lee, Ho-Jin [Korea Atomic Energy Research Institute; Park, Kwang Soo [Doosan Heavy Industries & Construction

    2011-01-01

    Residual stresses were determined through the thickness of a dissimilar weld overlay pipe using neutron diffraction. The specimen has a complex joining structure consisting of a ferritic steel (SA508), austenitic steel (F316L), Ni-based consumable (Alloy 182), and overlay of Ni-base superalloy (Alloy 52M). It simulates pressurized nozzle components, which have been a critical issue under the severe crack condition of nuclear power reactors. Two neutron diffractometers with different spatial resolutions have been utilized on the identical specimen for comparison. The macroscopic 'stress-free' lattice spacing (d{sub o}) was also obtained from both using a 2-mm width comb-like coupon. The results show significant changes in residual stresses from tension (300-400 MPa) to compression (-600 MPa) through the thickness of the dissimilar weld overlay pipe specimen.

  3. Effects of distance from center of a weld to fixed end on residual stress and stress intensity factor of a piping weld. Evaluation of SCC growth under residual stress field. Report 1

    International Nuclear Information System (INIS)

    Miyazaki, Katsumasa; Numata, Masanori; Saito, Koichi; Mochizuki, Masahito

    2006-01-01

    The fixed conditions of butt welds between straight pipe and valve or pump in the actual piping system are different from those of straight pipes. However, the effect of fixed condition on the residual stress and the stress intensity factor for evaluation of structural integrity of cracked piping was not clear. In this study, the finite element analyses were conducted by considering the differences in the distance from the center of weld to the fixed end L to clarify the effect of fixed condition on the residual stress and the stress intensity factor. For the 600 A piping, the axial residual stress distribution was not affected by the distance L. Furthermore, the stress intensity factor of circumferential crack under the residual stress field with fixed condition could be estimated by using the existing simplified solution for piping. (author)

  4. Residual stress measurement inside a dissimilar metal weld mock-up of the pressurizer safety and relief nozzle

    Energy Technology Data Exchange (ETDEWEB)

    Campos, Wagner R.C.; Rabello, Emerson G.; Silva, Luiz L.; Mansur, Tanius R., E-mail: wrcc@cdtn.br, E-mail: egr@cdtn.br, E-mail: silvall@cdtn.br, E-mail: tanius@cdtn.br [Centro de Desenvolvimento da Tecnologia Nuclear (CDTN/CNEN-MG), Belo Horizonte (Brazil). Servico de Integridade Estrutural; Martins, Ketsia S., E-mail: ketshinoda@hotmail.com [Universidade Federal de Minas Gerais (UFMG), Nelo Horizonte (Brazil). Departamento de Engenharia Metalurgica

    2015-07-01

    Residual stresses are present in materials or structural component in the absence of external loads or changes in temperatures. The most common causes of residual stresses being present are the manufacturing or assembling processes. All manufacturing processes, such as casting, welding, machining, molding, heat treatment, among others, introduces residual stresses into the manufactured object. The residual stresses effects could be beneficial or detrimental, depending on its distribution related to the component or structure, its load service and if it is compressive or tensile. In this work, the residual strains and stresses inside a mock-up that simulates the safety and relief nozzle of Angra 1 Nuclear Power Plant pressurizer were studied. The current paper presents a blind hole-drilling method residual stress measurements both at the inner surface of dissimilar metal welds of dissimilar metal weld nozzle mock-up. (author)

  5. Effects of Ultrasonic Nanocrystal Surface Modification on the Residual Stress, Microstructure, and Corrosion Resistance of 304 Stainless Steel Welds

    Science.gov (United States)

    Ye, Chang; Telang, Abhishek; Gill, Amrinder; Wen, Xingshuo; Mannava, Seetha R.; Qian, Dong; Vasudevan, Vijay K.

    2018-01-01

    In this study, ultrasonic nanocrystal surface modification (UNSM) of 304 stainless steel welds was carried out. UNSM effectively eliminates the tensile stress generated during welding and imparts beneficial compressive residual stresses. In addition, UNSM can effectively refine the grains and increase hardness in the near-surface region. Corrosion tests in boiling MgCl2 solution demonstrate that UNSM can significantly improve the corrosion resistance due to the compressive residual stresses and changes in the near-surface microstructure.

  6. Effects of Ultrasonic Nanocrystal Surface Modification on the Residual Stress, Microstructure, and Corrosion Resistance of 304 Stainless Steel Welds

    Science.gov (United States)

    Ye, Chang; Telang, Abhishek; Gill, Amrinder; Wen, Xingshuo; Mannava, Seetha R.; Qian, Dong; Vasudevan, Vijay K.

    2018-03-01

    In this study, ultrasonic nanocrystal surface modification (UNSM) of 304 stainless steel welds was carried out. UNSM effectively eliminates the tensile stress generated during welding and imparts beneficial compressive residual stresses. In addition, UNSM can effectively refine the grains and increase hardness in the near-surface region. Corrosion tests in boiling MgCl2 solution demonstrate that UNSM can significantly improve the corrosion resistance due to the compressive residual stresses and changes in the near-surface microstructure.

  7. Residual stress distribution in ferritic-austenitic steel joints made by laser welding

    OpenAIRE

    Iordachescu, Mihaela; Ocaña Moreno, José Luis

    2013-01-01

    The present investigation addresse the influence of laser welding process-ing parameters used for joining dis-similar metals (ferritic to austenitic steel), on the induced residual stress field. Welding was performed on a Nd:YAG laser DY033 (3300 W) in a continuous wave (CW), keyhole mode. The base metals (BM) employed in this study are AISI 1010 carbon steel (CS) and AISI 304L austenitic stainless steel (SS). Pairs of dissimilar plates of 200 mm x 45 mm x 3 mm were butt joined by laser weldi...

  8. Study on production mechanism of welding residual stress at the juncture of a pipe penetrating a thick plate

    International Nuclear Information System (INIS)

    Mochizuki, Masahito; Enomoto, Kunio; Okamoto, Noriaki; Saitoh, Hideyo; Hayashi, Eisaku.

    1994-01-01

    This paper studies welding residual stresses at the intersection of a small diameter pipe penetrating a thick plate. The pipe is welded to the plate, and Tungsten Innert Gas (TIG) cladding is melted on the inner surface of the pipe to protect it from stress corrosion cracking due to long operation in nuclear power plants. Stresses are calculated by heat conduction analysis and thermal elasto-plastic analysis, and also measured by strain gauges. Welding residual stresses are shown to have no corrosive influence on the inner pipe surface, and the stresses are compressed enough to protect the pipe against stress corrosion cracking on the outer surface. It was also studied to make clear the production mechanism of the residual stresses which were generated by welding processes at the pipe. (author)

  9. Investigation of Residual Stresses and Distortion in Welded Pipe-Flange Joint of Different Classes

    Directory of Open Access Journals (Sweden)

    Muhammad Abid

    2012-10-01

    Full Text Available ABSTRACT: Pipe and flange joints are commonly used in petrochemical, nuclear and process industries. Commonly, welding is used to make these joints which produces residual stresses and distortions. These stresses have detrimental effects on the structural integrity and service performance of the welded pipe joints. The objective of this study is to investigate the residual stresses and distortions during Gas Metal Arc Welding of pipe of schedule 40, nominal diameter 200 mm with different ANSI flanges of class numbers 150, 300, 600, 900, 1500, and 2500. Welding parameters including: voltage, current and heat as inputs were selected based on the literature available. The behaviour of the flanges of different classes is also discussed. In addition, the finite element methodology presented, in this paper, can be helpful for developing welding procedures for a range of pipe flange welded joint sizes in order to control the residual stresses and deformations. This will lead to optimised performance during bolt up and operating conditions.ABSTRAK: Paip dan sambungan flan biasanya digunakan dalam industri petrokimia, nuklear dan proses. Kimpalan menghasilkan tegasan sisa dan herotan, yang memberikan kesan yang merbahaya ke atas integriti struktur dan prestasi servis sambungan kimpalan paip. Objektif kajian ini adalah untuk mengkaji tegasan sisa dan herotan ketika kimpalan arka logam gas paip berjadual 40, diameter nominal 200mm dengan flan ANSI yang berbeza kelas # 150, 300, 600, 900, 1500, dan 2500. Parameter kimpalan termasuklah; voltan, arus dan haba input yang dipilih berdasarkan literatur sediada. Kelakuan flan yang berbeza kelas telah dibincangkan. Kaedah elemen finit yang dibentangkan adalah berguna dalam membangunkan prosedur kimpalan bagi julat saiz kimpalan flan paip unutk mengawal tegasan sisa dan canggaan i.e. bagi mengoptimakan prestasi ketika bolt up dan sedang beroperasi.                                 

  10. Residual stress determination in a dissimilar weld overlay pipe by neutron diffraction

    International Nuclear Information System (INIS)

    Woo, Wanchuck; Em, Vyacheslav; Hubbard, Camden R.; Lee, Ho-Jin; Park, Kwang Soo

    2011-01-01

    Highlights: → Determined residual stress distribution in a dissimilar weld overlay pipe. → Consists of a ferritic (SA508), austenitic (F316L) steels, Alloy 182 consumable. → Measured significant compression (-600 MPa) near the inner wall of overlay. → Validate integrity of the inner wall for the pressurized nozzle nuclear structure. - Abstract: Residual stresses were determined through the thickness of a dissimilar weld overlay pipe using neutron diffraction. The specimen has a complex joining structure consisting of a ferritic steel (SA508), austenitic steel (F316L), Ni-based consumable (Alloy 182), and overlay of Ni-base superalloy (Alloy 52M). It simulates pressurized nozzle components, which have been a critical issue under the severe crack condition of nuclear power reactors. Two neutron diffractometers with different spatial resolutions have been utilized on the identical specimen for comparison. The macroscopic 'stress-free' lattice spacing (d o ) was also obtained from both using a 2-mm width comb-like coupon. The results show significant changes in residual stresses from tension (300-400 MPa) to compression (-600 MPa) through the thickness of the dissimilar weld overlay pipe specimen.

  11. Residual stress determination in a dissimilar weld overlay pipe by neutron diffraction

    Energy Technology Data Exchange (ETDEWEB)

    Woo, Wanchuck, E-mail: chuckwoo@kaeri.re.kr [Neutron Science Division, Korea Atomic Energy Research Institute, Daejeon 305-353 (Korea, Republic of); Em, Vyacheslav [Neutron Science Division, Korea Atomic Energy Research Institute, Daejeon 305-353 (Korea, Republic of); Hubbard, Camden R. [Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831 (United States); Lee, Ho-Jin [Nuclear Materials Research Center, Korea Atomic Energy Research Institute, Daejeon 305-353 (Korea, Republic of); Park, Kwang Soo [Corporate R and D Institute, Doosan Heavy Industries and Construction, Changwon 641-792 (Korea, Republic of)

    2011-10-15

    Highlights: {yields} Determined residual stress distribution in a dissimilar weld overlay pipe. {yields} Consists of a ferritic (SA508), austenitic (F316L) steels, Alloy 182 consumable. {yields} Measured significant compression (-600 MPa) near the inner wall of overlay. {yields} Validate integrity of the inner wall for the pressurized nozzle nuclear structure. - Abstract: Residual stresses were determined through the thickness of a dissimilar weld overlay pipe using neutron diffraction. The specimen has a complex joining structure consisting of a ferritic steel (SA508), austenitic steel (F316L), Ni-based consumable (Alloy 182), and overlay of Ni-base superalloy (Alloy 52M). It simulates pressurized nozzle components, which have been a critical issue under the severe crack condition of nuclear power reactors. Two neutron diffractometers with different spatial resolutions have been utilized on the identical specimen for comparison. The macroscopic 'stress-free' lattice spacing (d{sub o}) was also obtained from both using a 2-mm width comb-like coupon. The results show significant changes in residual stresses from tension (300-400 MPa) to compression (-600 MPa) through the thickness of the dissimilar weld overlay pipe specimen.

  12. Effect of prior machining deformation on the development of tensile residual stresses in weld-fabricated nuclear components

    International Nuclear Information System (INIS)

    Prevey, P.S.; Mason, P.W.; Hornbach, D.J.; Molkenthin, J.P.

    1996-01-01

    Austenitic alloy weldments in nuclear systems may be subject to stress-corrosion cracking (SCC) failure if the sum of residual and applied stresses exceeds a critical threshold. Residual stresses developed by prior machining and welding may either accelerate or retard SCC, depending on their magnitude and sign. A combined x-ray diffraction and mechanical procedure was used to determine the axial and hoop residual stress and yield strength distributions into the inside-diameter surface of a simulated Alloy 600 penetration J-welded into a reactor pressure vessel. The degree of cold working and the resulting yield strength increase caused by prior machining and weld shrinkage were calculated from the line-broadening distributions. Tensile residual stresses on the order of +700 MPa were observed in both the axial and the hoop directions at the inside-diameter surface in a narrow region adjacent to the weld heat-affected zone. Stresses exceeding the bulk yield strength were found to develop due to the combined effects of cold working of the surface layers during initial machining and subsequent weld shrinkage. The residual stress and cold work distributions produced by prior machining were found to influence strongly the final residual stress state developed after welding

  13. Residual stress measurement of EB-welded plates with contour method. Part 2: FEM analysis of contour profiles

    International Nuclear Information System (INIS)

    Romppanen, A.-J.; Immonen, E.

    2013-12-01

    The residual stresses formed as a result of Electronic Beam welding (EB-welding) in copper are investigated by Posiva. In the present study, residual stresses of EB-welded copper plates were studied with contour method. In the method eleven copper plates (X436 - X440 and X453 - X458) were cut in half with wire electric discharge machining (EDM) after which the deformation due to stress relaxation was measured with coordinate measurement system. The measured data was then used as boundary displacement data for the FEM analyses, in which the corresponding residual stresses were calculated. Before giving the corresponding displacement boundary conditions to the FE models, the deformation data was processed and smoothed appropriately. The residual stress levels of the copper plates were found to be around 40 - 55 MPa at maximum. This corresponds to other reported residual stress measurements and current state of knowledge with this material in Posiva. (orig.)

  14. Residual stress measurements in a thick, dissimilar aluminum alloy friction stir weld

    International Nuclear Information System (INIS)

    Prime, Michael B.; Gnaeupel-Herold, Thomas; Baumann, John A.; Lederich, Richard J.; Bowden, David M.; Sebring, Robert J.

    2006-01-01

    Plates (25.4 mm thick) of aluminum alloys 7050-T7451 and 2024-T351 were joined in a butt joint by friction stir welding (FSW). A 54 mm long test specimen was removed from the parent plate, and cross-sectional maps of residual stresses were measured using neutron diffraction and the contour method. The stresses in the test specimen peaked at only about 32 MPa and had the conventional 'M' profile with tensile stress peaks in the heat-affected zone outside the weld. The asymmetric stress distribution is discussed relative to the FSW process and the regions of highest thermal gradients. The general agreement between the two measurement techniques validated the ability of each technique to measure the low-magnitude stresses, less than 0.05% of the elastic modulus. Subtle differences between the two were attributed to spatial variations in the unstressed lattice spacing (d 0 ) and also intergranular strains affecting the neutron results. The FSW stresses prior to relaxation from removal of the test specimen were estimated to have been about 43 MPa, demonstrating the ability of FSW to produce low-stress welds in even fairly thick sections. To avoid the estimated 25% stress relaxation from removing the test specimen, the specimen would have had to be quite long because the St. Venant's characteristic distance in this case was more related to the transverse dimensions of the specimen than to the plate thickness

  15. Welding Residual Stress Analysis and Fatigue Strength Assessment at Elevated Temperature for Multi-pass Dissimilar Material Weld Between Alloy 617 and P92 Steel

    Science.gov (United States)

    Lee, Juhwa; Hwang, Jeongho; Bae, Dongho

    2018-03-01

    In this paper, welding residual stress analysis and fatigue strength assessment were performed at elevated temperature for multi-pass dissimilar material weld between Alloy 617 and P92 steel, which are used in thermal power plant. Multi-pass welding between Alloy 617 and P92 steel was performed under optimized welding condition determined from repeated pre-test welding. In particular, for improving dissimilar material weld-ability, the buttering welding technique was applied on the P92 steel side before multi-pass welding. Welding residual stress distribution at the dissimilar material weld joint was numerically analyzed by using the finite element method, and compared with experimental results which were obtained by the hole-drilling method. Additionally, fatigue strength of dissimilar material weld joint was assessed at the room temperature (R.T), 300, 500, and 700 °C. In finite element analysis results, numerical peak values; longitudinal (410 MPa), transverse (345 MPa) were higher than those of experiments; longitudinal (298 MPa), transverse (245 MPa). There are quantitatively big differences between numerical and experimental results, due to some assumption about the thermal conductivity, specific heat, effects of enforced convection of the molten pool, dilution, and volume change during phase transformation caused by actual shield gas. The low fatigue limit at R.T, 300 °C, 500 °C and 700 °C was assessed to be 368, 276, 173 and 137 MPa respectively.

  16. Neutron-diffraction measurement of residual stresses in Al-Cu cold-cut welding

    CERN Document Server

    Fiori, F

    2002-01-01

    Usually, when it is necessary to join different materials with a large difference in their melting points, welding should be avoided. To overcome this problem we designed and built a device to obtain cold-cut welding, which is able to strongly decrease oxidation problems of the surfaces to be welded. Thanks to this device it is possible to achieve good joining between different pairs of materials (Al-Ti, Cu-Al, Cu-Al alloys) without reaching the material melting point. The mechanical and microstructural characterisation of the joining and the validation of its quality were obtained using several experimental methods. In particular, in this work neutron-diffraction experiments for the evaluation of residual stresses in Cu-Al junctions are described, carried out at the G5.2 diffractometer of LLB, Saclay. Neutron-diffraction results are presented and related to other experimental tests such as microstructural characterisation (through optical and scanning electron microscopy) and mechanical characterisation (ten...

  17. X-ray evaluation of residual stress distributions within surface machined layer generated by surface machining and sequential welding

    International Nuclear Information System (INIS)

    Taniguchi, Yuu; Okano, Shigetaka; Mochizuki, Masahito

    2017-01-01

    The excessive tensile residual stress generated by welding after surface machining may be an important factor to cause stress corrosion cracking (SCC) in nuclear power plants. Therefore we need to understand and control the residual stress distribution appropriately. In this study, residual stress distributions within surface machined layer generated by surface machining and sequential welding were evaluated by X-ray diffraction method. Depth directional distributions were also investigated by electrolytic polishing. In addition, to consider the effect of work hardened layer on the residual stress distributions, we also measured full width at half maximum (FWHM) obtained from X-ray diffraction. Testing material was a low-carbon austenitic stainless steel type SUS316L. Test specimens were prepared by surface machining with different cutting conditions. Then, bead-on-plate welding under the same welding condition was carried out on the test specimens with different surface machined layer. As a result, the tensile residual stress generated by surface machining increased with increasing cutting speed and showed nearly uniform distributions on the surface. Furthermore, the tensile residual stress drastically decreased with increasing measurement depth within surface machined layer. Then, the residual stress approached 0 MPa after the compressive value showed. FWHM also decreased drastically with increasing measurement depth and almost constant value from a certain depth, which was almost equal regardless of the machining condition, within surface machined layer in all specimens. After welding, the transverse distribution of the longitudinal residual stress varied in the area apart from the weld center according to machining conditions and had a maximum value in heat affected zone. The magnitude of the maximum residual stress was almost equal regardless of the machining condition and decreased with increasing measurement depth within surface machined layer. Finally, the

  18. Non destructive evaluation of residual stresses in welding and hard-surfacing processes

    International Nuclear Information System (INIS)

    Suarez, J.C.; Fernandez, L.M.; Cruz, C.; Aragon, B.; Merino, F.

    1995-01-01

    In this paper transversal and longitudinal stress profiles in welding and hard-surfacing by welding processes are presented. The stresses were measured by RMS of Barkhausen signal. In this work it is shown that in each case the level of stresses is strongly dependent on the number of weld beads of surfacing layers deposited. The subsequent deposition of new weld beads or surfacing layers produces a stress-relieving effect

  19. Discussion on accuracy of weld residual stress measurement by neutron diffraction. Influence of strain free reference

    International Nuclear Information System (INIS)

    Suzuki, Hiroshi; Akita, Koichi

    2012-01-01

    It is required to evaluate a strain-free reference, α 0 , to perform accurate stress measurement using neutron diffraction. In this study, accuracy of neutron stress measurement was quantitatively discussed from α 0 evaluations on a dissimilar metal butt-weld between a type 304 austenitic stainless steel and an A533B low alloy ferritic steel. A strain-free standard specimen and a sliced specimen with 10 mm thickness taken from the dissimilar metal butt-weld were utilized. In the lattice constant evaluation using the standard specimen, average lattice constant derived from multiple hkl reflections was evaluated as the stress-free reference with cancelling out an intergranular strain. Comparing lattice constant distributions in each reflection with average lattice constant distribution in the standard specimen, αFe211 and γFe311 reflections were judged as a suitable reflection for neutron strain measurement to reduce intergranular strain effects. Residual stress distribution in the sliced specimen evaluated using α 0 measured here exhibited higher accuracy than that measured using strain gauges. On the other hand, α 0 distributions were evaluated using the sliced specimen under the plane-stress condition. Existence of slight longitudinal residual stresses near the weld center decreased accuracy of the α 0 evaluations, which means that it is required to optimize the thickness of the sliced specimen for accurate α 0 evaluation under plane strain condition. As a conclusion of this study, it was confirmed that procedures of accurate α 0 evaluation, optimization of the measurement condition, and multiple evaluations on the results play an important role to improve accuracy of the residual stress measurement using neutron diffraction. (author)

  20. Characterizing Phase Transformations and Their Effects on Ferritic Weld Residual Stresses with X-Rays and Neutrons

    Science.gov (United States)

    Dai, H.; Francis, J. A.; Stone, H. J.; Bhadeshia, H. K. D. H.; Withers, P. J.

    2008-12-01

    Weld residual stresses often approach, or exceed, the yield strength of the material, with serious implications for the integrity of engineering structures. It is not always feasible to measure residual stresses, so integrity assessments often rely heavily on numerical models. In ferritic steels, the credibility of such models depends on their ability to account for solid-state phase transformations, which can have a controlling effect on the final residual stress state. Furthermore, a better understanding of weld transformations provides an opportunity to engineer the weld stress state and microstructure for improved life. In this article, the complementary merits of synchrotron X-ray and neutron diffraction are exploited both to verify and refine weld models and to inspire the development of weld filler metals to control weld stresses. In terms of weld filler metal design, X-ray diffraction is used to characterize phase transformations in real time during realistic weld cooling cycles, for understanding small-scale behavior and identifying features that need to be incorporated into finite-element models. Meanwhile, neutron diffraction is used to elucidate the practical consequences of solid-state phase transformations on the macroscopic scale, thereby providing crucial validatory structural integrity data.

  1. Residual stress measurements by neutron diffraction in laser and electron beam welded joints in 9Cr-1Mo(V, Nb) steel plates

    International Nuclear Information System (INIS)

    Kumar, Santosh; Viswanadham, C.S.; Bhanumurthy, K.; Dey, G.K.; Kundu, Amrita; Bouchard, P.J.

    2014-01-01

    Residual stresses are invariably associated with welded joints and have serious implications for integrity of welded components in service conditions. Laser and electron beam welding produces weld joints with narrow fusion zone and heat affected zone. Therefore, there exists very high spatial gradient of residual stresses across the weld joints; measurement of which is indeed a challenging task. Residual stress measurements in laser and electron beam welded 9Cr-1Mo (V, Nb) steel plates were carried out by neutron diffraction. Measurements for laser welded plates were carried out using monochromatic neutron beam at ILL, France and that for electron beam welded plates were carried out using white neutron beam at ISIS, UK. Measurements were made across the weld joints as well as along the weld centre-line for the three orthogonal components-longitudinal, transverse and normal of the residual stress. The cross-weld residual stress profile showed a low tensile/compressive trough in the fusion zone and a high tensile peak on the either side of the joint in the parent metal just outside of metallurgical HAZ. Besides, longitudinal and normal components of the residual stress are significant while the transverse component is the least significant. Residual stress profiles showed very similar characteristics in the weld joints made by laser and electron beam welding processes. These results are presented in this paper and discussed in the context of the metallurgical attributes of the material

  2. A Study on the Residual Stress Improvement of PWSCC(Primary Water Stress Corrosion Cracking) in DMW(Dissimilar Metal Weld)

    Energy Technology Data Exchange (ETDEWEB)

    Kang, Sung Sik; Kim, Seok Hun; Lee, Seung Gun [Korea Institute of Nuclear Safety, Daejeon (Korea, Republic of); Park, Heung Bae [KEPCO Engineering and Construction Company, Daejeon (Korea, Republic of)

    2010-10-15

    Since 2000s, most of the cracks are found in welds, especially in (DMW) dissimilar metal welds such as pressurizer safety relief nozzle, reactor head penetration, reactor bottom mounted instrumentation (BMI), and reactor nozzles. Even the cracks are revealed as a primary water stress corrosion cracking (PWSCC), it is difficult to find the cracks by current non destructive examination. The PWSCC is occurred by three incident factors, such as susceptible material, environmental corrosive condition, and welding residual stress. If one of the three factors can be erased or decreased, the PWSCC could be prevented. In this study, we performed residual stress analysis for DMW and several residual stress improvement methods. As the preventive methods of PWSCC, we used laser peening(IP) method, inlay weld(IW) method, and induction heating stress improvement(IHSI) method. The effect of residual stress improvement for preventive methods was compared and discussed by finite element modeling and residual stress of repaired DMW

  3. A Study on the Residual Stress Improvement of PWSCC(Primary Water Stress Corrosion Cracking) in DMW(Dissimilar Metal Weld)

    International Nuclear Information System (INIS)

    Kang, Sung Sik; Kim, Seok Hun; Lee, Seung Gun; Park, Heung Bae

    2010-01-01

    Since 2000s, most of the cracks are found in welds, especially in (DMW) dissimilar metal welds such as pressurizer safety relief nozzle, reactor head penetration, reactor bottom mounted instrumentation (BMI), and reactor nozzles. Even the cracks are revealed as a primary water stress corrosion cracking (PWSCC), it is difficult to find the cracks by current non destructive examination. The PWSCC is occurred by three incident factors, such as susceptible material, environmental corrosive condition, and welding residual stress. If one of the three factors can be erased or decreased, the PWSCC could be prevented. In this study, we performed residual stress analysis for DMW and several residual stress improvement methods. As the preventive methods of PWSCC, we used laser peening(IP) method, inlay weld(IW) method, and induction heating stress improvement(IHSI) method. The effect of residual stress improvement for preventive methods was compared and discussed by finite element modeling and residual stress of repaired DMW

  4. Final Report: Characterization of Canister Mockup Weld Residual Stresses

    Energy Technology Data Exchange (ETDEWEB)

    Enos, David [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States); Bryan, Charles R. [Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

    2016-12-01

    Stress corrosion cracking (SCC) of interim storage containers has been indicated as a high priority data gap by the Department of Energy (DOE) (Hanson et al., 2012), the Electric Power Research Institute (EPRI, 2011), the Nuclear Waste Technical Review Board (NWTRB, 2010a), and the Nuclear Regulatory Commission (NRC, 2012a, 2012b). Uncertainties exist in terms of the environmental conditions that prevail on the surface of the storage containers, the stress state within the container walls associated both with weldments as well as within the base metal itself, and the electrochemical properties of the storage containers themselves. The goal of the work described in this document is to determine the stress states that exists at various locations within a typical storage canister by evaluating the properties of a full-diameter cylindrical mockup of an interim storage canister. This mockup has been produced using the same manufacturing procedures as the majority of the fielded spent nuclear fuel interim storage canisters. This document describes the design and procurement of the mockup and the characterization of the stress state associated with various portions of the container. It also describes the cutting of the mockup into sections for further analyses, and a discussion of the potential impact of the results from the stress characterization effort.

  5. Influence of the microstructural changes and induced residual stresses on tensile properties of wrought magnesium alloy friction stir welds

    International Nuclear Information System (INIS)

    Commin, Loreleï; Dumont, Myriam; Rotinat, René; Pierron, Fabrice; Masse, Jean-Eric; Barrallier, Laurent

    2012-01-01

    Highlights: ► Study of AZ31 FSW mechanical behaviour. ► Early yielding occurs in the TMAZ, the nugget and base metal zones undergo almost no plastic strains. ► Texture gradient in the TMAZ localises the deformations in this area. ► Residual stresses have a major influence in FSW mechanical behaviour. - Abstract: Friction stir welding induces a microstructural evolution and residual stresses that will influence the resulting mechanical properties. Friction stir welds produced from magnesium alloy hot rolled plates were studied. Electron back scattered diffraction was used to determine the texture evolution, residual stresses were analysed using X ray diffraction and tensile tests coupled with speckle interferometry were performed. The residual stresses induced during friction stir welding present a major influence on the final mechanical properties.

  6. Residual stress distribution in austenitic stainless steel pipe butt-welded joint measured by neutron diffraction technique

    International Nuclear Information System (INIS)

    Maekawa, Akira; Noda, Michiyasu; Oumaya, Toru; Takahashi, Shigeru

    2009-01-01

    Residual stress is inevitable consequence of welding or manufacturing process, which might greatly affect propagation of high-cycle fatigue or SCC crack. In order to evaluate damages due to the crack, it is required to estimate residual stress and to reflect them to the evaluation process as well. The magnitude and distribution of residual stress greatly depend on the individual process of welding or manufacturing, while the accuracy of prediction or measurement is still insufficient. This paper reports the result of residual stress measurement of butt-welded pipe made of austenitic stainless steel. It also intended to improve prediction and measurement techniques concerning to residual stress. The measurement was conducted by neutron diffraction technique employing the diffractometer for residual stress analysis developed by Japan Atomic Energy Agency. The measured results showed typical characteristics of butt-welded pipe both in decline of stress along axial direction and in radial distribution of bending due to axial stress. The measured result agreed qualitatively with the result predicted by the finite element analysis. A quantitative comparison between measured result and analysis showed a shift of the measured stress toward higher tensile. The measured result was also compared with the results by X-ray diffraction and strain-gauge methods to grasp the distinctive results of the methods. (author)

  7. Investigation on narrow-gap welding residual stresses in ultra-thick ring-type mockups

    Science.gov (United States)

    Liu, Chuan; Yang, Jiawei; Shi, Yifeng; Zhao, Yong

    2018-01-01

    The stress distributions within two ring-type mockups manufactured by multi-pass narrow-gap submerged welding were investigated by numerical simulations and experiments. The large mockup consisted of a 300 mm thick ring welded to a large cylinder, and the small one was a butt-welded joint consisted of two 300 mm thick curved plates. The effect of structure form on the stress in the heavy-section component was also investigated. Results show that the stress distribution in the small mockup is similar to that in the large one. The location where the minimum hoop and radial stresses appear at the weld centerline is decided by the weld metal height of the second welding step of the welding procedure used in the present study. In addition, a sudden stress change occurs near the top surface of the weld metal after the first welding step due to the strong stiffness of the mockups. For the 300 mm thick welded mockups investigated, the structure form has no evident effect on the shape of the through-thickness stress distribution at the weld centerline, which is determined by the welding procedure; however, the structure form can affect the value of the minimum stress.

  8. Comparative study of residual stress by table of coordinates and X-ray diffraction in a welded joint

    International Nuclear Information System (INIS)

    Siqueira Filho, A.V.; Rolim, T.L.; Yadava, Y.P.; Ferreira, R.A.S.; Guimaraes, P.B.

    2010-01-01

    Residual stresses in a welded joint of naval steel ASTM AH-32 was measured either by the displacements of referenced points with a coordinated table (CT) or by x-ray diffraction (X-DR) after welding. For all tests, the welding was performed by a certified welder in the SMAW process, using an AWS E 7018 G3 electrode. Before welding, small holes evenly spaced were made in the specimens to be mapped on a coordinated table (CT). After labeling, the specimens were submitted to the welding process and new measurements by (CT) to evaluate the displacements produced by the tensions generated. In parallel, residual stress were measured by DR-X for validation of this new measurement methodology. (author)

  9. Characterization of residual stress as a function of friction stir welding parameters in oxide dispersion strengthened (ODS) steel MA956

    Energy Technology Data Exchange (ETDEWEB)

    Brewer, L.N., E-mail: lnbrewer1@eng.ua.edu [Naval Postgraduate School (United States); Bennett, M.S.; Baker, B.W. [Naval Postgraduate School (United States); Payzant, E.A.; Sochalski-Kolbus, L.M. [Oak Ridge National Laboratory (United States)

    2015-10-28

    Friction stir welding (FSW) can generate large residual stresses during solid state joining of oxide dispersion strengthened steels. In this work, a plate of MA956 steel was friction stir welded at three conditions: 500 rpm/25 mm per minute (mmpm), 400 rpm/50 mmpm and 400 rpm/100 mmpm. The residual stresses across these welds were measured using both x-ray and neutron diffraction techniques. The distribution and magnitude of the residual stresses agreed well between the two techniques. Longitudinal residual stresses up to eighty percent of the yield strength were observed for the 400 rpm/100 mmpm condition. The surface residual stresses were somewhat larger on the root side of the weld than on the crown side. Increases in the relative heat input during FSW decreased the measured residual stresses in the stir zone and the thermomechanically affected zone (TMAZ). Increasing the traverse rate while holding the rotational speed fixed increased the residual stress levels. The fatigue strength of the material is predicted to decrease by at least twenty percent with cracking most likely in the TMAZ.

  10. Characterization of residual stress as a function of friction stir welding parameters in oxide dispersion strengthened (ODS) steel MA956

    International Nuclear Information System (INIS)

    Brewer, L.N.; Bennett, M.S.; Baker, B.W.; Payzant, E.A.; Sochalski-Kolbus, L.M.

    2015-01-01

    Friction stir welding (FSW) can generate large residual stresses during solid state joining of oxide dispersion strengthened steels. In this work, a plate of MA956 steel was friction stir welded at three conditions: 500 rpm/25 mm per minute (mmpm), 400 rpm/50 mmpm and 400 rpm/100 mmpm. The residual stresses across these welds were measured using both x-ray and neutron diffraction techniques. The distribution and magnitude of the residual stresses agreed well between the two techniques. Longitudinal residual stresses up to eighty percent of the yield strength were observed for the 400 rpm/100 mmpm condition. The surface residual stresses were somewhat larger on the root side of the weld than on the crown side. Increases in the relative heat input during FSW decreased the measured residual stresses in the stir zone and the thermomechanically affected zone (TMAZ). Increasing the traverse rate while holding the rotational speed fixed increased the residual stress levels. The fatigue strength of the material is predicted to decrease by at least twenty percent with cracking most likely in the TMAZ.

  11. Neutron-diffraction measurement of residual stresses in Al-Cu cold-cut welding

    International Nuclear Information System (INIS)

    Fiori, F.; Marcantoni, M.

    2002-01-01

    Usually, when it is necessary to join different materials with a large difference in their melting points, welding should be avoided. To overcome this problem we designed and built a device to obtain cold-cut welding, which is able to strongly decrease oxidation problems of the surfaces to be welded. Thanks to this device it is possible to achieve good joining between different pairs of materials (Al-Ti, Cu-Al, Cu-Al alloys) without reaching the material melting point. The mechanical and microstructural characterisation of the joining and the validation of its quality were obtained using several experimental methods. In particular, in this work neutron-diffraction experiments for the evaluation of residual stresses in Cu-Al junctions are described, carried out at the G5.2 diffractometer of LLB, Saclay. Neutron-diffraction results are presented and related to other experimental tests such as microstructural characterisation (through optical and scanning electron microscopy) and mechanical characterisation (tensile-strength tests) of the welded interface. (orig.)

  12. Neutron-diffraction measurement of residual stresses in Al-Cu cold-cut welding

    Science.gov (United States)

    Fiori, F.; Marcantoni, M.

    Usually, when it is necessary to join different materials with a large difference in their melting points, welding should be avoided. To overcome this problem we designed and built a device to obtain cold-cut welding, which is able to strongly decrease oxidation problems of the surfaces to be welded. Thanks to this device it is possible to achieve good joining between different pairs of materials (Al-Ti, Cu-Al, Cu-Al alloys) without reaching the material melting point. The mechanical and microstructural characterisation of the joining and the validation of its quality were obtained using several experimental methods. In particular, in this work neutron-diffraction experiments for the evaluation of residual stresses in Cu-Al junctions are described, carried out at the G5.2 diffractometer of LLB, Saclay. Neutron-diffraction results are presented and related to other experimental tests such as microstructural characterisation (through optical and scanning electron microscopy) and mechanical characterisation (tensile-strength tests) of the welded interface.

  13. Measurement of the residual stresses in a stainless steel pipe girth weld containing long and short repairs

    International Nuclear Information System (INIS)

    Bouchard, P.J.; George, D.; Santisteban, J.R.; Bruno, G.; Dutta, M.; Edwards, L.; Kingston, E.; Smith, D.J.

    2005-01-01

    A series of residual measurements were made to obtain the through-thickness residual stress profiles in an as-welded and repair welded stainless steel pipe. Long and short length repairs were manufactured after initial measurements in the original girth weld. Measurements were made using neutron diffraction, deep hole and surface hole techniques. The various measurement methods were found to complement each other well. All the measurements revealed a characteristic profile for the through-thickness distribution of the residual stresses in the heat-affected zone. The residual stresses at mid-length of the heat affected zone of the short repair were found to be higher than in the long repair

  14. Local Cooling during Welding : Prediction and Control of Residual Stresses and Buckling Distortion

    NARCIS (Netherlands)

    Van der Aa, E.M.

    2007-01-01

    One of the major problems during welding of thin plate structures is the occurrence of buckling distortion. This type of distortion is caused by the formation of compressive welding stresses; when these stresses exceed a certain critical stress level, the structure will buckle. Most methods for

  15. Residual stress in a laser welded EUROFER blanket module assembly using non-destructive neutron diffraction techniques

    International Nuclear Information System (INIS)

    Hughes, D.J.; Koukovini-Platia, E.; Heeley, E.L.

    2014-01-01

    Highlights: • Residual stresses were determined in a welded EUROFER blanket assembly with integrated cooling channels. • Good agreement was seen between experimentally determined and predicted stresses. • We show that microstructure changes that occur in EUROFER steels during welding must be considered for residual stress determination. • An experimental route is proposed for validation of predicted stresses in reactor components using non-destructive diffraction techniques. - Abstract: Whilst the structural integrity and lifetime considerations in welded joints for blanket modules can be predicted using finite element software, it is essential to prove the validity of these simulations. This paper provides detailed analysis for the first time, of the residual stress state in a laser-welded sample with integral cooling channels. State-of-the-art non-destructive neutron diffraction was employed to determine the triaxial stress state and to understand microstructural changes around the heat affected zone. Synchrotron X-ray diffraction was used to probe the variation of strain-free lattice reference parameter around the weld zone allowing correction of the neutron measurements. This paper details an important experimental route to validation of predicted stresses in complex safety-critical reactor components for future applications

  16. Prediction of residual stress in the welding zone of dissimilar metals using data-based models and uncertainty analysis

    Energy Technology Data Exchange (ETDEWEB)

    Lim, Dong Hyuk; Bae, In Ho [Department of Nuclear Engineering, Chosun University, 375 Seosuk-dong, Dong-gu, Gwangju 501-759 (Korea, Republic of); Na, Man Gyun, E-mail: magyna@chosun.ac.k [Department of Nuclear Engineering, Chosun University, 375 Seosuk-dong, Dong-gu, Gwangju 501-759 (Korea, Republic of); Kim, Jin Weon [Department of Nuclear Engineering, Chosun University, 375 Seosuk-dong, Dong-gu, Gwangju 501-759 (Korea, Republic of)

    2010-10-15

    Since welding residual stress is one of the major factors in the generation of primary water stress-corrosion cracking (PWSCC), it is essential to examine the welding residual stress to prevent PWSCC. Therefore, several artificial intelligence methods have been developed and studied to predict these residual stresses. In this study, three data-based models, support vector regression (SVR), fuzzy neural network (FNN), and their combined (FNN + SVR) models were used to predict the residual stress for dissimilar metal welding under a variety of welding conditions. By using a subtractive clustering (SC) method, informative data that demonstrate the characteristic behavior of the system were selected to train the models from the numerical data obtained from finite element analysis under a range of welding conditions. The FNN model was optimized using a genetic algorithm. The statistical and analytical uncertainty analysis methods of the models were applied, and their uncertainties were evaluated using 60 sampled training and optimization data sets, as well as a fixed test data set.

  17. Modelling residual stresses in friction stir welding of Al alloys - a review of possibilities and future trends

    DEFF Research Database (Denmark)

    Hattel, Jesper Henri; Sonne, Mads Rostgaard; Tutum, Cem C.

    2015-01-01

    Residual stresses are very important in any joining process of materials since they act as pre-stresses in the loading situation of the joint, thereby affecting the final mechanical performance of the component. This is also the case for friction stir welding (FSW) which is a complex solid...

  18. Comparison of Measured Residual Stress in an Extra Thick Multi-pass Weld Using Neutron Diffraction Method and Inherent Strain Method

    International Nuclear Information System (INIS)

    Park, JeongUng; An, GyuBaek; Woo, Wan Chuck

    2015-01-01

    With the increase of large-scale containership, a large amount of high-strength steels with extra thick plates is being extensively used. The welding stress existing in the extra thick welded plates has a significant effect on the integrity of the component in terms of brittle fracture and fatigue behavior. It has been reported that welding residual stress distribution in an extra thick plate can affect the propagation path of the crack. Therefore, it is important to measure the distribution of welding residual stresses for the reliable design of the welded structures. So far various researches have been carried out for the determination of residual stresses on the surface of steels. In this paper, the total residual stresses in the 70 mm thick multipass FACW butt joint were measured by integrating initial stress into ISM. Concretely, two methods named as initial stress integrated ISM and initial inherent strain integrated ISM were employed to determine the total residual stresses. Furthermore, the distributions of residual stresses were compared with the results of the Neutron Diffraction Method(NDM). In order to measure the three dimensional residual stresses in the welded joint with initial stresses existing before welding, initial stress integrated ISM and initial inherent strain integrated ISM were developed. The residual stresses in 70 mm-thick butt joint by flux cored arc welding were carried out with a good accuracy using the two developed methods. The residual stresses in welded joint using both initial stress integrated ISM and initial inherent strain integrated ISM agreed well with the results measured by Neutron Diffraction Method. This suggests that the integrated ISM is a reliable method for residual stress measurement if initial stress existed

  19. Three-dimensional welding residual stresses evaluation based on the eigenstrain methodology via X-ray measurements at the surface

    Science.gov (United States)

    Ogawa, Masaru

    2014-12-01

    In order to assure structural integrity for operating welded structures, it is necessary to evaluate crack growth rate and crack propagation direction for each observed crack non-destructively. Here, three dimensional (3D) welding residual stresses must be evaluated to predict crack propagation. Today, X-ray diffraction is used and the ultrasonic method has been proposed as non-destructive method to measure residual stresses. However, it is impossible to determine residual stress distributions in the thickness direction. Although residual stresses through a depth of several tens of millimeters can be evaluated non-destructively by neutron diffraction, it cannot be used as an on-site measurement technique. This is because neutron diffraction is only available in special irradiation facilities. Author pays attention to the bead flush method based on the eigenstrain methodology. In this method, 3D welding residual stresses are calculated by an elastic Finite Element Method (FEM) analysis from eigenstrains which are evaluated by an inverse analysis from released strains by strain gauges in the removal of the reinforcement of the weld. Here, the removal of the excess metal can be regarded as non-destructive treatment because toe of weld which may become crack starters can be eliminated. The effectiveness of the method has been proven for welded plates and pipes even with relatively lower bead height. In actual measurements, stress evaluation accuracy becomes poorer because measured values of strain gauges are affected by processing strains on the machined surface. In the previous studies, the author has developed the bead flush method that is free from the influence of the affecting strains by using residual strains on surface by X-ray diffraction. However, stress evaluation accuracy is not good enough because of relatively poor measurement accuracy of X-ray diffraction. In this study, a method to improve the estimation accuracy of residual stresses in this method is

  20. Measurement and modelling of the residual stresses in autogenous and narrow gap laser welded AISI grade 316L stainless steel plates

    International Nuclear Information System (INIS)

    Elmesalamy, A.S.; Abdolvand, H.; Walsh, J.N.; Francis, J.A.; Suder, W.; Williams, S.; Li, L.

    2016-01-01

    Thick-section austenitic stainless steels have widespread industrial applications, where stress-corrosion cracking is often of major concern. Problems tend to arise in the vicinity of welds, where substantial residual stresses often reside. This paper describes an investigation into the residual stresses in autogenous high power laser welds and narrow gap laser welds (NGLW) in 10 mm thick AISI grade 316L steel plates, using both neutron diffraction and the contour method. The influences of laser power, welding speed and the time interval between weld passes on residual stress were analysed. For the NGLW process, finite element modelling was employed to understand the influence of thermal history on residual stress. The results for the NGLW technique show that the laser power has a significant effect on the peak value of residual stress, while the welding speed has a more significant influence on the width of the region sustaining tensile stresses. - Highlights: • We compare the residual stress behaviour in high power autogenous laser welding and Narrow gap laser welding [NGLW] of 10 mm thickplates of 316L stainless steel. • We use contour method for residual stress evaluation. The results have been validated by using neutron diffraction. • The experimental results show that, lower residual stress distribution can be achieved by using the NGLW technique. • We investigate the influence of the power and speed on both peak value and width of the tensile region for both autogenous laser welding and NGLW technique. • The welding speed in NGLW technique has a more significant influence on the width of the tensile region. The laser power shows a more significant influence on the peak value of the residual stress with respect to width of the residual stress tensile region.

  1. The use of neutron diffraction for the determination of the in-depth residual stresses profile in weld coatings

    International Nuclear Information System (INIS)

    Marques, Maria Jose; Batista, A.C.; Nobre, J.P.; Loureiro, Altino; Kornmeier, Joana R.

    2013-01-01

    The neutron diffraction is a non-destructive technique, particularly suitable for the analysis of residual stress fields in welds. The technique is used in this article to study ferritic samples, coated by submerged arc welding using stainless steel filler metals. This procedure is often used for manufacturing process equipment for chemical and nuclear industries, for ease of implementation and economic reasons. The main disadvantage of that processes is the cracking phenomenon that often occurs at the interface between the base material and coatings, which can be minimized by performing post-weld stress relief heat treatments. The samples analyzed in this study were made of carbon steel plates, coated by submerged arc welding two types of stainless steel filler metals. For the first layer was used one EN 12 072 - S 2 U 23 12 electrode, while for the second and third layers were used an EN 12 072 - 19 12 3 S L electrode. After cladding, the samples were submitted to a post-weld heat treatment for 1 hour at 620 deg C. The residual stress profiles obtained by neutron diffraction evidence the relaxation of residual stress given by the heat treatment. (author)

  2. Evaluation of J-groove weld residual stress and crack growth rate of PWSCC in reactor pressure vessel closure head

    International Nuclear Information System (INIS)

    Oh, Seung Hyuk; Ryu, Tae Young; Park, Seung Hyun; Won, Min Gu; Kang, Seok Jun; Kim, Moon Ki; Choi, Jae Boong; Lee, Kyoung Soo; Lee, Sung Ho

    2015-01-01

    Over the last decade, primary water stress corrosion cracking (PWSCC) has been frequently found in pressurized water reactor (PWR) applications. Especially, PWSCC has occurred in long-term operated PWRs. As this phenomenon leads to serious accidents, we must be beforehand with the anticipated problems. A typical PWR consists of J-groove welded components such as reactor pressure vessel closure head and nozzles. Reactor pressure vessel closure head is made of SA508 and it is covered by cladding. Alloy 600 is used for nozzles. And J-groove weld is conducted with alloy 82/182. Different material properties of these metals lead to residual stress and PWSCC consequentially. In this study, J-groove weld residual stress was investigated by a three-dimensional finite element analysis with an actual asymmetric J-groove weld model and process of construction. Also crack growth rate of PWSCC was evaluated from cracks applied on the penetration nozzles. Based on these two values, one cannot only improve the structural integrity of PWR, but also explain PWSCC behavior such that high residual stress at the J-groove weld area causes crack initiation and propagation through the surface of nozzles. In addition, crack behavior was predicted at the various points around the nozzle.

  3. Effects of LSP on micro-structures and residual stresses in a 4 mm CLAM steel weld joints

    Energy Technology Data Exchange (ETDEWEB)

    Chen, Xizhang, E-mail: chenxizhang@wzu.edu.cn [School of Mechanical and Electrical Engineering, Wenzhou University., Wenzhou 325035 (China); School of Materials Science and Engineering, Jiangsu University, Zhenjiang 212013, Jiangsu (China); Fang, Yuanyuan [School of Materials Science and Engineering, Jiangsu University, Zhenjiang 212013, Jiangsu (China); Zhang, Shuyan; Kelleher, Joe F. [ISIS, Rutherford Appleton Laboratory, Chilton, Didcot OX11 0QX (United Kingdom); Zhou, Jianzhong [School of Mechanical Engineering, Jiangsu University, Zhenjiang 212013, Jiangsu (China)

    2015-05-15

    The effects of laser shock processing (LSP) on the distribution of residual stress and micro-structure of China Low Activation Martensitic (CLAM) steel weldment were investigated via neutron diffraction and optical microscope (OM). A pair of 4 mm CLAM steel plates joined by GTA welding. Special attention is paid to the generation of high level compressive residual stresses introduced by LSP. Residual stress in longitudinal, normal and transversal direction at weldment surface and longitudinal stress through thickness are evaluated via neutron diffraction. Compressive residual stress after LSP occurred at more than 90% areas within the weld joint, it is almost double the areas of compressive stress compare to weldment surface before LSP. The maximum compressive normal residual stress becomes to −183 MPa after LSP from −63 MPa before LSP. The Modification of surface micro-structures including weld zone (WZ), heat affected zone (HAZ) and base metal (BM) are also discussed. Results to date demonstrate that laser shock processing has been a great potential method for the improvement of mechanical performance of components.

  4. Effects of LSP on micro-structures and residual stresses in a 4 mm CLAM steel weld joints

    International Nuclear Information System (INIS)

    Chen, Xizhang; Fang, Yuanyuan; Zhang, Shuyan; Kelleher, Joe F.; Zhou, Jianzhong

    2015-01-01

    The effects of laser shock processing (LSP) on the distribution of residual stress and micro-structure of China Low Activation Martensitic (CLAM) steel weldment were investigated via neutron diffraction and optical microscope (OM). A pair of 4 mm CLAM steel plates joined by GTA welding. Special attention is paid to the generation of high level compressive residual stresses introduced by LSP. Residual stress in longitudinal, normal and transversal direction at weldment surface and longitudinal stress through thickness are evaluated via neutron diffraction. Compressive residual stress after LSP occurred at more than 90% areas within the weld joint, it is almost double the areas of compressive stress compare to weldment surface before LSP. The maximum compressive normal residual stress becomes to −183 MPa after LSP from −63 MPa before LSP. The Modification of surface micro-structures including weld zone (WZ), heat affected zone (HAZ) and base metal (BM) are also discussed. Results to date demonstrate that laser shock processing has been a great potential method for the improvement of mechanical performance of components

  5. Effects of neutron radiation and residual stresses on the corrosion of welds in light water reactor internals

    International Nuclear Information System (INIS)

    Schaaf, Bob van der; Gavillet, Didier; Lapena, Jesus; Ohms, Carsten; Roth, Armin; Dyck, Steven van

    2006-01-01

    After many years of operation in Light Water Reactors (LWR) Irradiation Assisted Stress Corrosion Cracking (IASCC) of internals has been observed. In particular the heat-affected zone (HAZ) has been associated with IASCC attack. The welding process induces residual stresses and micro-structural modifications. Neutron irradiation affects the materials response to mechanical loading. IASCC susceptibility of base materials is widely studied, but the specific conditions of irradiated welds are rarely assessed. Core component relevant welds of Type 304 and 347 steels have been fabricated and were irradiated in the High Flux Reactor (HFR) in Petten to 0.3 and 1 dpa (displacement per atom). In-service welds were cut from the thermal shield of the decommissioned BR-3 reactor. Residual stresses, measured using neutron diffraction, ring core tests and X-ray showed residual stress levels up to 400 MPa. Micro-structural characterization showed higher dislocation densities in the weld and HAZ. Neutron radiation increased the dislocation density, resulting in hardening and reduced fracture toughness. The sensitization degree of the welds, measured with the electrochemical potentio-dynamic reactivation method, was negligible. The Slow Strain Rate Tensile (SSRT) tests, performed at 290 deg. C in water with 200 ppb dissolved oxygen, (DO), did not reveal inter-granular cracking. Inter-granular attack of in-service steel is observed in water with 8 ppm (DO), attributed not only to IASCC, but also to IGSCC from thermal sensitization during fabrication. Stress-relieve annealing has caused Cr-grain boundary precipitation, indicating the sensitization. The simulated internal welds, irradiated up to 1.0 dpa, did not show inter-granular cracking with 8 ppm DO. (authors)

  6. Status report. Characterization of Weld Residual Stresses on a Full-Diameter SNF Interim Storage Canister Mockup.

    Energy Technology Data Exchange (ETDEWEB)

    Enos, David [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States); Bryan, Charles R. [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)

    2015-08-01

    This report documents the mockup specifications and manufacturing processes; the initial cutting of the mockup into three cylindrical pieces for testing and the measured strain changes that occurred during the cutting process; and the planned weld residual stress characterization activities and the status of those activities.

  7. Numerical sensitivity analysis of welding-induced residual stress depending on variations in continuous cooling transformation behavior

    Science.gov (United States)

    Heinze, C.; Schwenk, C.; Rethmeier, M.; Caron, J.

    2011-06-01

    The usage of continuous cooling transformation (CCT) diagrams in numerical welding simulations is state of the art. Nevertheless, specifications provide limits in chemical composition of materials which result in different CCT behavior and CCT diagrams, respectively. Therefore, it is necessary to analyze the influence of variations in CCT diagrams on the developing residual stresses. In the present paper, four CCT diagrams and their effect on numerical calculation of residual stresses are investigated for the widely used structural steel S355J2 + N welded by the gas metal arc welding (GMAW) process. Rather than performing an arbitrary adjustment of CCT behavior, four justifiable data sets were used as input to the numerical calculation: data available in the Sysweld database, experimental data acquired through Gleeble dilatometry tests, and TTT/CCT predictions calculated from the JMatPro and Edison Welding Institute (EWI) Virtual Joining Portal software. The performed numerical analyses resulted in noticeable deviations in residual stresses considering the different CCT diagrams. Furthermore, possibilities to improve the prediction of distortions and residual stress based on CCT behavior are discussed.

  8. On Residual Stresses in Resistance Spot-Welded Aluminum Alloy 6061-T6: Experimental and Numerical Analysis

    Science.gov (United States)

    Afshari, D.; Sedighi, M.; Karimi, M. R.; Barsoum, Z.

    2013-12-01

    In this study, an electro-thermal-structural-coupled finite element (FE) model and x-ray diffraction residual stress measurements have been utilized to analyze distribution of residual stresses in an aluminum alloy 6061-T6 resistance spot-welded joint with 2-mm-thickness sheet. Increasing the aluminum sheet thickness to more than 1 mm leads to creating difficulty in spot-welding process and increases the complexity of the FE model. The electrical and thermal contact conductances, as mandatory factors are applied in contact areas of electrode-workpiece and workpiece-workpiece to resolve the complexity of the FE model. The physical and mechanical properties of the material are defined as thermal dependent to improve the accuracy of the model. Furthermore, the electrodes are removed after the holding cycle using the birth-and-death elements method. The results have a good agreement with experimental data obtained from x-ray diffraction residual stress measurements. However, the highest internal tensile residual stress occurs in the center of the nugget zone and decreases toward nugget edge; surface residual stress increases toward the edge of the welding zone and afterward, the area decreases slightly.

  9. A finite element elastic-plastic analysis of residual stresses due to clad welding in reactor vessels

    International Nuclear Information System (INIS)

    Buchalet, C.; Riccardella, P.C.

    1972-01-01

    Residual stresses due to weld deposited cladding on the inside of a typical Westinghouse pressurized water reactor vessel are investigated using an axisymmetric finite element elastic-plastic analysis. At the beginning of the analysis, one head of the weld cladding is assumed to lie on the reactor vessel wall at melting temperature (2600degF), but in the solid phase, while the vessel remains at 300degF (preheat temperature). All material properties used in the calculations are taken as temperature-dependent. Temperature profiles are obtained in the cladding and base metal at several discrete time intervals. These temperatures profiles are used to obtain the stress distribution for the same time intervals. Residual hoop tensile stresses of approximately 25 ksi were found to exist in the cladding. Peak tensile stresses in the hoop direction occur in the base metal near the cladding interface and reach a value of 60 ksi at the end of the transient. The tensile stress decreases very rapidly through the thickness of the base metal and becomes insignificant at about two inches from the inside surface. In order to lower residual stresses, a post-weld heat treatment is performed by uniformly heating the vessel to 1100degF, holding at that temperature for a specified period of time and then cooling slowly. The analysis shows that after this treatment, the peak stresses in the base metal decrease from 60 ksi to 32 ksi, while the stress in the cladding does not change significantly. (author)

  10. Residual stress in a laser welded EUROFER blanket module assembly using non-destructive neutron diffraction techniques

    CERN Document Server

    Hughes, D J; Heeley, E L

    2014-01-01

    Whilst the structural integrity and lifetime considerations in welded joints for blanket modules can be predicted using finite element software, it is essential to prove the validity of these simulations. This paper provides detailed analysis for the first time, of the residual stress state in a laser-welded sample with integral cooling channels. State-of-the-art non-destructive neutron diffraction was employed to determine the triaxial stress state and to understand microstructural changes around the heat affected zone. Synchrotron X-ray diffraction was used to probe the variation of strain-free lattice reference parameter around the weld zone allowing correction of the neutron measurements. This paper details an important experimental route to validation of predicted stresses in complex safety-critical reactor components for future applications.

  11. Welding residual stress estimation by inherent strain analysis and thermal elastic plastic analysis and its verification using neutron diffraction measurement

    International Nuclear Information System (INIS)

    Mochizuki, Masahito; Hayashi, Makoto; Hattori, Toshio

    1997-01-01

    The internal residual stress distribution that resulted from welding a 4-inch-diameter carbon-steel pipe butt-joint was evaluated using several methods and the results were compared. The analytical evaluation methods used were inherent strain analysis and thermal elastic plastic analysis, and the experimental methods were X-ray diffraction and strain gauge for the surface residual stress, and neutron diffraction for the internal stress. The residual stress distributions determined using the various methods agreed well with each other, both for surface stress and internal stress. The characteristics of the evaluation methods were summarized and it was found the most suitable method for any particular situation can be selected by considering the evaluated location and the operating conditions of the object to be evaluated. (author)

  12. Effect of residual stress and hardening on grain boundary sliding in welds of low-carbon stainless steels with surface machining

    International Nuclear Information System (INIS)

    Mori, Hiroaki; Mochizuki, Masahito; Nishimoto, Kazutoshi; Katsuyama, Jinya

    2008-01-01

    To clarify the effects of residual stress and hardening on intergranular stress corrosion cracking (IGSCC) behavior in welds of low-carbon austenitic stainless steels with surface machining, residual stress and hardness were evaluated by 3-dimentional thermo elastic-plastic analysis and grain boundary sliding behavior was examined using a constant strain rate tensile test. It was revealed that grain boundary sliding occurred in the material at 561K by the tensile test with the numerically simulated tensile residual stress due to multi-pass welding and surface machining. In addition, it was clarified that the grain boundary energy is raised by the grain boundary sliding. On the basis of these results, it was concluded that the cause of IGSCC in the welds of low-carbon austenitic stainless steel with surface hardening is the increase in grain boundary energy due to grain boundary sliding induced by residual stress of multi pass welding and surface hardening. (author)

  13. A full-field residual stress estimation scheme for fitness-for-service assessment of pipe girth welds: Part II – A shell theory based implementation

    International Nuclear Information System (INIS)

    Song, Shaopin; Dong, Pingsha; Pei, Xianjun

    2015-01-01

    With the two key controlling parameters identified and their effectiveness demonstrated in Part I of this study series for constructing a continuous residual stress profile at weld region, a classical shell theory based model is proposed in this paper (Part II) for describing through-thickness residual stress distributions of both axial and hoop components at any axial location beyond weld region. The shell theory based model is analytically constructed through an assembly of two parts: One represents weld region and the other represents the remaining component section away from weld. The final assembly of the two parts leads to a closed form solution to both axial and hoop residual stress components as a function of axial distance from weld toe position. The effectiveness of the full-field residual stress estimation scheme is demonstrated by comparing with a series of finite element modeling results over a broad range of pipe weld geometries and welding conditions. The present development should provide a consistent and effective means for estimating through-thickness residual stress profile as a continuous function of pipe geometry, welding heat input, as well as material characteristics. - Highlights: • A shell theory based two-part assembly model is developed for generalizing residual stress distributions. • A full-field estimation of through-thickness residual stress profiles can be achieved. • The proposed estimation scheme offers both consistency and mechanics basis in residual stress profile generation. • An estimation scheme for welding-induced plastic zone size is proposed and validated. • The shell theory based estimation scheme can also provide a reasonable estimate on distortion in radial direction

  14. An accurate method for determining residual stresses with magnetic non-destructive techniques in welded ferromagnetic steels

    Science.gov (United States)

    Vourna, P.

    2016-03-01

    The scope of the present research work was to investigate the proper selection criteria for developing a suitable methodology for the accurate determination of residual stresses existing in welded parts. Magnetic non-destructive testing took place by the use of two magnetic non-destructive techniques: by the measurement of the magnetic Barkhausen noise and by the evaluation of the magnetic hysteresis loop parameters. The spatial distribution of residual stresses in welded metal parts by both non-destructive magnetic methods and two diffraction methods was determined. The conduction of magnetic measurements required an initial calibration of ferromagnetic steels. Based on the examined volume of the sample, all methods used were divided into two large categories: the first one was related to the determination of surface residual stress, whereas the second one was related to bulk residual stress determination. The first category included the magnetic Barkhausen noise and the X-ray diffraction measurements, while the second one included the magnetic permeability and the neutron diffraction data. The residual stresses determined by the magnetic techniques were in a good agreement with the diffraction ones.

  15. 3-D numerical evaluation of residual stress and deformation due welding process using simplified heat source models

    Energy Technology Data Exchange (ETDEWEB)

    Eslampanah, Amir Hossein [Islamic Azad University, Arak (Iran, Islamic Republic of); Aalami-aleagha, Mohammad Ebrahim; Feli, Saeid [Razi University, Kermanshah (Iran, Islamic Republic of); Ghaderi, Mohammad Reza [Islamic Azad University, Sanandaj (Iran, Islamic Republic of)

    2015-01-15

    Thermal elastic-plastic finite element method has been employed to predict residual stress and deformation in a T-Fillet welded joint. An uncoupled thermal-mechanical three-dimensional (3-D) model has been developed. A nonlinear-transient heat flow analysis was used to obtain the temperature distribution; then by applying thermal results in the three dimensional elastic-plastic model, residual stress and deformation distribution were obtained. Experiments were carried out to find fusion zone dimensions and displacement. Two heat source models with infinite speed are proposed and the mechanical result of the mentioned models and normal moving heat source are compared.

  16. Measurement of residual stress fields in FHPP welding: a comparison between DSPI combined with hole-drilling and neutron diffraction

    Science.gov (United States)

    Viotti, Matias R.; Albertazzi, Armando; Staron, Peter; Pisa, Marcelo

    2013-04-01

    This paper shows a portable device to measure mainly residual stress fields outside the optical bench. This system combines the traditional hole drilling technique with Digital Speckle Pattern Interferometry. The novel feature of this device is the high degree of compaction since only one base supports simultaneously the measurement module and the hole-drilling device. The portable device allows the measurement of non-uniform residual stresses in accordance with the ASTM standard. In oil and gas offshore industries, alternative welding procedures among them, the friction hydro pillar processing (FHPP) is highlighted and nowadays is an important maintenance tool since it has the capability to produce structure repairs without risk of explosions. In this process a hole is drilled and filled with a consumable rod of the same material. The rod, which could be cylindrical or conical, is rotated and pressed against the hole, leading to frictional heating. In order to assess features about the residual stress distribution generated by the weld into the rod as well as into the base material around the rod, welded samples were evaluated by neutron diffraction and by the hole drilling technique having a comparison between them. For the hole drilling technique some layers were removed by using electrical discharge machining (EDM) after diffraction measurements in order to assess the bulk stress distribution. Results have shown a good agreement between techniques.

  17. Residual stress characterization in low transformation temperature 13%Cr-4%Ni stainless steel weld by neutron diffraction and the contour method

    International Nuclear Information System (INIS)

    Thibault, Denis; Bocher, Philippe; Thomas, Marc; Gharghouri, Michael; Cote, Marjolaine

    2010-01-01

    This study presents the results of residual stress characterization by neutron diffraction and the contour method on 13%Cr-4%Ni welds made using 410NiMo weld filler metal. The transverse, longitudinal and normal components of stress were determined by neutron diffraction. The longitudinal stress distribution was also measured by the contour method. The last bead of the weld was found to be in a state of triaxial compression while a part of the heat-affected zone as well as a region beneath the weld were in a state of longitudinal tension. These results are explained with reference to the low martensitic transformation start temperature (M s ) of the alloy. The same measurements were made on an identical weld that had undergone a standardized post-weld heat treatment. The maximum tensile stress was reduced from 534 to 136 MPa, and the maximum compressive stress was reduced from 371 to 152 MPa.

  18. Fracture Mechanics Approach to X-Ray Diffraction Method for Spot Welded Lap Joint Structure of Rolled Steel Considered Residual Stress

    International Nuclear Information System (INIS)

    Baek, Seung Yeb; Bae, Dong Ho

    2011-01-01

    Cold and hot-rolled carbon steel sheets are commonly used in railroad cars or commercial vehicles such as the automobile. The sheets used in these applications are mainly fabricated by spot welding, which is a type of electric resistance welding. However, the fatigue strength of a spot-welded joint is lower than that of the base metal because of high stress concentration at the nugget edge of the spot-welded part. In particular, the fatigue strength of the joint is influenced by not only geometrical and mechanical factors but also the welding conditions for the spot-welded joint. Therefore, there is a need for establishing a reasonable criterion for a long-life design for spot-welded structures. In this thesis, ΔP-N f relation curves have been used to determine a long-life fatigue-design criterion for thin-sheet structures. However, as these curves vary under the influence of welding conditions, mechanical conditions, geometrical factors, etc. It is very difficult to systematically determine a fatigue-design criterion on the basis of these curves. Therefore, in order to eliminate such problems, the welding residual stresses generated during welding and the stress distributions around the weld generated by external forces were numerically and experimentally analyzed on the basis of the results, reassessed fatigue strength of gas welded joints

  19. Numerical Analysis of Residual Stress and Distortion Use Finite Element Method on Inner Bottom Construction of Geomarin IV Survey Ship with Welding Sequence Variations

    Science.gov (United States)

    Syahroni, N.; Hartono, A. B. W.; Murtedjo, M.

    2018-03-01

    In the ship fabrication industry, welding is the most critical stage. If the quality of welding on ship fabrication is not good, then it will affect the strength and overall appearance of the structure. One of the factors that affect the quality of welding is residual stress and distortion. In this research welding simulation is performed on the inner bottom construction of Geomarin IV Ship Survey using shell element and has variation to welding sequence. In this study, welding simulations produced peak temperatures at 2490 K at variation 4. While the lowest peak temperature was produced by variation 2 with a temperature of 2339 K. After welding simulation, it continued simulating residual stresses and distortion. The smallest maximum tensile residual stress found in the inner bottom construction is 375.23 MPa, and the maximum tensile pressure is -20.18 MPa. The residual stress is obtained from variation 3. The distortion occurring in the inner bottom construction for X=720 mm is 4.2 mm and for X=-720 mm, the distortion is 4.92 mm. The distortion is obtained from the variation 3. Near the welding area, distortion value reaches its minimum point. This is because the stiffeners in the form of frames serves as anchoring.

  20. Verification of an optimized condition for low residual stress employed water-shower cooling during welding in austenitic stainless steel plates

    International Nuclear Information System (INIS)

    Yanagida, N.; Enomoto, K.; Anzai, H.

    2004-01-01

    To reduce tensile residual stress in a welded region, we have developed a new cooling method that uses a water-shower behind the welding torch. When this method is applied to the welding of austenitic stainless steel, the welding and cooling conditions mainly determine how much the residual stress can be reduced. To optimize these conditions, we first used a robust design method to determine the effects of the preheating temperature, the heat input quantity, and the water-shower area on the residual stress, and found that, to decrease the tensile residual stress, the preheating temperature should be high, the heat input low, and the water-shower area large. To confirm the effectiveness of these optimized conditions, the residual stresses under optimized or non-optimized conditions were measured experimentally. It was found that the residual stresses were tensile under the non-optimized conditions, but compressive under the optimized ones. These measurements agree well with the 3D-FEM analyses. It can therefore be concluded that the optimized conditions are valid and appropriate for reducing residual stress in an austenitic stainless-steel weld. (orig.)

  1. Welding simulation of large-diameter thick-walled stainless steel pipe joints. Fast computation of residual stress and influence of heat source model

    International Nuclear Information System (INIS)

    Maekawa, Akira; Serizawa, Hisashi; Nakacho, Keiji; Murakawa, Hidekazu

    2011-01-01

    There are many weld zones in the apparatus and piping installed in nuclear power plants and residual stress generated in the zone by weld process is the most important influence factor for maintaining structural integrity. Though the weld residual stress is frequently evaluated using numerical simulation, fast simulation techniques have been demanded because of the enormous calculation times used. Recently, the fast weld residual stress evaluation based on three-dimensional accurate analysis became available through development of the Iterative Substructure Method (ISM). In this study, the computational performance of the welding simulation code using the ISM was improved to get faster computations and more accurate welding simulation. By adding functions such as parallel processing, the computation speed was much faster than that of the conventional finite element method code. Furthermore, the accuracy of the improved code was validated by measurements. The influence of two different weld heat source models on the simulation results was also investigated and it was found that the moving heat source was effective to achieve accurate weld simulation for multi-pass welds. (author)

  2. Evaluation of mechanical vibration effect on the residual stresses levels in steel welded joints using an Interface Matlab based on Norm API 579

    Directory of Open Access Journals (Sweden)

    R Rodrigues

    2016-10-01

    Full Text Available Nowadays with the high growth of petrochemical welding technology a great development due to high manufacturing offshore structures, storage tanks of petroleum, boilers and pressure vessels for refining plants have been done. Due to various metallurgical changes and restrictions to contraction and expansion undergone by materials when subjected to welding thermal cycle, internal stresses are generated in welded joint which are nominated residual stresses. It is generally undesirable because it can lead to several problems, such as cracks, cold stress fracture, stress corrosion, among others. Although several studies involving residual stresses have been developed in recent years, few information about the variation of the residual stresses level in welded joints when subjected to stress relief treatment by mechanical vibration have been done. Likewise, there are few information related to the comparison between the degree of efficiency by using the post-weld heat treatment and those treatment. Therefore, the goal of this work was to apply the relieve residual stresses treatment by mechanical vibration in steel welded joints used in oil industry, and compare the results with those obtained by post heat treatment and evaluate the efficiency level of this technique In addition, this works also hope to contribute for a better understanding of this technique and to find which parameters have a greater influence on the results.

  3. Use of neutron and synchrotron X-ray diffraction for evaluation of residual stresses in a 2024-T351 aluminum alloy variable-polarity plasma-arc weld

    Science.gov (United States)

    Ganguly, S.; Fitzpatrick, M. E.; Edwards, L.

    2006-02-01

    The residual stress fields associated with variable-polarity plasma-arc (VPPA) welds in 2024-T351 aluminum alloy plates have been measured nondestructively using neutron and synchrotron X-ray diffraction. Neutron diffraction allows in-depth measurements of the full strain tensor to be made in thick components; synchrotron X-rays allow for rapid measurements of strains inside components, although their penetration is less than that of the neutrons and constraints arising from the diffraction geometry generally lead to only two strain components being easily measurable. Hence, a combination of the two techniques, applied as described herein, is ideal for a detailed nondestructive evaluation of residual stresses in plates. The residual stresses in a 12-mm-thick VPPA-welded aluminum 2024-T351 alloy plate have been measured using neutron diffraction. The stresses were then remeasured by a combination of neutron and synchrotron X-ray diffraction after the plate had been reduced in thickness (or, skimmed) to 7 mm by machining both sides of the weld, mimicking the likely manufacturing operation, should such welds be used in aerospace structures. A strong tensile residual stress field was measured in the longitudinal direction, parallel to the weld, in both the as-welded and skimmed specimens. There was only a slight modification of the residual stress state on skimming.

  4. Study on distribution and optimization of residual stress inside plate-fin structure after braze welding

    International Nuclear Information System (INIS)

    Zhou Guoyan; Tu Shandong; Xuan Fuzhen; Wang Zhengdong

    2010-01-01

    The residual stress inside the plate-fin structure has been analyzed by the finite element method under different operation conditions. The calculated results show that a large scale of residual stress will occur in the plate-fin structure and the maximum value is found at the braze corner. The rapid cooling process and the pressured assembly technology have a significant effect on the distribution of the residual stress. The brazed material owns a better performance with a quicker cooling rate. However, the quicker cooling rate also leads to a tensile residual stress near the brazed seam, which is deleterious to the whole structure. The pressure assembly technology can change the residual stress from a tensile state to the compressed state which can improve the safety and extend the service life of the plate-fin structure effectively. (authors)

  5. Thermal Aging Effects on Residual Stress and Residual Strain Distribution on Heat Affected Zone of Alloy 600 in Dissimilar Metal Weld

    International Nuclear Information System (INIS)

    Ham, Junhyuk; Choi, Kyoung Joon; Kim, Ji Hyun

    2016-01-01

    Dissimilar metal weld (DMW), consisting of Alloy 600, Alloy 182, and A508 Gr.3, has been widely used as a joining material of the reactor pressure vessel penetration nozzle and the steam generator tubing for pressurized water reactors (PWR) because of its good mechanical strength, thermal conductivity, and corrosion resistance. Residual tensile stress is mainly nominated as a cause of SCC in light water reactors by IAEA report. So, to relax the residual stress, post-weld heat treatment is required after manufacturing process such as welding. However, thermal treatment has a great effect on the microstructure and the chromium depletion profile on Alloy 600, so called sensitization. By this reason, HAZ on Alloy 600 is critical to crack. According to G.A. Young et al., Crack growth rates (CGR) in the Alloy 600 HAZ were about 30 times faster than those in the Alloy 600 base metal tested under the same conditions. And according to Z.P. Lu et al., CGR in the Alloy 600 HAZ can be more than 20 times higher than that in its base metal. There are some methods to measure the exact value of residual stress on the material surface. The most common way is X-ray diffraction method (XRD). The principle of XRD is based on lattice strains and depends on the changes in the spacing of the atomic planes in material. And there is a computer simulation method to estimate residual stress distribution which is called ANSYS. This study was conducted to investigate how thermal aging affects residual stress and residual strain distribution of Alloy 600 HAZ. Following conclusions can be drawn from this study. According to preceding researches and this study, both the relaxation of residual stress and the change of residual strain follow as similar way, spreading out from concentrated region. The result of Vickers micro-hardness tester shows that tensile residual stresses are distributed broadly on the material aged by 15 years. Therefore, HT400 Y 15 material is weakest state for PWSCC. The

  6. Numerical Evaluation of Temperature Field and Residual Stresses in an API 5L X80 Steel Welded Joint Using the Finite Element Method

    Directory of Open Access Journals (Sweden)

    Jailson A. Da Nóbrega

    2016-01-01

    Full Text Available Metallic materials undergo many metallurgical changes when subjected to welding thermal cycles, and these changes have a considerable influence on the thermo-mechanical properties of welded structures. One method for evaluating the welding thermal cycle variables, while still in the project phase, would be simulation using computational methods. This paper presents an evaluation of the temperature field and residual stresses in a multipass weld of API 5L X80 steel, which is extensively used in oil and gas industry, using the Finite Element Method (FEM. In the simulation, the following complex phenomena were considered: the variation in physical and mechanical properties of the material as a function of the temperature, welding speed and convection and radiation mechanisms. Additionally, in order to characterize a multipass weld using the Gas Tungsten Arc Welding process for the root pass and the Shielded Metal Arc Welding process for the filling passes, the analytical heat source proposed by Goldak and Chakravarti was used. In addition, we were able to analyze the influence of the mesh refinement in the simulation results. The findings indicated a significant variation of about 50% in the peak temperature values. Furthermore, changes were observed in terms of the level and profile of the welded joint residual stresses when more than one welding pass was considered.

  7. Prediction of residual stress for dissimilar metals welding at nuclear power plants using fuzzy neural network models

    International Nuclear Information System (INIS)

    Na, Man Gyun; Kim, Jin Weon; Lim, Dong Hyuk

    2007-01-01

    A fuzzy neural network model is presented to predict residual stress for dissimilar metal welding under various welding conditions. The fuzzy neural network model, which consists of a fuzzy inference system and a neuronal training system, is optimized by a hybrid learning method that combines a genetic algorithm to optimize the membership function parameters and a least squares method to solve the consequent parameters. The data of finite element analysis are divided into four data groups, which are split according to two end-section constraints and two prediction paths. Four fuzzy neural network models were therefore applied to the numerical data obtained from the finite element analysis for the two end-section constraints and the two prediction paths. The fuzzy neural network models were trained with the aid of a data set prepared for training (training data), optimized by means of an optimization data set and verified by means of a test data set that was different (independent) from the training data and the optimization data. The accuracy of fuzzy neural network models is known to be sufficiently accurate for use in an integrity evaluation by predicting the residual stress of dissimilar metal welding zones

  8. Evaluation of residual stress distribution of butt-weld pipe and redistribution behavior with crack extension using neutron diffraction method

    International Nuclear Information System (INIS)

    Okido, Shinobu; Hayashi, Makoto; Minakawa, Nobuaki; Morii, Yukio; Ando, Kotoji

    2005-01-01

    Residual stress is known to be redistributed as a result of crack extension. The neutron diffraction method was used to evaluate this residual stress redistribution, using a specimen consisting of a butt-weld-jointed pipe made of type-304 austenitic stainless steel (inner diameter φ=97.1 mm, thickness t=8.9mm). Half-elliptical cracks were introduced by an electrical discharge machining at the inner surface of a heat-affected zone. The ratios of a/t, for crack depth a and specimen thickness t, were 0.25 and 0.5, with aspect ratios a/c, for crack half-length c, of 0.1 and 0.5 Comparing the residual stress distribution before and after the crack introduction showed that although the residual stress distribution along the line of the ligament at the deepest point of the crack changed slightly in front of the crack tip, it did not change throughout the ligament. This result shows that residual stress redistributes through-out in the whole crack tip region, including the width of the crack. (author)

  9. The influence of plate thickness on the welding residual stresses from submerged arc welding in offshore steel structures

    DEFF Research Database (Denmark)

    Andreassen, Michael Joachim; Yu, Zhenzhen; Liu, Stephen

    2017-01-01

    to an improved design, which consequently may be included in future norms and standards. Submerged Arc Welding (SAW) was used to make a fully penetrated butt weld in 10 mm and 40 mm thick steel plates with the same welding parameters as used in the production procedures. The base material is thermomechanical hot...

  10. Effects of filler wire on residual stress in electron beam welded QCr0.8 copper alloy to 304 stainless steel joints

    International Nuclear Information System (INIS)

    Zhang, Bing-Gang; Zhao, Jian; Li, Xiao-Peng; Chen, Guo-Qing

    2015-01-01

    The electron beam welding (EBW) of 304 stainless steel to QCr0.8 copper alloy with or without copper filler wire was studied in detail. The temperature fields and magnitude and distribution of stress fields in the joints during the welding process were numerically simulated using finite element method. The temperature cycles and residual stresses were also experimentally measured by thermometric and hole-drilling methods, respectively. The accuracy of the modeling procedure was verified by the good agreement between the calculated results and experimental data. The temperature distribution in the joint was found to be asymmetric along the center of weld. In particular, the temperature in the copper alloy plate is much higher than that in the 304 SS plate owing to the great difference in thermal conductivity between the two materials. The peak three-dimensional residual stresses all appeared at the interface between the copper and steel in the two different joints. Furthermore, the weld was subjected to tensile stress. The longitudinal residual stress, generally the most harmful to the integrity of the structure among the stress components in EBW with filler wire (EBFW), was 53 MPa lower than that of autogenous EBW (AEBW), and the through-thickness residual stress was 12 MPa lower. The transverse residual stress of EBFW was 44 MPa higher than that of AEBW. However, analysis of the von Mises stress showed that the EBFW process effectively reduced the extent of the high residual stress region in the weld location and the magnitude of the residual stresses in the copper side compared with those of the AEBW joint. - Highlights: • Copper and steel was welded by electron beam welding with copper filler wire. • The copper wire fed into gap can reduce the peak value of residual stress. • The peak value of longitudinal stress can be reduced 53 MPa by the filler wire. • The range of nov Mises stress in the weld could be reduced by the wire

  11. Control of welding distortion during gas metal arc welding of AH36 plates by stress engineering

    NARCIS (Netherlands)

    Pazooki, A.M.A.; Hermans, M.J.M.; Richardson, I.M.

    2017-01-01

    Welding residual stress and distortion are strongly linked together. One of the ways to control or reduce the welding distortions is the manipulation of the generated stresses during welding, and final residual stresses exist in the workpiece (stress engineering). In this paper, the control of gas

  12. Effect of residual stress relaxation by means of local rapid induction heating on stress corrosion cracking behavior and electrochemical characterization of welded Ti-6Al-4V alloy under slow strain rate test

    Science.gov (United States)

    Liu, Yan; Tang, Shawei; Liu, Guangyi; Sun, Yue; Hu, Jin

    2017-05-01

    In this study, a welded Ti-6Al-4V alloy was treated by means of local rapid induction heating in order to relax the residual stress existed in the weldment. The welded samples were heat treated at the different temperatures. The stress corrosion cracking behavior and electrochemical characterization of the as-welded samples before and after the post weld heat treatment as a function of residual stress were investigated. Electrochemical impedance spectroscopy measurements of the samples under slow strain rate test were performed in a LiCl-methanol solution. The results demonstrated that the residual stress in the as-welded sample was dramatically reduced after the post weld heat treatment, and the residual stress decreased with the increase in the heat treatment temperature. The stress corrosion cracking susceptibility and electrochemical activity of the as-welded sample were significantly reduced after the heat treatment due to the relaxation of the residual stress, which gradually decreased with the decreasing value of the residual stress distributed in the heat treated samples.

  13. Influence of treatment by vibration in residual stress generated in the laser welding of HSLA and IF steels; Influencia do tratamento de vibracao nas tensoes residuais geradas na soldagem a laser de acos ARBL e IF

    Energy Technology Data Exchange (ETDEWEB)

    Chuvas, T.C.; Fonseca, M.P. Cindra, E-mail: chuvas@vm.uff.b [Universidade Federal Fluminense (PGMEC/UFF), Niteroi, RJ (Brazil). Programa de Pos-graduacao em Engenharia Mecanica; Castello, D.A. [Universidade Federal do Rio de Janeiro (DEM/UFRJ), RJ (Brazil). Dept. de Engenharia Mecanica

    2010-07-01

    The stress relieving treatment by vibration is a new technology under development, which has many advantages over thermal methods. In this work was analyzed the surface residual stress generated in the laser welding of biphasic HSLA and IF steels, both used in the automotive industry. Residual stresses were measured by X-ray diffraction, by the sen{sup 2} {Psi} method. Residual stresses generated in the welding of the samples were tensile at all points measured. After welding, the samples were submitted to the mechanical vibration treatment. Some samples presented a significant reduction in the stress values. The welded joints were also characterized by optical microscopy. (author)

  14. Study of residual stresses in welded joints of dual phase HSLA steel used in automotive industry; Estudo das tensoes residuais em juntas soldadas de aco ARBL bifasico usado na industria automobilistica

    Energy Technology Data Exchange (ETDEWEB)

    Barbato, D.S.; Fonseca, M.P. Cindra; Marques Junior, A.S.; Chuvas, T.C.; Pardal, J.M., E-mail: mcindra@vm.uff.b [Universidade Federal Fluminense (PGMEC/UFF), Niteroi, RJ (Brazil). Programa de Pos-graduacao em Engenharia Mecanica; Berretta, J.R. [Instituto de Pesquisas Energeticas e Nucleares (IPEN/CNEN-SP), Sao Paulo, SP (Brazil)

    2010-07-01

    One way of weight reduction in automotive vehicles is through the use of high strength and low alloy (HSLA) steels, which enables the use of small thickness plates. Whereas the appearance of residual stresses is intrinsic to the welding process, this study evaluates the residual stresses generated in welded joints obtained by TIG and LASER welding processes and comparing them. Residual stresses were measured by X-rays diffraction technique, using a portable device with Cr{kappa}{alpha} radiation applying the double exposure method. It also evaluates the influence of shot peening treatment applied after welding, in the bend tests conducted for both welding conditions and TIG welded joints showed higher stability of compressive stresses after welding. The metallographic analysis by optical microscopy complemented the welded joints characterization. (author)

  15. Residual stress reduction in beam welded joints by means of stress redistribution using defocused electron or laser beams; Eigenspannungsreduktion in strahlgeschweissten Naehten mittels Spannungsumlagerung durch den Einsatz defokussierter Elektronen- bzw. Laserstrahlen

    Energy Technology Data Exchange (ETDEWEB)

    Toelle, Florian

    2013-08-01

    Among the multiple advantages of beam welding processes the high longitudinal residual stresses in beam welds ranging till the local yield stress are one disadvantage. These high stresses can influence the service life of the welded components. The residual stresses in other welding processes exist in an equal high level but primarily in the transverse direction to the weld. To mitigate the high residual stresses a couple of methods were developed for these welding processes in the last decades. However these methods need large contact surfaces next to the welds for the installation of matched heating and cooling elements and other additional equipment. Furthermore, the previous developed stress mitigating processes offer a low efficiency for the small beam welds. The stress reduction by using the welding source after the welding process for a remote heat treatment of the welded components afford a flexible tool for the stress mitigation in beam welds. This method does not need any additional equipment and it is applicable for complex welding and component geometries. During this post welding heat treatment the material next to the weld is heated by the defocused electron or by the defocused laser beam, respectively, to temperatures of some hundreds degree Celsius. Hereby low plastic deformations in these regions are generated. While cooling down due to the thermal shrinkage the material between the weld and the heat treated region is compressed in longitudinal direction to the weld. This intermediate material zone constrained the shrinkage of the weld while cooling down from the melting temperature and leads to the high longitudinal residual stresses in the weld. In consequence of the compression of this intermediate zones by the heat treated zones the resistance to the shrinkage of the weld is lowered and the longitudinal stresses in the weld are reduced. In the process the quantity of the stress reduction is controlled by the selection of the process parameters

  16. Residual strains in girth-welded linepipe

    International Nuclear Information System (INIS)

    MacEwen, S.R.; Holden, T.M.; Powell, B.M.; Lazor, R.B.

    1987-07-01

    High resolution neutron diffraction has been used to measure the axial residual strains in and adjacent to a multipass girth weld in a complete section of 914 mm (36 inches) diameter, 16 mm (5/8 inch) wall, linepipe. The experiments were carried out at the NRU reactor, Chalk River using the L3 triple-axis spectrometer. The through-wall distribution of axial residual strain was measured at 0, 4, 8, 20 and 50 mm from the weld centerline; the axial variation was determined 1, 5, 8, and 13 mm from the inside surface of the pipe wall. The results have been compared with strain gauge measurements on the weld surface and with through-wall residual stress distributions determined using the block-layering and removal technique

  17. Weld residual stresses near the bimetallic interface in clad RPV steel: A comparison between deep-hole drilling and neutron diffraction data

    OpenAIRE

    James, MN; Newby, M; Doubell, P; Hattingh, DG; Serasli, K; Smith, DJ

    2014-01-01

    The inner surface of ferritic steel reactor pressure vessels (RPV) is clad with strip welded austenitic stainless steel primarily to increase the long-term corrosion resistance of the ferritic vessel. The strip welding process used in the cladding operation induces significant residual stresses in the clad layer and in the RPV steel substrate, arising both from the thermal cycle and from the very different thermal and mechanical properties of the austenitic clad layer and the ferritic RPV ste...

  18. Characterising electron beam welded dissimilar metal joints to study residual stress relaxation from specimen extraction

    OpenAIRE

    Abburi Venkata, Kiranmayi; Truman, Christopher E; Smith, David J; Bhaduri, Arun K

    2016-01-01

    Nuclear power plants require dissimilar metal weld joints to connect the primary steam generator made from ferritic steel to the intermediate heat exchanger made from austenitic steel. Such joints are complex because of the mismatch in the thermal and the mechanical properties of the materials used in the joint. Electron Beam (EB) welding is emerging as a promising technique to manufacture dissimilar joints providing a great many advantages over conventional welding techniques, in terms of lo...

  19. Residual Stresses in Thick Bi-metallic Fusion Welds : A Neutron Diffraction Study

    NARCIS (Netherlands)

    Ohms, C.

    2013-01-01

    Welding is applied in many industrial sectors to join components, and has become an important manufacturing process because it enables the fabrication of structures that could not otherwise be constructed. Weld regions have inhomogeneous microstructures and are more susceptible to crack initiation

  20. Study of residual stresses generated in P91 pipe steel welded by MCAW / FCAW processes; Estudo das tensoes residuais geradas na soldagem de tubulacao de aco P91 pelos processos MCAW/FCAW

    Energy Technology Data Exchange (ETDEWEB)

    Chuvas, Tatiane C.; Pardal, Juan M.; Garcia, Pedro P.; Souza, Guttemberg C. de; Fonseca, Maria P. Cindra, E-mail: chuvas@vm.uff.br [Universidade Federal Fluminense (PGMEC/UFF), Niteroi, RJ (Brazil). Departamento de Engenharia Mecanica; Cardote, Ismael [UTC Engenharia S/A, Niteroi, Rio de Janeiro, RJ (Brazil)

    2014-07-01

    The welding is one of the main industrial manufacturing processes structures and piping, knowledge of residual stress from this process is of paramount importance because the mechanical properties of welded components are not only determined by the microstructures present in the joint, but also by residual stresses heterogeneous introduced by thermal cycling during the process. The aim of this work is the characterization ASTM P91 joints welded by MCAW / FCAW (Metal Cored Arc Welding / Flux Cored Arc Welding) processes through the residual stresses evaluating associated with welding and post-weld heat treatments. Residual stresses were measured using X-rays diffraction sin2psi method, with Crκα radiation and they presented tensile at the root joints with larger magnitudes in the weld metal region and compressive on the surface. The post weld heat treatment resulted relief of residual stresses at the root of the joints. However, the same effect was observed in compressive surface stresses, which could adversely affect the service life of the pipe, reducing the fatigue and stress corrosion cracking resistances. (author)

  1. NET TG1: Residual stress assessment by neutron diffraction and finite element modeling on a single bead weld on a steel plate

    International Nuclear Information System (INIS)

    Ohms, C.; Wimpory, R.C.; Katsareas, D.E.; Youtsos, A.G.

    2009-01-01

    In the context of the efforts of Task Group 1 (TG1) of the European Network on Neutron Techniques Standardization for Structural Integrity (NET), the Joint Research Centre (JRC) participated in the experimental round robin campaign for residual stress analysis on a single weld bead on a steel plate. In parallel, the University of Patras (UP), in collaboration with the JRC, contributed to the corresponding numerical analysis round robin exercise. Neutron diffraction measurements were performed on a specimen, designated as A12, using the residual stress diffractometer at beam tube HB5 at the High Flux Reactor (HFR) in Petten, The Netherlands. Several line scans of strains and stresses were performed in accordance with an experimental protocol devised for this exercise and their results are presented in this paper. Two scans were made along the weld longitudinal direction beneath the upper surface of the plate, three were made in the weld transverse direction, and three through the thickness of the plate. The measured residual stresses are presented in detail. The measurements confirm that the stress distribution around this single weld bead on a plate is intrinsically 3-dimensional. The procedure followed by UP in the numerical assessment of the problem is presented in detail. The numerical results are presented in direct comparison to the JRC measurement data

  2. Residual stresses in steel and zirconium weldments

    International Nuclear Information System (INIS)

    Root, J.H.; Coleman, C.E.; Bowden, J.W.

    1997-01-01

    Three-dimensional scans of residual stress within intact weldments provide insight into the consequences of various welding techniques and stress-relieving procedures. The neutron diffraction method for nondestructive evaluation of residual stresses has been applied to a circumferential weld in a ferritic steel pipe of outer diameter 114 mm and thickness 8.6 mm. The maximum tensile stresses, 250 MPa in the hoop direction, are found at mid-thickness of the fusion zone. The residual stresses approach zero within 20 mm from the weld center. The residual stresses caused by welding zirconium alloy components are partially to blame for failures due to delayed-hydride cracking. Neutron diffraction measurements in a GTA-welded Zr-2.5 Nb plate have shown that heat treatment at 530 C for 1 h reduces the longitudinal residual strain by 60%. Neutron diffraction has also been used to scan the residual stresses near circumferential electron beam welds in irradiated and unirradiated Zr-2.5 Nb pressure tubes. The residual stresses due to electron beam welding appear to be lower than 130 MPa, even in the as-welded state. No significant changes occur in the residual stress pattern of the electron-beam welded tube, during a prolonged exposure to thermal neutrons and the temperatures typical of an operating nuclear reactor

  3. Weld residual stresses near the bimetallic interface in clad RPV steel: A comparison between deep-hole drilling and neutron diffraction data

    Energy Technology Data Exchange (ETDEWEB)

    James, M.N., E-mail: mjames@plymouth.ac.uk [School of Marine Science and Engineering, University of Plymouth, Drake Circus, Plymouth (United Kingdom); Department of Mechanical Engineering, Nelson Mandela Metropolitan University, Port Elizabeth (South Africa); Newby, M.; Doubell, P. [Eskom Holdings SOC Ltd, Lower Germiston Road, Rosherville, Johannesburg (South Africa); Hattingh, D.G. [Department of Mechanical Engineering, Nelson Mandela Metropolitan University, Port Elizabeth (South Africa); Serasli, K.; Smith, D.J. [Department of Mechanical Engineering, University of Bristol, Queen' s Building, University Walk, Bristol (United Kingdom)

    2014-07-01

    Highlights: • Identification of residual stress trends across bimetallic interface in stainless clad RPV. • Comparison between deep hole drilling (DHD – stress components in two directions) and neutron diffraction (ND – stress components in three directions). • Results indicate that both techniques can assess the trends in residual stress across the interface. • Neutron diffraction gives more detailed information on transient residual stress peaks. - Abstract: The inner surface of ferritic steel reactor pressure vessels (RPV) is clad with strip welded austenitic stainless steel primarily to increase the long-term corrosion resistance of the ferritic vessel. The strip welding process used in the cladding operation induces significant residual stresses in the clad layer and in the RPV steel substrate, arising both from the thermal cycle and from the very different thermal and mechanical properties of the austenitic clad layer and the ferritic RPV steel. This work measures residual stresses using the deep hole drilling (DHD) and neutron diffraction (ND) techniques and compares residual stress data obtained by the two methods in a stainless clad coupon of A533B Class 2 steel. The results give confidence that both techniques are capable of assessing the trends in residual stresses, and their magnitudes. Significant differences are that the ND data shows greater values of the tensile stress peaks (∼100 MPa) than the DHD data but has a higher systematic error associated with it. The stress peaks are sharper with the ND technique and also differ in spatial position by around 1 mm compared with the DHD technique.

  4. Weld residual stresses near the bimetallic interface in clad RPV steel: A comparison between deep-hole drilling and neutron diffraction data

    International Nuclear Information System (INIS)

    James, M.N.; Newby, M.; Doubell, P.; Hattingh, D.G.; Serasli, K.; Smith, D.J.

    2014-01-01

    Highlights: • Identification of residual stress trends across bimetallic interface in stainless clad RPV. • Comparison between deep hole drilling (DHD – stress components in two directions) and neutron diffraction (ND – stress components in three directions). • Results indicate that both techniques can assess the trends in residual stress across the interface. • Neutron diffraction gives more detailed information on transient residual stress peaks. - Abstract: The inner surface of ferritic steel reactor pressure vessels (RPV) is clad with strip welded austenitic stainless steel primarily to increase the long-term corrosion resistance of the ferritic vessel. The strip welding process used in the cladding operation induces significant residual stresses in the clad layer and in the RPV steel substrate, arising both from the thermal cycle and from the very different thermal and mechanical properties of the austenitic clad layer and the ferritic RPV steel. This work measures residual stresses using the deep hole drilling (DHD) and neutron diffraction (ND) techniques and compares residual stress data obtained by the two methods in a stainless clad coupon of A533B Class 2 steel. The results give confidence that both techniques are capable of assessing the trends in residual stresses, and their magnitudes. Significant differences are that the ND data shows greater values of the tensile stress peaks (∼100 MPa) than the DHD data but has a higher systematic error associated with it. The stress peaks are sharper with the ND technique and also differ in spatial position by around 1 mm compared with the DHD technique

  5. Creep Deformation, Rupture Analysis, Heat Treatment and Residual Stress Measurement of Monolithic and Welded Grade 91 Steel for Power Plant Components

    Science.gov (United States)

    Shrestha, Triratna

    Modified 9Cr-1 Mo (Grade 91) steel is currently considered as a candidate material for reactor pressure vessels (RPVs) and reactor internals for the Very High Temperature Reactor (VHTR), and in fossil-fuel fired power plants at higher temperatures and stresses. The tensile creep behavior of Grade 91 steel was studied in the temperature range of 600°C to 750°C and stresses between 35 MPa and 350 MPa. Heat treatment of Grade 91 steel was studied by normalizing and tempering the steel at various temperatures and times. Moreover, Thermo-Ca1c(TM) calculation was used to predict the precipitate stability and their evolution, and construct carbon isopleths of Grade 91 steel. Residual stress distribution across gas tungsten arc welds (GTAW) in Grade 91 steel was measured by the time-of-flight neutron diffraction using the Spectrometer for Materials Research at Temperature and Stress (SMARTS) diffractometer at Lujan Neutron Scattering Center, Los Alamos National Laboratory, Los Alamos, NM, USA. Analysis of creep results yielded stress exponents of ˜9-11 in the higher stress regime and ˜1 in the lower stress regime. The creep behavior of Grade 91 steel was described by the modified Bird-Mukherjee-Dorn relation. The rate-controlling creep deformation mechanism in the high stress regime was identified as the edge dislocation climb with a stress exponent of n = 5. On the other hand, the deformation mechanism in the Newtonian viscous creep regime (n = 1) was identified as the Nabarro-Herring creep. Creep rupture data were analyzed in terms of Monkman-Grant relation and Larson-Miller parameter. Creep damage tolerance factor and stress exponent were used to identify the cause of creep damage. The fracture surface morphology of the ruptured specimens was studied by scanning electron microscopy to elucidate the failure mechanisms. Fracture mechanism map for Grade 91 steel was developed based on the available material parameters and experimental observations. The microstructural

  6. Residual-stress measurements

    Energy Technology Data Exchange (ETDEWEB)

    Ezeilo, A.N.; Webster, G.A. [Imperial College, London (United Kingdom); Webster, P.J. [Salford Univ. (United Kingdom)

    1997-04-01

    Because neutrons can penetrate distances of up to 50 mm in most engineering materials, this makes them unique for establishing residual-stress distributions non-destructively. D1A is particularly suited for through-surface measurements as it does not suffer from instrumental surface aberrations commonly found on multidetector instruments, while D20 is best for fast internal-strain scanning. Two examples for residual-stress measurements in a shot-peened material, and in a weld are presented to demonstrate the attractive features of both instruments. (author).

  7. Study on welding thermal cycle and residual stress of UNS S32304 duplex steel selected as external shield for a transport packaging of Mo-99

    International Nuclear Information System (INIS)

    Betini, Evandro G.; Gomes, Maurilio P.; Milagre, Mariana X.; Machado, Caruline S.C.; Reis, Luis A.M.; Mucsi, Cristiano S.; Rossi, Jesualdo L.; Orlando, Marcos T.D.; Luz, Temístocles S.

    2017-01-01

    Thin plates of duplex stainless steel UNS S32304 were welded using the pulsed gas tungsten arc GTAW process (butt joint) without filler addition. The used shielding gas was pure argon and 98% argon plus 2% of nitrogen. The thermal cycles were acquired during welding, in regions near the melting pool. This alloy is candidate for the external clad of a cask for the transport of high activity radiopharmaceuticals substances. For the residual stress measurements in austenite phase an X-ray diffractometer was used in a Bragg-Brentano geometry with CuKα radiation (γ= 0.154 and for ferrite phase was used a pseudo-parallel geometry with CrKα radiation (γ= 0.2291 nm). The results of residual stress using sin 2 Ψ methodology shown that the influence of the high welding temperature leads to compressive stresses in for both phase of the duplex steels mainly in heat-affected zone. It was observed a high temperature peak and an increase of the mean residual stress after addition of nitrogen to the argon shielding gas. (author)

  8. Study on welding thermal cycle and residual stress of UNS S32304 duplex steel selected as external shield for a transport packaging of Mo-99

    Energy Technology Data Exchange (ETDEWEB)

    Betini, Evandro G.; Gomes, Maurilio P.; Milagre, Mariana X.; Machado, Caruline S.C.; Reis, Luis A.M.; Mucsi, Cristiano S.; Rossi, Jesualdo L., E-mail: egbetini@ipen.br [Instituto de Pesquisas Energética s e Nucleares (IPEN/CNEN-SP), São Paulo, SP (Brazil); Orlando, Marcos T.D.; Luz, Temístocles S., E-mail: mtdorlando@gmail.com [Universidade Federal do Espirito Santo (DFIS/UFES), Vitória, ES (Brazil). Departamento de Física

    2017-07-01

    Thin plates of duplex stainless steel UNS S32304 were welded using the pulsed gas tungsten arc GTAW process (butt joint) without filler addition. The used shielding gas was pure argon and 98% argon plus 2% of nitrogen. The thermal cycles were acquired during welding, in regions near the melting pool. This alloy is candidate for the external clad of a cask for the transport of high activity radiopharmaceuticals substances. For the residual stress measurements in austenite phase an X-ray diffractometer was used in a Bragg-Brentano geometry with CuKα radiation (γ= 0.154 and for ferrite phase was used a pseudo-parallel geometry with CrKα radiation (γ= 0.2291 nm). The results of residual stress using sin{sup 2} Ψ methodology shown that the influence of the high welding temperature leads to compressive stresses in for both phase of the duplex steels mainly in heat-affected zone. It was observed a high temperature peak and an increase of the mean residual stress after addition of nitrogen to the argon shielding gas. (author)

  9. Transformation behaviour and residual stresses in welding of new LTT filler materials; Umwandlungsverhalten und Eigenspannungen beim Schweissen neuartiger LTT-Zusatzwerkstoffe

    Energy Technology Data Exchange (ETDEWEB)

    Kromm, Arne

    2011-07-06

    It has long been recognized that phase transformation plays a prominent part in the evolution of welding residual stresses in high-strength steel. But thus far, no approaches have been available to practically utilize this effect for welding residual stress control. Innovative Low Transformation Temperature (LTT) alloys featuring a characteristic chemical composition open up the possibility for joining high strength steels on their own strength level. Furthermore, martensitic phase transformation is supposed to permit deliberate adjustment of the welding residual stresses. Even though numerous investigations can be found in the literature on this issue, they provide only little insight into the interaction between phase transformation and resulting welding residual stresses. In order to clarify the problem presented, a matrix of LTT alloys was defined based on evaluated literature. The alloys were characterized with respect to their microstructure, mechanical properties and transformation temperature. Furthermore, it was possible within the scope of this study to realize in-situ experiments during welding using energy-dispersive diffraction methods. The new design and implementation of a welding setup specifically for use at synchrotron beamlines enabled the in-situ diffraction analysis of transformation processes. In the course of these experiments it could be managed to determine the transformation temperatures prevailing in the LTT weld metal. In addition the transformation kinetics of these alloys could be analyzed. The effects of the transformation behavior were analyzed based on the residual stress distributions at the surface of varying specimen geometries. The results illustrate on the one hand that the desired residual stress control by using LTT alloys is actually feasible. This is particularly found in cases with largely free shrinkage of the weld. With increasing shrinkage restraint, however, a shift of the residual stress level into the area of tension

  10. 3D finite element simulation of temperature distribution, residual stress and distortion on 304 stainless steel plates using GTA welding

    Energy Technology Data Exchange (ETDEWEB)

    Venkatkumar, D.; Ravindran, D. [National Engineering College, Tamilnadu (India)

    2016-01-15

    In the present study, the distortion induced in rectangular plate of AISI 304 SS during autogenous GTA welding process is measured experimentally and further validated using Finite element (FE) analysis. The thermal histories are measured at fixed locations over the surface of the plate and the results are compared with FE analysis. The Gaussian surface and Volumetric heat source models are simulated and transient heat transfer analysis is performed. The heat source models have been tested with two different speeds. The effectiveness of change in thermal histories of the heat sources have been studied and reported. In FE analysis, the sequentially coupled thermomechanical analysis is performed using the thermal histories as input and the distortion of the plates are predicted and compared with experimental measurements. The large and small displacement theories are employed for the above purpose and the effectiveness of the theories are reported. The edge deformation of the plates have been measured and validated for both the theories. The residual stress and distortion at the mid span are predicted and discussed. The results predicted using large displacement theory is in good agreement with measured values.

  11. Improvement in accuracy of the measurements of residual stresses due to circumferential welds in thin-walled pipe using Rayleigh wave method

    International Nuclear Information System (INIS)

    Akhshik, Siamak; Moharrami, Rasool

    2009-01-01

    To achieve an acceptable safety in many industrial applications such as nuclear power plants and power generation, it is extremely important to gain an understanding of the magnitudes and distributions of the residual stresses in a pipe formed by joining two sections with a girth butt weld. Most of the methods for high-accuracy measurement of residual stress are destructive. These destructive measurement methods cannot be applied to engineering systems and structures during actual operation. In this paper, we present a method based on the measurement of ultrasonic Rayleigh wave velocity variations versus the stress state for nondestructive evaluation of residual stress in dissimilar pipe welded joint. We show some residual stress profile obtained by this method. These are then compared with other profiles determined using a semi-destructive technique (hole-drilling) that makes it possible to check our results. According to the results, we also present a new method for adjusting the ultrasonic measurements to improve the agreement with the results obtained from other techniques.

  12. Development of nondestructive hybrid measuring method for three-dimensional residual stress distribution of thick welded joint. Hybrid measuring method of inherent strain method and neutron diffraction method

    International Nuclear Information System (INIS)

    Nakacho, Keiji; Kasahara, Norifumi; Tamura, Ryota

    2012-01-01

    The measuring methods of the residual stress are classified into destructive one and nondestructive one. The inherent strain method (ISM) is destructive one. The neutron diffraction method (NDM) is nondestructive one. But the measurable depth is limited within about 20 mm and the method cannot measure the weld zone, without destruction of the object. So, in this study, the hybrid measuring method has been developed, by combining the ISM and the NDM. The theory of the hybrid method is the same as the ISM. In the analysis, the strains measured by the NDM without destruction are used. This hybrid measuring method is a true nondestructive measuring method for a thick welded joint. The applicability of the hybrid method has been verified by simulation, using a butt welded joint of thick pipes. In the simulation, the reliable order of the strains measured by the present NDM is very important, and was considered as 10 micro. The measurable regions by the present NDM were assumed. Under the above conditions, the data (the residual elastic strains assumed to be measured by the NDM) were made, and used in the ISM. As a result of such simulation, it has been cleared that the estimated residual stress has very high accuracy, if enough data are used. The required number of data is less than the ISM. (author)

  13. Vibration stress relief of DH 36 rectangle welded plates

    Science.gov (United States)

    Li, Shuqi; Fang, Hongyuan

    2018-03-01

    Vibration stress relief (VSR) is widely used in reducing residual stress in welded structures. However, the effectiveness of this method is still instable in some circumstance. In this study, a covert negative treatment phenomenon was investigated, i.e. natural frequency of welded structures decreased after VSR but residual stress in one direction increased. When the alteration of natural frequency after VSR is significant, the residual stresses in both the longitudinal and transversal directions shall decrease. Otherwise, residual stresses may increase on one direction. Thus, sufficient power shall be applied to the welded structures to avoid negative results.

  14. An overview of the NeT international round-robin programme: weld residual stress measurement and modelling in nuclear materials

    International Nuclear Information System (INIS)

    Reid, M.H.; Hamelin, C.J.

    2016-01-01

    This talk provides an overview of the European Network on Neutron Techniques Standardisation for Structural Integrity (NeT). The network involves some 35 organisations from industry and academia, whose goal is to identify best practice in the application of modern experimental and numerical techniques to problems related to the structural integrity of components, mainly relevant to nuclear applications. While the programme was originally built around neutron scattering techniques for residual stress measurement, it has grown considerably to include studies of X-ray diffraction, deep-hole drilling, the contour method and other measurement techniques. Significant efforts have also been made within NeT to understand and predict weld residual stresses, often employing commercially available finite element (FE) codes. Several Task Groups have been developed to address unique challenges found in nuclear applications, from stress development in multi-pass AISI 316LN austenitic steel welds to the effects of solid-state phase transformation on residual stress development in SA508 ferritic steel, which is often used for reactor pressure vessel (RPV) construction. Some current and future work performed under the auspices of NeT are provided, with a focus on work Conducted at ANSTO. The aim is to give the audience a comprehensive overview of the work undertaken in NeT, and to shed some light on the potential present in this kind of collaborative effort. (author)

  15. Thermal Stresses in Welding

    DEFF Research Database (Denmark)

    Hansen, Jan Langkjær

    1998-01-01

    Studies of the transient temperature fields and the hereby induced deformations and stressses in a butt-welded mild steel plate modelledrespectively in 2D plane stress state (as well as plane strain state) and in full 3D have been done. The model has been implemented in the generalpurpose FE-soft......-software package ABAQUS. In this work, the results have been qualitatively evaluated....

  16. Prediction of residual stresses induced by TIG welding of a martensitic steel (X10CrMoVNb9-1)

    International Nuclear Information System (INIS)

    Roux, G.M.

    2007-11-01

    Within the frame of the development of very high temperature nuclear reactors (VHTR) with gas as heat transfer fluid, some technological challenges are to be faced because of these high temperatures, notably the selection of the material used for the reactor vessel and its welding process. This research thesis aims at developing and validating numerical tools and behaviour models for the thermal-metallurgical-mechanical simulation of the multi-pass TIG welding process. The first part describes the development of simple welding tests (Disk-Spot and Disk-Cycle), the use of temperature and displacement measurement during these tests, and deep residual stress measurements, as well as the identification of the thermal limit conditions for the Disk-Spot test. It then discusses the choice and the identification of the thermal-metallurgical-mechanical behaviour model, with a particular attention to phase transformations and to their coupling with thermal and mechanical aspects. Experimental and simulation results are compared, notably in terms of residual stresses. The numerical implementation of the behaviour model and its integration into the CAST3M finite element software are also described

  17. Comparative study of residual stress by table of coordinates and X-ray diffraction in a welded joint; Estudo comparativo das tensoes residuais por mesa de coordenadas e DR-X numa junta soldada

    Energy Technology Data Exchange (ETDEWEB)

    Siqueira Filho, A.V.; Rolim, T.L.; Yadava, Y.P.; Ferreira, R.A.S., E-mail: anibal_siqueira@yahoo.com.b [Universidade Federal de Pernambuco (UFPE), Recife, PE (Brazil). Dept. de Engenharia Mecanica; Cardoso, F.I.B. [Universidade de Pernambuco (POLI/UPE), Recife, PE (Brazil); Guimaraes, P.B. [Instituto Federal de Educacao, Ciencia e Tecnologia de Pernambuco, Recife, PE (Brazil)

    2010-07-01

    Residual stresses in a welded joint of naval steel ASTM AH-32 was measured either by the displacements of referenced points with a coordinated table (CT) or by x-ray diffraction (X-DR) after welding. For all tests, the welding was performed by a certified welder in the SMAW process, using an AWS E 7018 G3 electrode. Before welding, small holes evenly spaced were made in the specimens to be mapped on a coordinated table (CT). After labeling, the specimens were submitted to the welding process and new measurements by (CT) to evaluate the displacements produced by the tensions generated. In parallel, residual stress were measured by DR-X for validation of this new measurement methodology. (author)

  18. Residual Stresses In 3013 Containers

    International Nuclear Information System (INIS)

    Mickalonis, J.; Dunn, K.

    2009-01-01

    The DOE Complex is packaging plutonium-bearing materials for storage and eventual disposition or disposal. The materials are handled according to the DOE-STD-3013 which outlines general requirements for stabilization, packaging and long-term storage. The storage vessels for the plutonium-bearing materials are termed 3013 containers. Stress corrosion cracking has been identified as a potential container degradation mode and this work determined that the residual stresses in the containers are sufficient to support such cracking. Sections of the 3013 outer, inner, and convenience containers, in both the as-fabricated condition and the closure welded condition, were evaluated per ASTM standard G-36. The standard requires exposure to a boiling magnesium chloride solution, which is an aggressive testing solution. Tests in a less aggressive 40% calcium chloride solution were also conducted. These tests were used to reveal the relative stress corrosion cracking susceptibility of the as fabricated 3013 containers. Significant cracking was observed in all containers in areas near welds and transitions in the container diameter. Stress corrosion cracks developed in both the lid and the body of gas tungsten arc welded and laser closure welded containers. The development of stress corrosion cracks in the as-fabricated and in the closure welded container samples demonstrates that the residual stresses in the 3013 containers are sufficient to support stress corrosion cracking if the environmental conditions inside the containers do not preclude the cracking process.

  19. Experimental investigation of the residual stresses of 304L tubular welded joints; Caracterisation des contraintes residuelles sur assemblages soudes tubulaires en acier 304L

    Energy Technology Data Exchange (ETDEWEB)

    Monin, L.; Panier, S.; Hariri, S.; Zakrzewski, D. [Ecole des Mines de Douai, 941, rue Charles Bourseul, BP 10838, 59508 DOUAI Cedex (France); Faidi, C. [EDF-SEPTEN, 12-14, avenue Dutrievoz, 69628 VILLEURBANNE (France)

    2007-07-01

    In the nuclear energy industry, the use of components made of austenitic stainless steel is widely spread, because of its specific thermal properties. The assembly of these pressure vessels and piping by welding processes often requires surface mechanical operations. These operations aim at hardening surfaces and lowering roughness. Nevertheless the main effect of these operations is the occurrence of residual stresses which can have positive or negative effects on the fatigue life. In this study, we focus on the evaluation and relaxation of residual stresses level on AISI 304L austenitic stainless steel tubular welded structures. Some of these rings are base metal rings (which stand as reference), the rest presents a longitudinal and symmetrical Y-weld joint, with or without grinding. Surface residual stresses, and their relaxation, were determined by using the X-ray diffraction method. (authors) [French] L'utilisation de composants en acier inoxydable austenitique, aux proprietes thermiques bien specifiques, est tres courante dans le domaine de la production d'energie nucleaire. Les procedes d'assemblage par soudage de ces equipements sous pression requierent des traitements de parachevement mecanique afin d'ameliorer l'etat de surface et modifier l'etat mecanique en introduisant des contraintes residuelles, qui peuvent avoir une influence sur la duree de vie de la structure. Cette etude porte sur la caracterisation et la relaxation des contraintes residuelles, determinees sur des eprouvettes annulaires specifiques en acier inoxydable austenitique de type 304L, a l'etat brut ou avec des soudures, arasees ou non. La methode de determination utilisee est la diffraction des rayons X. La relaxation de ces contraintes au cours d'essais de fatigue est egalement etudiee. (auteurs)

  20. finite element model for predicting residual stresses in shielded

    African Journals Online (AJOL)

    eobe

    Diffractometer (XRD 6000). From the Finite Element Model Simulation, the transverse residual stress in the x ... Keywords: Residual stress, 3D FEM, Shielded manual metal arc welding, Low Carbon Steel (ASTM A36), X-Ray diffraction, degree of ..... I. ''Residual stress effects on fatigue life of welded structures using LEFM'',.

  1. Evaluation of residual stresses in electron-beam welded Zr2.5Nb0.9Hf Zircadyne flange mock-up of a reflector vessel beam tube flange

    Energy Technology Data Exchange (ETDEWEB)

    Muránsky, O., E-mail: ondrej.muransky@ansto.gov.au [Institute of Material Engineering, ANSTO, Locked Bag 2001, Kirrawee DC, 2234 NSW (Australia); Holden, T.M. [Northern Stress Technologies, Deep River, Ontario, Canada K0J 1P0 (Canada); Kirstein, O. [European Spallation Source, EES AB, Tunavagen 24, SE-211 00 Lund (Sweden); James, J.A. [Open University, Materials Engineering, Milton Keynes MK7 6BJ (United Kingdom); Paradowska, A.M. [Bragg Institute, ANSTO, Locked Bag 2001, Kirrawee DC, 2234 NSW (Australia); Edwards, L. [Institute of Material Engineering, ANSTO, Locked Bag 2001, Kirrawee DC, 2234 NSW (Australia)

    2013-07-15

    The dual-phase alloy Zr2.5Nb alloy is an important nuclear material, because of its use in current and possible use in future nuclear reactors. It is, however, well-known that Zr2.5Nb weldments can fail through a time-dependent mechanism called delayed hydride cracking which is typically driven by the presence of tensile residual stresses. With a view to understanding the development of residual stresses associated with Zr2.5Nb welds the current study focuses on the evaluation of the residual stresses in a mock-up of a reactor beam tube flange made from Zr2.5Nb0.9Hf. The present results suggests that, like ferritic welds which undergo a solid-state phase transformation upon welding, Zr2.5Nb0.9Hf welds also develop high tensile residual stresses in the heat-affected zone whereas the stresses closer to the weld tip are reduced by the effects of the β → α solid-state phase transformation.

  2. Assessment of the Contour Method for 2-D Cross Sectional Residual Stress Measurements of Friction Stir Welded Parts of AA2024-T3—Numerical and Experimental Comparison

    DEFF Research Database (Denmark)

    Sonne, Mads Rostgaard; Carlone, Pierpaolo; Hattel, Jesper Henri

    2017-01-01

    The contour method is one of the newest techniques for obtaining residual stress fields from friction stir welded (FSW) parts, experimentally. This method has many advantages; however, edge effects coming from the process itself might introduce artifacts in the obtained results, and this was slig......The contour method is one of the newest techniques for obtaining residual stress fields from friction stir welded (FSW) parts, experimentally. This method has many advantages; however, edge effects coming from the process itself might introduce artifacts in the obtained results...

  3. Control of the development of residual stresses and heat affected zone (HAZ) microstructure during welding of low alloy steels and influence on stress relieve cracking

    Energy Technology Data Exchange (ETDEWEB)

    Storesund, J.; Rui Wu; Sandstroem, R.; von Walden, E. [Swedish Inst. for Metals Research, Stockholm (Sweden)

    1990-12-31

    Creep resistant 1 Cr 0.5 Mo steels are frequently used as steam pipes at operating temperature of 450 degree C to 500 degrees C. Welded joints have been post weld heat treated (PWHT). The results show: - In fully refined microstructures close to the fusion boundary of the weldments a reduction of the grain size by a factor of 3-4 was measured. The impact transition temperature was up to 27 degree C lower for test series notched in the refined HAZ (Heat Affected Zone) than in the coarse grained HAZ of the as welded condition. The overlay heat treatments were not observed to significantly influence the hardness and the room temperature tensile properties of the weldments. - The influence of refinement on impact transition temperature (ITT) and upper shelf energy was beneficial. In the coarse grained HAZ, for which the ITT was significantly higher than for weld metal and base metal, the refinement resulted in a 30 degrees C lower value of the ITT. The influence of PWHT on impact properties was also studied. The PWHT raised the upper shelf energy greatly. The effect on the ITT was smaller than that of refinement. - For cross welds in the as-welded (AW) condition refinement improved the creep properties. After PWHT the creep ductility was significantly increased at the same as a considerable reduction of life was observed. At lower stresses the effects of refinement and especially PWHT were less pronounced. Beneficial influence of refinement in inhibiting the formation of creep cavitation was apparent regardless stress level in both AW and PWHT conditions. (K.A.E).

  4. Control of the development of residual stresses and heat affected zone (HAZ) microstructure during welding of low alloy steels and influence on stress relieve cracking

    International Nuclear Information System (INIS)

    Storesund, J.; Rui Wu; Sandstroem, R.; von Walden, E.

    1990-01-01

    Creep resistant 1 Cr 0.5 Mo steels are frequently used as steam pipes at operating temperature of 450 degree C to 500 degrees C. Welded joints have been post weld heat treated (PWHT). The results show: - In fully refined microstructures close to the fusion boundary of the weldments a reduction of the grain size by a factor of 3-4 was measured. The impact transition temperature was up to 27 degree C lower for test series notched in the refined HAZ (Heat Affected Zone) than in the coarse grained HAZ of the as welded condition. The overlay heat treatments were not observed to significantly influence the hardness and the room temperature tensile properties of the weldments. - The influence of refinement on impact transition temperature (ITT) and upper shelf energy was beneficial. In the coarse grained HAZ, for which the ITT was significantly higher than for weld metal and base metal, the refinement resulted in a 30 degrees C lower value of the ITT. The influence of PWHT on impact properties was also studied. The PWHT raised the upper shelf energy greatly. The effect on the ITT was smaller than that of refinement. - For cross welds in the as-welded (AW) condition refinement improved the creep properties. After PWHT the creep ductility was significantly increased at the same as a considerable reduction of life was observed. At lower stresses the effects of refinement and especially PWHT were less pronounced. Beneficial influence of refinement in inhibiting the formation of creep cavitation was apparent regardless stress level in both AW and PWHT conditions. (K.A.E)

  5. The use of neutron diffraction for the determination of the in-depth residual stresses profile in weld coatings; A utilizacao da difracao de neutroes na determinacao do perfil de tensoes residuais em revestimentos por soldadura

    Energy Technology Data Exchange (ETDEWEB)

    Marques, Maria Jose; Batista, A.C.; Nobre, J.P. [Universidade de Coimbra (Portugal). Dept. de Fisica. Centro de Estudos de Materiais por Difraccao de Raios X (CEMDRX); Loureiro, Altino [Universidade de Coimbra (Portugal). Dept. de Engenharia Mecanica. Centro de Engenharia Mecanica (CEMUC); Kornmeier, Joana R., E-mail: mjvaz@fe.up.pt [Technische Universitaet Muenchen, Garching (Germany). FRM II

    2013-04-15

    The neutron diffraction is a non-destructive technique, particularly suitable for the analysis of residual stress fields in welds. The technique is used in this article to study ferritic samples, coated by submerged arc welding using stainless steel filler metals. This procedure is often used for manufacturing process equipment for chemical and nuclear industries, for ease of implementation and economic reasons. The main disadvantage of that processes is the cracking phenomenon that often occurs at the interface between the base material and coatings, which can be minimized by performing post-weld stress relief heat treatments. The samples analyzed in this study were made of carbon steel plates, coated by submerged arc welding two types of stainless steel filler metals. For the first layer was used one EN 12 072 - S 2 U 23 12 electrode, while for the second and third layers were used an EN 12 072 - 19 12 3 S L electrode. After cladding, the samples were submitted to a post-weld heat treatment for 1 hour at 620 deg C. The residual stress profiles obtained by neutron diffraction evidence the relaxation of residual stress given by the heat treatment. (author)

  6. Systematic Review of Ultrasonic Impact Treatment Parameters on Residual Stresses of Welded Non-Sensitized Versus Sensitized Aluminum-Magnesium

    Science.gov (United States)

    2015-03-01

    cycles of wet and dry exposure in this environment, in which concentrated amounts of chloride (dried seawater ) are in contact with the aluminum...around welds in AA5083 installed on-board a U.S. naval combatant and in AA5083 after in situ smface preparat ion . In the AA5456, we examined the...17 1. Systematically Ultrasonic Impact Treated, Gas Metal Arc Welded, Aluminum-Alloy 5456 Plates

  7. Neutron diffraction measurement of residual stress in NPP construction materials

    International Nuclear Information System (INIS)

    Hinca, R.; Bokuchava, G.

    2000-01-01

    The aim of the investigation is to study the level of residual stresses induced by the surfacing in the weld deposit zone and in the base metal, where considerable thermal gradients are present. Surfacing high-nickel filler on an austenitic base metal is one of techniques in repair of primary collector the primary circuit of nuclear power plant type VVER. The repair technology was developed at Welding Research Institute Bratislava. Measurements of residual stresses in the weld overlay and the base metal are necessary for approving the mechanical analysis and verifying of residual stresses determination on welded material by numerical weld g computer simulation. Investigations of residual stresses are important for developing optimal welding techniques. (authors)

  8. Controlling BWR pipe cracking by residual stress modification

    International Nuclear Information System (INIS)

    Gilman, J.D.; Giannuzzi, A.J.; Childs, W.J.

    1983-01-01

    Intergranular stress corrosion cracking may occur in the weld heat-affected zone of susceptible stainless steel materials which have been used in some boiling water reactor piping systems. One of the prerequisite conditions for stress corrosion attack is a high tensile stress in the exposed, locally sensitized material near the weld root. Several processes have been developed which can deter stress corrosion attack by altering the residual stress distributions near the welds to ensure that low stresses prevail in critical locations. These residual stress modification remedies and their qualification testing are described in this paper. (author)

  9. Characterization of Residual Stress as a Function of Friction Stir Welding Parameters in ODS Steel MA956

    Science.gov (United States)

    2013-06-01

    close-up of the goniometer and the position sensitive scintillation detectors is given in (b). Chromium x-rays traveling through the collimator...ACKNOWLEDGMENTS I would like to acknowledge the hard work and mentorship of Professors Luke Brewer and Sarath Menon. Without their guidance and patience... microstructural attributes which give this steel its strength can be severely altered by fusion welding techniques traditionally used for steels

  10. Neutron diffraction residual strain / stress measurements

    International Nuclear Information System (INIS)

    Paradowska, Anna

    2012-01-01

    Residual stresses affect mechancial properties of materials and prodcuts, it is essential to estimate them practically in order to esatblish acceptable limits. Knowledge of the development of residual stresses in components at the various production stages- extrusion, rolling, machining, welding and heat treating-can be used to imporve product reliability and performance. This short article gives an example relevant to the power industry using ANSTO's 'Kowari' neutron strain scanner.

  11. Analysis of the unstressed lattice spacing, d0, for the determination of the residual stress in a friction stir welded plate of an age-hardenable aluminum alloy – Use of equilibrium conditions and a genetic algorithm

    International Nuclear Information System (INIS)

    Cioffi, F.; Hidalgo, J.I.; Fernández, R.; Pirling, T.; Fernández, B.; Gesto, D.; Puente Orench, I.; Rey, P.; González-Doncel, G.

    2014-01-01

    Procedures based on equilibrium conditions (stress and bending moment) have been used to obtain an unstressed lattice spacing, d 0 , as a crucial requirement for calculating the residual stress (RS) profile across a joint conducted on a 10 mm thick plate of age-hardenable AA2024 alloy by friction stir welding (FSW). Two procedures have been used that take advantage of neutron diffraction measurements. First, equilibrium conditions were imposed on sections parallel to the weld so that a constant d 0 value corresponding to the base material region could be calculated analytically. Second, balance conditions were imposed on a section transverse to the weld. Then, using the data and a genetic algorithm, suitable d 0 values for the different regions of the weld have been found. For several reasons, the comb method has proved to be inappropriate for RS determination in the case of age-hardenable alloys. However, the equilibrium conditions, together with the genetic algorithm, has been shown to be very suitable for determining RS profiles in FSW joints of these alloys, where inherent microstructural variations of d 0 across the weld are expected

  12. Modelling the residual stresses and microstructural evolution in Friction Stir Welding of AA2024-T3 including the Wagner-Kampmann precipitation model

    DEFF Research Database (Denmark)

    Sonne, Mads Rostgaard; Hattel, Jesper Henri

    In this work, a numerical finite element model for friction stir welding of 2024-T3 aluminum alloy, consisting of a heat transfer analysis and a sequentially coupled quasi-static stress analysis is proposed. Metallurgical softening of the material is properly considered and included...

  13. Critical comparison of two independent measurements of residual stress in an electron-beam welded uranium cylinder: Neutron diffraction and the contour method

    Energy Technology Data Exchange (ETDEWEB)

    Brown, D.W., E-mail: dbrown@lanl.gov [Los Alamos National Laboratory, Los Alamos, NM 87545 (United States); Holden, T.M. [Northern Stress Technologies, Deep River, Ontario, K0J 1P0 (Canada); Clausen, B.; Prime, M.B.; Sisneros, T.A.; Swenson, H. [Los Alamos National Laboratory, Los Alamos, NM 87545 (United States); Vaja, J. [Atomic Weapons Establishment, Aldermaston, Reading, Berkshire RG7 4PR (United Kingdom)

    2011-02-15

    Neutron diffraction and contour method measurements were conducted to assess the stresses associated with an electron-beam, circumferential, partial penetration weld of a uranium tube. To obtain reasonable results in the coarse-grained base metal, the specimen was continuously rotated during the neutron experiments to average over the entire circumference. The severe anisotropic character of uranium, which has an orthorhombic crystal structure, forces a number of judicious choices to be made in the neutron analysis. For the contour method, the cylindrical geometry necessitated the development of a two-step process, and discontinuities across the unwelded portion of the joint required special treatment. High tensile hoop stresses ({approx}300 MPa) were found in the center of the weld close to the outside diameter. Balancing hoop compression was observed in the far-field stress profile. Also, a tensile axial stress (85 {+-} 25 MPa) was observed near the outer diameter.

  14. Residual stress effects in tubular K-joints crack growth

    OpenAIRE

    Acevedo, Claire; Nussbaumer, Alain

    2010-01-01

    Seeking light and transparent bridge designs, engineers and architects have found an efficient and artistic way to fulfill their requirements: steel tubular bridges. Like any other welded structure, the joints of this kind of bridge suffer from high tensile weld residual stresses. Combined with high stress concentrations, tensile residual stress is a relevant factor in fatigue crack development. Therefore, an experimental study has been carried out on tubular joints in order to characterize ...

  15. Micro stresses in welded high-strength stainless steels

    International Nuclear Information System (INIS)

    Lukas, P.; Mikula, P.; Strunz, P.; Vrana, M.; Zaffagnini, M.; Janovec, J.; Macek, K.

    1995-01-01

    The dependence of residual stresses in martensitic-austenitic age-hardenable steels on a different technological treatment (welding by electron beam, postweld heat treatment) were investigated using neutron diffraction. Experiments were performed in NPI Rez on a high-resolution diffractometer equipped with cylindrically bent perfect crystals. The resolution of the instrument (Δd/d ∼ 10 -4 ; d-lattice spacing) enabled the authors to investigate plastic strains in weld joints

  16. Numerical modeling of AA2024-T3 friction stir welding process for residual stress evaluation, including softening effects

    DEFF Research Database (Denmark)

    Sonne, Mads Rostgaard; Carlone, Pierpaolo; Palazzo, Gaetano S.

    2014-01-01

    In the present paper, a numerical finite element model of the precipitation hardenable AA2024-T3 aluminum alloy, consisting of a heat transfer analysis based on the Thermal Pseudo Mechanical model for heat generation, and a sequentially coupled quasi-static stress analysis is proposed. Metallurgi......In the present paper, a numerical finite element model of the precipitation hardenable AA2024-T3 aluminum alloy, consisting of a heat transfer analysis based on the Thermal Pseudo Mechanical model for heat generation, and a sequentially coupled quasi-static stress analysis is proposed...

  17. Formation of welding residual stresses in low transformation temperature (LTT materials Tensões residuais de soldagem em materias de baixa temperatura de transformação (BTT

    Directory of Open Access Journals (Sweden)

    Thomas Kannengiesser

    2009-03-01

    Full Text Available For the safety and cost efficiency of welded high-strength steel structures, precise knowledge of the level and distribution of welding- and cooling-specific stresses and residual stresses is essential, since they exert a decisive influence on strength, crack resistance, and finally on the bearable service load. This paper presents innovative filler materials, of which the phase transformation temperature was deliberately adjusted via the chemical composition. The transformation behaviour of these martensitic Low Transformation Temperature (LTT- filler materials shows direct effects on the local residual stresses in the weld and the HAZ. These effects can purposefully be exploited to counteract the thermally induced shrinkage of the material and to produce significant compressive residual stresses in the weld. Comparative welding experiments were carried out on 690 MPa high-strength base materials using various LTT-filler materials. High energy synchrotron radiation was used for residual stress measurement. Particularly the use of high energy synchrotron radiation makes it possible to detect the residual stress condition fast without destruction of material. Thereby, residual stress depth gradients can be determined simultaneously without removing material. In steel, gradients of up to 150 µm can be resolved in such a way. Furthermore, the application of high energy radiation permits determination of residual stresses of any available residual austenite contents. Results show significant dependence of transformation temperatures on the resulting residual stress level and distribution.Para a segurança e eficiência do custo de estruturas soldadas de aço de alta resistência, um conhecimento preciso do nível e distribuição das tensões residuais de soldagem é essencial pois estas exercem uma influência decisiva na resistência à fissuração e na carga suportada em serviço. Este artigo apresenta metais de adição inovativos nos quais a

  18. Study of residual stresses i electron-beam welded F82H modified martensitic steel using X-ray and neutron diffraction

    International Nuclear Information System (INIS)

    Coppola, R.; Braham, C.; Ceretti, M.

    1998-01-01

    Ferritic/martensitic steels are presently considered as one of the most realistic options for the construction of the 'first-wall' and other components in future fusion reactors. More specifically the modified martensitic Chromium steel F82H is being characterised as a reference material in view of a possible utilisation in the DEMO reactor. This work presents the results of a study, carried out using X-ray and neutron diffraction to investigate the stress field in a prototype F82H-mod. weld obtained using the electron-beam welding technique. The stress has been measured, both with X-rays and neutrons, at different distances from the heat-affected zone. The differences between the results obtained with X-ray and neutron diffraction are tentatively discussed in terms of phase inhomogeneity inside the HAZ. (author)

  19. Development of residual stress prediction model in pipe weldment

    Energy Technology Data Exchange (ETDEWEB)

    Eom, Yun Yong; Lim, Se Young; Choi, Kang Hyeuk; Cho, Young Sam; Lim, Jae Hyuk [Korea Advanced Institute of Science and Technology, Taejon (Korea, Republic of)

    2002-03-15

    When Leak Before Break(LBB) concepts is applied to high energy piping of nuclear power plants, residual weld stresses is a important variable. The main purpose of his research is to develop the numerical model which can predict residual weld stresses. Firstly, basic theories were described which need to numerical analysis of welding parts. Before the analysis of pipe, welding of a flat plate was analyzed and compared. Appling the data of used pipes, thermal/mechanical analysis were accomplished and computed temperature gradient and residual stress distribution. For thermal analysis, proper heat flux was regarded as the heat source and convection/radiation heat transfer were considered at surfaces. The residual stresses were counted from the computed temperature gradient and they were compared and verified with a result of another research.

  20. Stress-induced birefringence control in femtosecond laser glass welding

    Science.gov (United States)

    Gstalter, M.; Chabrol, G.; Bahouka, A.; Serreau, L.; Heitz, J.-L.; Taupier, G.; Dorkenoo, K.-D.; Rehspringer, J.-L.; Lecler, S.

    2017-11-01

    Glass welding by femtosecond laser pulses causes microscopic structural modifications, affecting the refractive index due to residual stress. Locally induced birefringence is studied by photoelasticimetry using a polarized light microscope. The study is performed on borosilicate thin glass plates using an industrial femtosecond laser generating 300 fs pulses at 500 kHz, with a 100 mm focusing length F-theta lens allowing fast welding. For low-energy deposition, the principal birefringence axes are determined to be homogenous along the seam and perpendicular and parallel to the laser scanning direction. Tensile stress is induced in the laser scanning direction by the welding seams. The induced birefringence is determined to be equivalent for in-volume irradiated track and welding seams. An inhomogeneity of the birefringence within the seam is observed for the first time at high-energy deposition. The distribution of the birefringence can be controlled with the laser scanning patterns. The amount of residual stress is measured by compensating the local birefringence. The birefringence Δ n is estimated at 2.4 × 10^{-4}, corresponding to a residual stress amount around 59 MPa. The influence of the welding geometry is also illustrated.

  1. Study of thermal stress in heat affected zones during welding

    International Nuclear Information System (INIS)

    Devaux, J.C.

    1979-01-01

    The importance of applications of welding in the nuclear industry leads to the study of the main problem concerning metal welding: sensibility to cracking. The development of computation methods allows the numerical simulation of welding effects. Due to the complexity of this problem, it is divided in three steps: thermal, metallurgical and mechanical calculus. Interactions between the 3 steps are examined. Mathematical models necessary to get residual stress (i.e. stress remaining when welding is completed and structure at ambient temperature) are described. Then parameters for metallurgical structure determination are given and compared to experiments. A508 and A533 type steels of primary coolant circuit of PWR reactors are taken as examples and the numerical simulation of a test is presented [fr

  2. In situ Weak Magnetic-Assisted Thermal Stress Field Reduction Effect in Laser Welding

    Science.gov (United States)

    Liang, Lvjie; Pang, Shengyong; Shao, Xinyu; Wang, Chunming; Jiang, Ping; Chen, Xin

    2018-01-01

    For decades, post-welding magnetic treatment has been used to reduce residual stress of welds by improving the crystal structure of solid-state welds. In this paper, we propose a new magnetic treatment method, which can reduce the time-dependent thermal stress field in situ and reduce the final residual stress of welds by simply exerting an assisted weak magnetic field perpendicular to the welding direction and workpiece during laser welding. A new finite-element model is developed to understand the thermal-mechanical physical process of the magnetic-assisted laser welding. For the widely used 304 austenite stainless steel, we theoretically observed that this method can reduce around 10 pct of the time-dependent thermal stress field, and finally reduce approximately 20 MPa of residual stress near the heat-affected zone with a 415-mT magnetic field for typical welding process parameters. A new mechanism based on magneto-fluid dynamics is proposed to explain the theoretical predications by combining high-speed imaging experiments of the transient laser welding process. The developed method is very simple but surprisingly effective, which opens new avenues for thermal stress reduction in laser welding of metals, particularly heat-sensitive metallic materials.

  3. Effect of residual stress on the integrity of a branch connection

    International Nuclear Information System (INIS)

    Law, M.; Kirstein, O.; Luzin, V.

    2012-01-01

    A new connection to an existing gas pipeline was made by hot-tapping, welding directly onto a pressurised pipeline. The welds were not post-weld heat treated, causing significant residual stresses. The critical weld had residual stresses determined by neutron diffraction using ANSTO's residual stress diffractometer, Kowari. The maximum measured residual stress (290 MPa) was 60% of the yield strength. The magnitudes of errors from a number of sources were estimated. An integrity assessment of the welded branch connection was performed with the measured residual stress values and with residual stress distributions from the BS 7910 and API 579 analysis codes. Analysis using estimates of residual stress from API 579 overestimated the critical crack size. Highlights: ► Residual stresses were measured by neutron diffraction in a thick section, non post-weld heat treated ferritic weld. ► There is little published data on these welds. ► The work compares the measured residual stresses with code-based residual stress distributions.

  4. Residual-stress distributions near stainless steel butt weldments

    International Nuclear Information System (INIS)

    Elligson, W.A.; Shack, W.J.

    1978-01-01

    Concern for the integrity of stainless steel butt-weldments in boiling-water-reactor (BWR) piping systems has stimulated study of the conditions that cause stress corrosion cracking (SCC) in the heat-affected zones (HAZ) of the weldments. It is generally agreed that a high stress exceeding the initial yield strength is one of the essential elements for crack initiation. Since design procedures usually ensure that load stresses are below initial yield, the source of the high stresses necessary to produce SCC is thought to be the residual stresses due to welding. To examine the level of residual stresses in the weldments of interest, bulk residual stresses were measured on 100 mm (4-in.) and 254 mm (10-in.) diameter Schedule 80 piping weldments using strain relief techniques. Both laboratory welded specimens and field welded specimens from reactors in service were studied. Axial bulk residual stress distributions were obtained at 45 0 intervals around the circumference. At each azimuthal position, the residual stresses were measured at seven axial positions: on the weld centerline and 13, 20, and 25 mm on either side of the weld centerline on both the inside and outside surfaces

  5. Residual strains and microstructure development in single and sequential double sided friction stir welds in RQT-701 steel

    International Nuclear Information System (INIS)

    Barnes, S.J.; Steuwer, A.; Mahawish, S.; Johnson, R.; Withers, P.J.

    2008-01-01

    Single and double sided partial penetration friction stir butt welds, in a rolled, quenched and tempered steel (RQT-701), were produced at The Welding Institute (TWI) under controlled process conditions. The residual strain distributions in the longitudinal and transverse directions have been measured using energy dispersive synchrotron X-ray diffraction. The measured strains were indicative of longitudinal tensile residual stresses at levels greater than the 0.2% yield stress of the parent metal in both the single and double pass welds. In both cases, the maximum tensile strain was found in the parent metal at the boundary of the heat affected zone (HAZ). Microstructural analysis of the welds was carried out using optical microscopy and hardness variations were also mapped across the weld-plate cross-section. The maximum hardness was observed in the mixed bainite/martensite structure of the weld nugget on the advancing side of the stir zone. The minimum hardness was observed in the HAZ

  6. Analysis of residual stresses in a long hollow cylinder

    International Nuclear Information System (INIS)

    Tokovyy, Yuriy V.; Ma, Chien-Ching

    2011-01-01

    This paper presents an analytical method for solving the axisymmetric stress problem for a long hollow cylinder subjected to locally-distributed residual (incompatible) strains. This method is based on direct integration of the equilibrium and compatibility equations, which thereby have been reduced to the set of two governing equations for two key functions with corresponding boundary and integral conditions. The governing equations were solved by making use of the Fourier integral transformation. Application of the method is illustrated with an analysis of the welding residual stresses in a butt-welded thick-walled pipe. - Highlights: → A solution to the axisymmetric stress problem for a hollow cylinder is constructed. → The cylinder is subjected to a field of locally-distributed residual strains. → The method is based on direct integration of the equilibrium equations. → An application of our solution to analysis of welding residual stresses is considered.

  7. Stress measurements in welds: Problem areas

    Energy Technology Data Exchange (ETDEWEB)

    Holden, T.M. [Northern Stress Technologies, Deep River, Ont., K0J 1P0 (Canada); Suzuki, H. [Japan Atomic Energy Institute, Tokai (Japan); Carr, D.G. [Australian Science and Technology Organization, Lucas Heights, NSW (Australia)]. E-mail: david.carr@ansto.gov.au; Ripley, M.I. [Australian Science and Technology Organization, Lucas Heights, NSW (Australia); Clausen, B. [Los Alamos National Laboratory, Los Alamos, NM 87545 (United States)

    2006-11-10

    There have been many stress measurements on welds by neutron diffraction over the past 20 years but there are still a number of serious experimental issues that are often not addressed. The primary fact is that the microstructure generally changes across the weld and accompanying this may be a change in the concentration of strengthening elements in solution. This will lead to a shift in lattice spacing which may be incorrectly interpreted as a strain. Secondly, a gradient of plastic deformation near the weld may be expected. Since plastic deformation by application of a stress always generates intergranular (type-2) strains this may lead to a range of intergranular effects superposed on the conventional weld-related strains. The effects are illustrated by neutron diffraction studies of Zr-4, ferritic and austenitic welds where chemistry, intergranular effects and crystallographic texture can all play a role.

  8. Dimentional welding control using vibratory stress relief

    Directory of Open Access Journals (Sweden)

    Fernando Casanova García

    2008-01-01

    Full Text Available The effectiveness of applying vibratory stress relief to controlling deformations due to internal stresses on plates pro-duced by welding was evaluated in this research. The magnitude of distortion produced in three groups of specimens which had been treated with vibration during and after welding was also evaluated. The specimens consisted of aus-tenitic stainless steel plates which tend to become deformed due to high expansion and shrinkage coefficient and low thermal conductivity during arc welding. Their deformation was quantified by measuring the vertical distance which the end of the plate moved after the welding bead was applied. The magnitude of stress produced by the effect of vi-bration was measured too. The results revealed a clear reduction of the final deformation in treated specimens com-pared to non-treated ones. It was also found that the magnitude of stress produced during vibration had no impor-tant effect on the treatment’s effectiveness.

  9. Stresses In A Cylinder Welded With Mismatch

    Science.gov (United States)

    Min, J. B.; Spanyer, K. L.; Brunair, R. M.

    1993-01-01

    NASA technical memorandum presents parametric study of additional stresses introduced into cylindrical pressure vessel that is round except for radial mismatch in longitudinal butt weld in sidewall. Prompted by concern over fatigue caused by cyclic stresses in longitudinally welded cylindrical titanium inlet of high-pressure turbopump in main engine of Space Shuttle. Results applicable to any round cylindrical pressure vessel characterized by parameters, and conform to simplifying assumptions, used in analysis.

  10. Numerical and Experimental Analyses of Residual Stresses in

    DEFF Research Database (Denmark)

    Hansen, Jan Langkjær; Hattel, Jesper; Lorentzen, Torben

    1999-01-01

    been done using the novel non-destructive technique of neutron diffraction.The thermal model takes into account the moving heat source in the V-shaped weld. The heat source is modelled by filler material being added continuously in connection with a body flux. In order to obtain a more realistic weld......Butt-welding in one pass with SMAW of two 10mm mild steel plates is investigated. In order to predict the residual stress fields associated with the welding procedure, a finite element model in 3D has been developed in ABAQUS. This model applies a sequential thermal and mechanical numerical...

  11. Residual stresses in material processing

    Science.gov (United States)

    Kozaczek, K. J.; Watkins, T. R.; Hubbard, C. R.; Wang, Xun-Li; Spooner, S.

    Material manufacturing processes often introduce residual stresses into the product. The residual stresses affect the properties of the material and often are detrimental. Therefore, the distribution and magnitude of residual stresses in the final product are usually an important factor in manufacturing process optimization or component life prediction. The present paper briefly discusses the causes of residual stresses. It then addresses the direct, nondestructive methods of residual stress measurement by X ray and neutron diffraction. Examples are presented to demonstrate the importance of residual stress measurement in machining and joining operations.

  12. Prediction of welding residual distortions of large structures using a local/global approach

    International Nuclear Information System (INIS)

    Duan, Y. G.; Bergheau, J. M.; Vincent, Y.; Boitour, F.; Leblond, J. B.

    2007-01-01

    Prediction of welding residual distortions is more difficult than that of the microstructure and residual stresses. On the one hand, a fine mesh (often 3D) has to be used in the heat affected zone for the sake of the sharp variations of thermal, metallurgical and mechanical fields in this region. On the other hand, the whole structure is required to be meshed for the calculation of residual distortions. But for large structures, a 3D mesh is inconceivable caused by the costs of the calculation. Numerous methods have been developed to reduce the size of models. A local/global approach has been proposed to determine the welding residual distortions of large structures. The plastic strains and the microstructure due to welding are supposed can be determined from a local 3D model which concerns only the weld and its vicinity. They are projected as initial strains into a global 3D model which consists of the whole structure and obviously much less fine in the welded zone than the local model. The residual distortions are then calculated using a simple elastic analysis, which makes this method particularly effective in an industrial context. The aim of this article is to present the principle of the local/global approach then show the capacity of this method in an industrial context and finally study the definition of the local model

  13. Comparison of neutron and synchrotron diffraction measurements of residual stress in bead-on-plate weldments

    International Nuclear Information System (INIS)

    Paradowska, A.M.; Price, J.W.; Finlayson, T.R.; Lienert, U.; Ibrahim, R.

    2010-01-01

    This paper explores the use of neutron and synchrotron diffractions for the evaluation of residual stresses in welded components. It has been shown that it is possible to achieve very good agreement between the two independent diffraction techniques. This study shows the significance of the weld start and end sites on the residual strain/stress distribution. Quantitative evaluation of the residual stress development process for multibead weldments has been presented. Some measurements were also taken before and after postweld stress relieving to establish the reduction and redistribution of the residual stress. The detailed measurements of residual stress around the weld achieved in this work significantly improve the knowledge and understanding of residual stress in welded components.

  14. Measurement of residual stresses induced by sequential weld buttering and cladding operations involving a 2.25Cr-1Mo substrate material

    OpenAIRE

    Javadi, Yashar; Walsh, Joanna; Elrefaey, Ahmed; Roy, Matthew; Francis, John

    2017-01-01

    Dissimilar metal welds are necessary in high-pressure subsea systems and in cases where forged components must be welded to pipelines. F22 (2.25Cr-1Mo) steel is often used in such forged steel components and, since this steel cannot enter service without undergoing post-weld heat treatment (PWHT), the components are usually prepared for field welds through the application of a buttering layer. Furthermore, a weld overlay is deposited for the purpose of mitigating corrosion. This combination o...

  15. Residual Stresses in Thermoplastic Composites: A Review

    Directory of Open Access Journals (Sweden)

    M.M. Shokrieh

    2008-12-01

    Full Text Available Applications of thermoplastic composites have developed extensively. The thermoplastic composites in comparison with the thermoset composites have many advantages. Thermoplastic composites can be melted and remolded many times. The duration of manufacturing process of these composites is short, producing very tough material, and the welding ability and multiple recyclings are their further advantages. The lack of knowledge in this group of composites is the main obstacle in their development. In this review the research works in the field of residual stresses in thermoplastic composites is presented. First, a literature survey on the available research on residual stresses on thermoplastics and thermoplastic composites reinforced with short fibers is compiled. Moreover a review on the available research on residual stresses on thermoplastic composites reinforced with long fibers is presented as well. The effects of the residual stresses on these composites are discussed. Experimental techniques for the measurement of residual stresses in thermoplastic composites and the methods for reducing the existing residual stresses are studied.

  16. Correlation of Magnetic Properties and Residual Stress Distribution Monitored by X-Ray and Neutron Diffraction in Welded AISI 1008 Steel Sheets

    Czech Academy of Sciences Publication Activity Database

    Vourna, P.; Hervoches, Charles; Vrána, Miroslav; Ktena, A.; Hristoforou, E.

    2015-01-01

    Roč. 51, č. 1 (2015), s. 6200104 ISSN 0018-9464 R&D Projects: GA ČR GB14-36566G; GA MŠk LM2011019 EU Projects: European Commission(XE) 283883 - NMI3-II Institutional support: RVO:61389005 Keywords : Magnetic Barkhausen noise (MBN) * neutron diffraction (ND) * residual stress * X- ray diffraction Subject RIV: BM - Solid Matter Physics ; Magnetism Impact factor: 1.277, year: 2015

  17. Development and Applications of Residual Stress Measurements Using Neutron Beams

    OpenAIRE

    ABRIOLA S. A.; BALAGUROV A.; BASHIR J.; DAS A.; EDWARDS L.; GNAEUPEL-HEROLD T.; GOH B.; IONITA I.; MIKULA P.; OHMS Carsten; PELD N.; SCHNEIDER Rainer; SUTIARSO S.; TOROK G.; VENTER A.

    2012-01-01

    The deep penetration and selective absorption of neutrons make them a powerful tool in nondestructive testing of materials with large samples or objects. Residual stress formed in a material during manufacturing, welding, utilization or repairs can be measured by means of neutron diffraction. In fact, neutron diffraction is the only non-destructive testing method, which can facilitate 3-D mapping of residual stress in a bulk component. Stress measurement using neutron beams is a technique ...

  18. A study on the mechanical stress relieving and safety assessment without post-weld heat treatment

    International Nuclear Information System (INIS)

    Xu Jijin; Chen Ligong; Ni Chunzhen

    2007-01-01

    For full welded body valve, the temperature of grommet cannot exceed 150 deg. C in order to prevent it from damaging and assure the tightness and the service life of valve. Therefore, post-weld heat treatment (PWHT) cannot be used to relieve the residual stresses. In this study, the effect of the mechanical stress relieving (MSR) treatment on the residual stresses was studied by the finite element method and experimental work. A pressure and time diagram of MSR treatment was established. A two-dimensional axisymmetric finite element model was used to simulate the residual stresses field. Before and after MSR treatment, the residual stresses on the outer surface were measured by the blind hole drilling method. Finally, the fracture toughness behaviors of weld zone (WZ) and heat affected zone (HAZ) were investigated in terms of crack tip opening displacement (CTOD) according to BS7448 and DNV-OS-C401 fracture toughness tests standards. The safety of the valve in active service was assessed without PWHT. Through comparison and analysis, the axial residual stresses and the hoop residual stresses on the outer surface of valve are mainly tensile. The peak value of tensile stress occurs nearer to the outer surface of the valve. MSR treatment can decrease the peak value of axial residual stresses and hoop residual stresses on the outer surface obviously and make the residual stresses distribution more uniform. The safety of the valve in active service is reliable without PWHT

  19. Stress Analysis of Non-Ferrous Metals Welds by Numerical Simulation

    Directory of Open Access Journals (Sweden)

    Kravarikova Helena

    2017-01-01

    Full Text Available Thermal energy welded material unevenly heated and thus supports the creation of tension. During the fusing process welding transient tensions generated in the welded material. Generation of the transient tensions depends on the thermal expansion and fixed permanently welded parts. Tensions are the result of the interaction of material particles. For welded parts and constructions it is necessary to know the size and direction of application of tensions. The emerging tensions can cause local change or a total deformation of welded materials. Deformations and residual stresses impair the performance of a welded construction, reduces the stability of the parts. To reduce or eliminate of action or a screening direction stresses and strains it is necessary to know the mechanism of their emergence. It is now possible to examine the emergence of tensions numerical experiments on any model using numerical simulation using FEM. Results of numerical experiment is the analysis of stress and deformation course. In the plane the tension it divided into normal σ and τ tangential folders. Decomposition stress on components simplifies the stress analysis. The results obtained from numerical analysis are correct to predict the stress distribution and size. The paper presents the results of numerical experiments stress analysis solutions fillet welds using FEM numerical simulation of welding of non-ferrous metals.

  20. Relationship between ultrasonic Rayleigh waves and surface residual stress

    International Nuclear Information System (INIS)

    Adler, L.; Cook, K.V.; Dewey, B.R.; King, R.T.

    1977-01-01

    Local variations of Rayleigh (surface) circumferential ultrasonic wave velocity near a pipe-girth weld in large-diameter thin-wall type 316H stainless steel pipe were measured. The weldment was similar to those anticipated for the Liquid Metal Fast Breeder Reactor (LMFBR) piping systems. The residual stress distribution was estimated independently from shell theory for an elastic, infinite, thin shell with circumferential line loading. An upper bound on the magnitude of the residual stresses was estimated assuming the deformation of the shell was entirely elastic. The pattern of surface wave velocity variations matches the theoretical residual stress pattern closely. It is suggested that the monitoring of surface wave velocity variations might be used for characterizing residual stress patterns near critical welds in piping, aiding in design calculations, and for in-service monitoring of the state of stress of weldments

  1. Residual stress measurements in thick structural weldments by means of neutron diffraction

    International Nuclear Information System (INIS)

    Ohms, C.; Youtsos, A.G.; Idsert, P. v.d.; Timke, T.

    2000-01-01

    Welding residual stresses in large structural components are a major concern with respect to their performance and lifetime. In large structures reasonable thermal stress relief treatment is usually impossible due to the component size. On the other hand, prediction of welding stresses by numerical modelling has not yet proven to be generally reliable, while the experimental determination of such stresses remains a demanding task. At the high flux reactor (HFR), Petten, a new residual stress diffractometer has been installed recently capable of handling of components up to 1000 kg - the large component neutron diffraction facility (LCNDF). It has facilitated residual stress measurements in two large welded components, of which results are presented here. The first component represents a bi-metallic weld in form of a pipe of 25 mm wall thickness. Three dimensional measurements of residual stress are discussed in detail. The second specimen is a 66 mm wall thickness austenitic steel nuclear piping weld. Results on relief of strain within the weld through post weld heat treatment (PWHT) are presented. Additionally results obtained earlier at former CRNL (CAN) on a section of a thick nuclear piping weld are presented in order to illustrate the variation in the reference lattice parameter trough the weld and the heat affected zone (HAZ). These results clearly show the necessity to determine the reference parameters for each location in all measurement directions by means of measurements in small coupons free of macro-stresses. (orig.)

  2. Neutron and synchrotron measurements of residual strain in TIG welded aluminium alloy 2024

    International Nuclear Information System (INIS)

    Owen, R.A.; Preston, R.V.; Withers, P.J.; Shercliff, H.R.; Webster, P.J.

    2003-01-01

    Tungsten inert gas (TIG) welding is one method of joining aluminium alloys with potential application in the aerospace industry. However, for it to be seriously considered as an alternative to mechanical fasteners the interrelated problems of residual stress and distortion need to be addressed. In this paper neutron, laboratory and synchrotron X-ray diffraction methods are used to provide non-destructive information about the residual stress field in TIG-welded 2024 Al alloy. The results compare well despite the differing penetration and sampling volumes associated with each technique. It is found that the magnitudes of the tensile longitudinal stresses decrease along the plate due to progressive heating up of the plate ahead of the arc during welding, so that steady-state conditions are not achieved. Comparison of the data with a finite element model indicates that softening of the heat-affected region must be included to simulate the resulting stress field. The FE model is found to be in good agreement with the data especially in the vicinity of the weld slope-out

  3. Application of the contour method to validate residual stress predictions

    International Nuclear Information System (INIS)

    Welding is the most widespread method employed to join metallic components in nuclear power plants. This is an aggressive process that introduces complex three-dimensional residual stresses of substantial magnitude into engineering components. For safety-critical applications it can be of crucial importance to have an accurate characterisation of the residual stress field present in order to assess plant lifetime and risk of failure. Finite element modelling approaches are being increasingly employed by engineers to predict welding residual stresses. However, such predictions are challenging owing to the innate complexity of the welding process and can give highly variable results. Therefore, it is always desirable to validate residual stress predictions by experimental data. This paper illustrates how the contour method of measuring residual stress can be applied to various weldments in order to provide high quality experimental data. The contour method results are compared with data obtained by other well-established residual stress measurement techniques such as neutron diffraction and slitting methods and show a very satisfactory correlation. (author)

  4. Computer modeling of the stress-strain state of welded construction

    Science.gov (United States)

    Nurguzhin, Marat; Danenova, Gulmira; Akhmetzhanov, Talgat

    2017-11-01

    At the present time the maintenance of the welded construction serviceability over normative service life is provided by the maintenance system on the basis of the guiding documents according to the concept of "fail safe". However, technology factors relating to welding such as high residual stresses and significant plastic strains are not considered in the guiding documents. The design procedure of the stressed-strained state of welded constructions is suggested in the paper. The procedure investigates welded constructions during welding and the external load using the program ANSYS. In this paper, the model of influence of the residual stress strain state on the factor of stress intensity is proposed. The calculation method of the residual stressed-strained state (SSS) taking into account the phase transition is developed by the authors. Melting and hardening of a plate material during heating and cooling is considered. The thermomechanical problem of heating a plate by a stationary heat source is solved. The setup of the heating spot center on distance (190 mm) from the crack top in a direction of its propagation leads to the fact that the value of total factor of stress intensity will considerably decrease under action of the specified residual compressing stresses. It can lower the speed of the crack propagation to zero. The suggested method of survivability maintenance can be applied during operation with the purpose of increasing the service life of metal constructions up to running repair of technological machines.

  5. In Situ Tensile Deformation and Residual Stress Measurement by Neutron Diffraction in Modified 9Cr-1Mo Steel

    Science.gov (United States)

    Shrestha, Triratna; Charit, Indrajit; Potirniche, Gabriel

    2015-12-01

    The deformation behavior of monolithic modified 9Cr-1Mo (Grade 91) steel during uniaxial tensile loading was studied using the in situ neutron diffraction technique. The residual stress distribution across gas tungsten arc welds in the Grade 91 steel was measured by the time-of-flight neutron diffraction method using the SMARTS diffractometer at Lujan Neutron Scattering Center, Los Alamos National Laboratory. Grade 91 plates were welded using the gas tungsten arc welding (GTAW) technique. The load sharing by different grain orientations was observed during the tensile loading. The residual stresses along three orthogonal directions were determined at the mid-thickness, 4.35 and 2.35 mm below the surface of both the as-welded and post-weld heat-treated plates. The residual stresses of the as-welded plates were compared with those of the post-weld heat-treated plates. The post-weld heat treatment significantly reduced the residual stress level in the base metal, the heat-affected zone, and the weld zone. Vickers microhardness across the weld zone of the as-welded and post-weld heat-treated specimens was evaluated and correlated with the observed residual stress profile and microstructure.

  6. Effect of vibratory stress relief during welding of thick stainless steel plate

    Science.gov (United States)

    Spooner, S.; David, S. A.; Wang, X. L.; Hubbard, C. R.; Holden, T. M.; Root, J. H.

    1993-12-01

    Residual strains were measured in two welded 25-mm thick plates of type 304 stainless steel by the neutron diffraction technique. The filler metal employed to weld these plates was type 308 stainless steel. One of the two welds was prepared without any vibratory stress relief treatment and the other was vibrated at a frequency below the resonant condition which gives a fraction the resonant amplitude during welding. In both plates the largest residual stress component found in the heat affected zone and in the base metal is along the fusion joint (longitudinal) and is found at the boundary between the weld zone and the heat affected zone. This longitudinal component is 300 +/- 50 MPa in tension. The associated normal stress was close to zero and the transverse stress was 80 +/- 50 MPa. Variations in residual stresses with thickness through the base metal plate were small. The treated plate and untreated plate showed nearly identical patterns of stress distribution. Differences in the measured stresses between the vibratory-stress-relief treated and the untreated plates fall within the error bars of the stress determination in these particular 25 mm thick 300-type stainless steel plates.

  7. Study on influence of three kinds of stress on crack propagation in butt welds of spiral coil waterwall for ultra supercritical boiler

    Science.gov (United States)

    Yan, Zhenrong; Si, Jun

    2017-09-01

    The spiral coil waterwall is the main pressure parts and the core functional components of Ultra Supercritical Boiler. In the process of operation, the spiral coil waterwall is under the combined action of welding residual stress, installation defects stress and working fluid stress, Cracks and crack propagation are easy to occur in butt welds with defects. In view of the early cracks in the butt welds of more T23 water cooled walls, in this paper, the influence of various stresses on the crack propagation in the butt welds of spiral coil waterwall was studied by numerical simulation. Firstly, the welding process of T23 water cooled wall tube was simulated, and the welding residual stress field was obtained. Then,on the basis, put the working medium load on the spiral coil waterwall, the supercoated stress distribution of the welding residual stress and the stress of the working medium is obtained. Considering the bending moment formed by stagger joint which is the most common installation defects, the stress field distribution of butt welds in T23 water-cooled wall tubes was obtained by applying bending moment on the basis of the stress field of the welding residual stress and the working medium stress. The results show that, the welding residual stress is small, the effect of T23 heat treatment after welding to improve the weld quality is not obvious; The working medium load plays a great role in the hoop stress of the water cooled wall tube, and promotes the cracks in the butt welds; The axial stress on the water cooled wall tube produced by the installation defect stress is obvious, the stagger joint, and other installation defects are the main reason of crack propagation of spiral coil waterwall. It is recommended that the control the bending moment resulting from the stagger joint not exceed 756.5 NM.

  8. Recent advances in residual stress measurement

    International Nuclear Information System (INIS)

    Withers, P.J.; Turski, M.; Edwards, L.; Bouchard, P.J.; Buttle, D.J.

    2008-01-01

    Until recently residual stresses have been included in structural integrity assessments of nuclear pressure vessels and piping in a very primitive manner due to the lack of reliable residual stress measurement or prediction tools. This situation is changing the capabilities of newly emerging destructive (i.e. the contour method) and non-destructive (i.e. magnetic and high-energy synchrotron X-ray strain mapping) residual stress measurement techniques for evaluating ferritic and austenitic pressure vessel components are contrasted against more well-established methods. These new approaches offer the potential for obtaining area maps of residual stress or strain in welded plants, mock-up components or generic test-pieces. The mapped field may be used directly in structural integrity calculations, or indirectly to validate finite element process/structural models on which safety cases for pressurised nuclear systems are founded. These measurement methods are complementary in terms of application to actual plant, cost effectiveness and measurements in thick sections. In each case an exemplar case study is used to illustrate the method and to highlight its particular capabilities

  9. Development of stress corrosion cracking resistant welds of 321 stainless steel by simple surface engineering

    Science.gov (United States)

    Mankari, Kamal; Acharyya, Swati Ghosh

    2017-12-01

    We hereby report a simple surface engineering technique to make AISI grade 321 stainless steel (SS) welds resistant to stress corrosion cracking (SCC) in chloride environment. Heat exchanger tubes of AISI 321 SS, welded either by (a) laser beam welding (LBW) or by (b) metal inert gas welding (MIG) were used for the study. The welds had high magnitude of tensile residual stresses and had undergone SCC in chloride environment while in service. The welds were characterized using field emission scanning electron microscopy (FESEM) and X-ray diffraction (XRD). Subsequently, the welded surfaces were subjected to buffing operation followed by determination of residual stress distribution and surface roughness by XRD and surface profilometer measurements respectively. The susceptibility of the welds to SCC was tested in buffed and un-buffed condition as per ASTM G-36 in boiling MgCl2 for 5 h and 10 h, followed by microstructural characterization by using optical microscope and FESEM. The results showed that the buffed surfaces (both welds and base material) were resistant to SCC even after 10 h of exposure to boiling MgCl2 whereas the un-buffed surfaces underwent severe SCC for the same exposure time. Buffing imparted high magnitude of compressive stresses on the surface of stainless steel together with reduction in its surface roughness and reduction in plastic strain on the surface which made the welded surface, resistant to chloride assisted SCC. Buffing being a very simple, portable and economic technique can be easily adapted by the designers as the last step of component fabrication to make 321 stainless steel welds resistant to chloride assisted SCC.

  10. Measured residual stresses in overlay pipe weldments removed from service

    International Nuclear Information System (INIS)

    Shack, W.J.

    1985-02-01

    Surface and throughwall residual stresses were measured on an elbow-to-pipe weldment that had been removed from the Hatch-2 reactor about a year after the application of a weld overlay. The results were compared with experimental measurements on three mock-up weldments and with finite-element calculations. The comparison shows that there are significant differences in the form and magnitude of the residual stress distributions. However, even after more than a year of service, the residual stresses over most of the inner surface of the actual plant weldment with an overlay were strongly compressive. 3 refs., 7 figs

  11. Residual Stresses and Other Properties of Teardrops

    Energy Technology Data Exchange (ETDEWEB)

    Stroud, Mary Ann [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Veirs, Douglas Kirk [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Berg, John M. [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Hill, Mary Ann [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Rios, Daniel [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Duque, Juan [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

    2017-07-26

    The Department of Energy’s 3013 Standard for packaging plutonium-bearing materials for storage up to fifty years specifies a minimum of two individually welded, nested containers herein referred to as the 3013 outer and the 3013 inner.1 Stress corrosion cracking (SCC) is a potential failure mechanism for 3013 inner containers.2,3 The bagless transfer container (BTC), a 3013 inner container used by Hanford and Savanna River Site (SRS) made from 304L stainless steel (SS), poses the greatest concern for SCC.4,5 The Surveillance and Monitoring Program (SMP) use stressed metal samples known as teardrops as screening tools in SCC studies to evaluate factors that could result in cracks in the 3013 containers.6,7 This report provides background information on the teardrops used in the Los Alamos National Laboratory (LANL) SMP studies including method of construction, composition and variability. In addition, the report discusses measurements of residual stresses in teardrops and compares the results with residual stresses in BTCs reported previously.4 Factors affecting residual stresses, including teardrop dimensions and surface finish, are also discussed.

  12. Residual stresses in a weldment of pressure vessel steel

    International Nuclear Information System (INIS)

    Gott, K.E.

    1978-01-01

    A study was made of the distribution of residual stresses around a typical weld from a light water reactor pressure vessel by an X-ray double-exposure camera technique. So that the magnitude, sign, and distribution of the residual stresses were as similar as possible to those found in practice, a wide, full-thickness specimen of A533B Cl 1 steel containing a submerged-arc weld was stress-relief annealed. To obtain a three-dimensional distribution of the stresses the specimen was examined at different levels through the thickness. Following the removal of material by milling, the specimen surface was electropolished to free it from cold work. Corrections have been made to take into account specimen relaxation. To completely define the original stress system it is desirable also to measure the change in curvature on removing a layer of material. Unless this is done assumptions must be made which complicate the calculations unnecessarily. This became apparent after the experimental work was completed. In the centre of the plate the methods of correction which can be used are sensitive to errors in the measurements. The corrected results show that the dominant residual stress is perpendicular to the weld. It is positive at the surfaces and negative in the centre of the plate. The maximum value can reach the yield stress. The residual stresses in the weld metal can locally vary considerably: from 100 to 350N/mm 2 over a distance of 5mm. Such large variations have been found to coincide with the heat-affected zones of the individual weld runs. (author)

  13. Reduction of residual strains in weldments in explosion welding

    International Nuclear Information System (INIS)

    Tsemakhovich, B.D.

    1985-01-01

    Peculiarities of large-size item strains in explosion cladding have been investigated. Causes of explosion-welded item destruction under the action of reflected waves have been established by means of the acoustic analysis of the item-support system. It is suggested to use grit as a support which permits to decrease 3-4 times and stabilize residual strains and reduce to minimum the probability of crack appearance

  14. Residual stress studies of austenitic and ferritic steels

    International Nuclear Information System (INIS)

    Chrenko, R.M.

    1978-01-01

    Residual studies have been made on austenitic and ferritic steels of the types used as structural materials. The residual stress results presented here will include residual stress measurements in the heat-affected zone on butt welded Type 304 stainless steel pipes, and the stresses induced in Type 304 austenitic stainless steel and Type A508 ferritic steel by several surface preparations. Such surface preparation procedures as machining and grinding can induce large directionality effects in the residual stresses determined by X-ray techniques and some typical data will be presented. A brief description is given of the mobile X-ray residual stress apparatus used to obtain most of the data in these studies. (author)

  15. The effect of stress relieving treatment on mechanical properties and microstructure of different welding areas of A517 steel

    Science.gov (United States)

    Sharifi, Hassan; Raisi, Solyman; Tayebi, Morteza

    2017-12-01

    Quench and temper steels are classified as low alloy steels. In these types of steel, post-weld heat treatment is used to obtain high toughness, elevated strength and better corrosion resistance in addition to decline residual stress and hydrogen cracking for high pressure vessel applications. In this study, welding mechanical properties were characterized by hardness measurements, tensile and impact tests. Additionally, optical microscopy and scanning electron microscopy (SEM) was carried out in order to characterize the microstructure and the fracture analysis of A517 steel before and after the post-weld heat treatment. Residual stress examinations were employed to confirm the data reliability. Results showed no changes in the weld zone microstructures. The residual stress measurements revealed the highest and the lowest residual stresses in non-treated samples and heat treated samples in 560 °C, respectively. On the other side, hardness and ultimate tensile strength of the specimens was decreased after heat treatment.

  16. Distributions of temperature and stress fields on penetration assembly during multi-pass welding

    International Nuclear Information System (INIS)

    Li Hong; Li Li

    2010-01-01

    Welding is a fundamental manufacturing technique used to join metal components. They cause errors during the assembly of the structure and reduce the strength of the structure. Based on an elastic-plastic-model, a three-dimensional finite element numerical simulation of a stainless steel penetration assembly during multi-pass welding with girth welds is carried out in this paper. And then the transient temperature field and the real-time dynamic stresses field of the structure are obtained. The heat source is modeled as a moving heat flux along girth welds following a double ellipsoid distribution. The 'birth and death' element method is applied to simulate the gradual growth of welding pass metal. The way of predicting the residual stresses in this paper can prepare an error-minimizing guide at design stage and can be used in accuracy management.

  17. Residual stress measurement round robin on an electron beam welded joint between austenitic stainless steel 316L(N) and ferritic steel P91

    OpenAIRE

    Javadi, Y.; Smith, M.C.; Abburi Venkata, K.; Naveed, N.; Forsey, A.N.; Francis, J.A.; Ainsworth, R.A.; Truman, C.E.; Smith, D.J.; Hosseinzadeh, F.; Gungor, S.; Bouchard, P. J.; Dey, H.C.; Bhaduri, A.K.; Mahadevan, S.

    2017-01-01

    This paper is a research output of DMW-Creep project which is part of a national UK programme through the RCUK Energy programme and India's Department of Atomic Energy. The research is focussed on understanding the characteristics of welded joints between austenitic stainless steel and ferritic steel that are widely used in many nuclear power generating plants and petrochemical industries as well as conventional coal and gas-fired power systems. The members of the DMW-Creep project have under...

  18. Neutron Diffraction Residual Stress Measurements in Key-Hole Laser Formed Weldments

    Science.gov (United States)

    Paradowska, A. M.; Suder, W.; Williams, S.

    2010-11-01

    There is a new generation of lasers available for materials processing. The new lasers include fibre and disc laser are characterized by very high beam quality at very high power levels providing extremely high energy density. In general laser welding is selected over other welding processes because of the minimisation of the heat input, residual stresses and distortion, for this reason they are increasingly popular over a wide range of industries. The narrowness of the welds makes it challenging to resolve the details of the residual stresses produced by the welding process. Residual strain/stress measurements of two specimens produced using the fibre laser were performed on Engin-X. Across the weld and through thickness distributions are reported in this paper.

  19. Residual stress analysis: a review

    International Nuclear Information System (INIS)

    Finlayson, T.R.

    1983-01-01

    The techniques which are or could be employed to measure residual stresses are outlined. They include X-ray and neutron diffraction. Comments are made on the reliability and accuracy to be expected from particular techniques

  20. Effects on Machining on Surface Residual Stress of SA 508 and Austenitic Stainless Steel

    International Nuclear Information System (INIS)

    Lee, Kyoung Soo; Lee, Seong Ho; Park, Chi Yong; Yang, Jun Seok; Lee, Jeong Geun; Park, Jai Hak

    2011-01-01

    Primary water stress corrosion cracking has occurred in dissimilar weld areas in nuclear power plants. Residual stress is a driving force in the crack. Residual stress may be generated by weld or surface machining. Residual stress due to surface machining depends on the machining method, e.g., milling, grinding, or EDM. The stress is usually distributed on or near the surface of the material. We present the measured residual stress for machining on SA 508 and austenitic stainless steels such as TP304 and F316. The residual stress can be tensile or compressive depending on the machining method. The depth and the magnitude of the residual stress depend on the material and the machining method

  1. Residual stresses around Vickers indents

    International Nuclear Information System (INIS)

    Pajares, A.; Guiberteau, F.; Steinbrech, R.W.

    1995-01-01

    The residual stresses generated by Vickers indentation in brittle materials and their changes due to annealing and surface removal were studied in 4 mol% yttria partially stabilized zirconia (4Y-PSZ). Three experimental methods to gain information about the residual stress field were applied: (i) crack profile measurements based on serial sectioning, (ii) controlled crack propagation in post indentation bending tests and (iii) double indentation tests with smaller secondary indents located around a larger primary impression. Three zones of different residual stress behavior are deduced from the experiments. Beneath the impression a crack free spherical zone of high hydrostatic stresses exists. This core zone is followed by a transition regime where indentation cracks develop but still experience hydrostatic stresses. Finally, in an outward third zone, the crack contour is entirely governed by the tensile residual stress intensity (elastically deformed region). Annealing and surface removal reduce this crack driving stress intensity. The specific changes of the residual stresses due to the post indentation treatments are described and discussed in detail for the three zones

  2. Investigating Resulting Residual Stresses during Mechanical Forming Process

    Science.gov (United States)

    Akinlabi, Stephen A.; Fatoba, Olawale S.; Mashinini, Peter M.; Akinlabi, Esther T.

    2018-03-01

    Most manufacturing processes such as machining, welding, heat treatment, laser forming, laser cladding and, laser metal deposition, etc. are subjected to a form of heat or energy to change the geometrical shape thus changing the inherent engineering and structural properties of the material. These changes often cause the development of locked up stresses referred to as residual stresses as a result of these activities. This study reports on the residual stresses developed due to the mechanical forming process to maintain a suitable structural integrity for the formed components. The result of the analysis through the X-ray diffraction confirmed that residual stresses were induced in the manufactured parts and further revealed that residual stresses were compressive in nature as found in the parent material but with values less than the parent material.

  3. A comparison of residual stresses in built-up steel beams using hole-drilling method

    International Nuclear Information System (INIS)

    Nawafleh, M. A.; Hunaiti, Y. M.; Younes, R. M.

    2009-01-01

    Residual stresses have a significant effect on the stability resistance of metal building systems. An experimental program was conducted to measure these stresses in built-up steel beams using incremental hole-drilling method. The experimental results reveal that the predicted residual stress type of pattern for built-up I-sections with fillet welds on one side of the web is not the same as the pattern of residual stresses in built-up I-sections with fillet welds on both sides of the web

  4. Stress corrosion life experience of 182 and 82 welds in French PWRs

    International Nuclear Information System (INIS)

    Amzallag, C.; Pages, C.; Gimond, C.

    2002-01-01

    Large Components of Pressurized Water Reactors (PWR) include many parts fabricated from alloy 600 welded with 182 and 82 alloys. Long-term operating experience shows that the alloy 600 is susceptible to Stress Corrosion Cracking in primary water at high temperature (PWSCC). In the 1980's the first indications were detected in steam generator tubes, and then in pressurizer nozzles. In the 1990's, the vessel head penetrations were in turn affected. In such components, stress corrosion cracks initiated in the base metal and, in some cases propagated in the weld metal. For this reason, much attention has been paid to the behavior of the base metal. In comparison, relatively few studies have been carried out on the weld metal, essentially because of the better service experience and experimental difficulties. Alloy 182 is susceptible to stress corrosion cracking in PWR primary water only if the applied stress exceeds the yield stress. Most of the welds in alloys 182 and 82 of EDF plants are ground and stress relieved with the exception of vessel head penetrations and the weld between the divider plate and the partition stub of the steam generator channel head. The stress-relief at 600 deg. C, primarily used for stress-relieving low alloy components, has a favorable effect in reducing the residual stresses but does not modify the intrinsic PWSCC resistance of the welds. Up to now, the service behavior of 182 welds in EDF plants appears to be better than the components in alloy 600. It can be explained by the following causes -the SCC threshold is generally higher for alloy 182 than for alloy 600, - in alloy 182, the manufacturing processes (final welding, grinding) rarely induce applied stresses higher than yield stress, whereas in alloy 600, various manufacturing processes (expansion, deformations caused by welding, machining) sometimes induce applied stresses higher than yield stress. Due to the recent incidents reported on CRDM nozzles and safe-end welds, significant

  5. Peening as a stress relieving method for welded joints

    International Nuclear Information System (INIS)

    Ferreira, M.L.R.

    1984-01-01

    The efficacy of the process of stress relieving by hammer-peening, in heavy plates of low carbon steel is analysed. The effects of peening in the mechanical properties of welded metal deposited by shield metal arc welding, using the electrodes E-6010, E-7018 and E-8018C-2, and the weld metal deposited by submerged arc welding, using the filler metals ENil and EA3, are also analysed. X-ray diffraction was used in order to verify the efficacy of peening as a stress-relieving process. The obtained results and the literature reviewed show that, peening is effective in stress relieving. (author) [pt

  6. Residual Stresses in SAVY 4000 and Hagan Container Bodies

    Energy Technology Data Exchange (ETDEWEB)

    Stroud, Mary Ann [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Hill, Mary Ann [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Tokash, Justin Charles [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Forsyth, Robert Thomas [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Hyer, Holden Christopher [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

    2017-11-02

    Chloride-induced stress corrosion cracking (SCC) has been investigated as a potential failure mechanism for the SAVY 4000 and the Hagan containers used to store plutonium-bearing materials at Los Alamos National Laboratory. This report discusses the regions of the container bodies most susceptible to SCC and the magnitude of the residual stresses in those regions. Boiling MgCl2 testing indicated that for both containers the region near the top weld was most susceptible to SCC. The Hagan showed through wall cracking after 22-24 hours of exposure both parallel (axial stresses) and perpendicular (hoop stresses) to the weld. The SAVY 4000 container showed significant cracking above and below the weld after 47 hours of exposure but there was no visual evidence of a through wall crack and the cracks did not leak water. Two through wall holes formed in the bottom of the SAVY 4000 container after 44-46 hours of exposure. For both containers, average “through wall” residual stresses were determined from hole drilling data 4 mm below the weld. In the Hagan body, average tensile hoop stresses were 194 MPa and average compressive axial stresses were -120 MPa. In the SAVY 4000 body, average compressive hoop stresses were 11 MPa and average tensile axial stresses were 25 MPa. Results suggest that because the Hagan container exhibited through wall cracking in a shorter time in boiling MgCl2 and had the higher average tensile stress, 194 MPa hoop stress, it is more susceptible to SCC than the SAVY 4000 container.

  7. An experimental analysis of temperature and stress fields in girth welded 304L stainless steel pipes

    International Nuclear Information System (INIS)

    Li, M.; Atteridge, D.G.; Anderson, W.E.; Hubbard, C.R.; Spooner, S.

    1996-01-01

    The thermal and deformation/strain histories were measured by a computer data acquisition system for three 406-mm-diameter, Type 304L stainless steel (SS), schedule 40 (12.7 mm thickness) pipe girth welds. Two welds were standard V groove preparations and completed in six and nine (discontinuous) passes with multiple start-stop positions, while the third one was a narrow groove configuration and finished with four continuous passes with one start-stop position. The thermomechanical history measurements were taken on the pipe inner surface, encompassing the weld centerline (WCL) and heat-affected zone; a total of 47 data acquisition instruments were used for each weld to monitor weld shrinkages, surface temperatures, surface strains, and radial deformations. The experimental data give the following general conclusions: (1) the temperature profiles in the two V groove weldments are, in general, axisymmetric, while the temperature profile in the narrow gap groove weldment is axisymmetric in locations far from WCL, but is not axisymmetric in locations near start-stop position; (2) the strain/deformation histories are controlled by the thermal histories with the final strain/deformation value largely determined by the last one or two passes of welding; (3) the strain/deformation profile in the weldment is not axisymmetric suggesting that the residual stress is not axisymmetrically distributed; (4) the four-pass narrow gap weldment experienced the fewest time and temperature cycles during welding, and has the lowest level of radial deformation among the three pipe weldments indicating that the narrow gap weldment would have the lowest overall residual stress level among the three pipe weldments. Residual stress measurements on the inner surface of four-pass pipe weldment were performed using the neutron diffraction (ND) technique. The ND results show that a tensile zone exists on the pipe inner surface and in the weld and its heat-affected zone (HAZ) area

  8. Comparison of hot spot stress evaluation methods for welded structures

    Directory of Open Access Journals (Sweden)

    Jae-Myung Lee

    2010-12-01

    Full Text Available In this paper, different evaluation methods of Hot Spot Stresses (HSS have been applied to four different welded structure details in order to compare them and to illustrate their differences. The HSSs at failure-critical locations were calculated by means of a series of finite element analyses. There was good overall agreement between calculated and experimentally determined HSS on the critical locations. While different methods and procedures exist for the computation of the structural hot-spot stress at welded joints, the recommendations within the International Institute of Welding (IIW guideline concerning the ‘Hot Spot Stress’ approach were found to give good reference stress approximations for fatigue-loaded welded joints. This paper recommends and suggests an appropriate finite element modeling and hot spot stress evaluation technique based on round-robin stress analyses and experimental results of several welded structure details.

  9. Neutron Diffraction Residual Strain Tensor Measurements Within The Phase IA Weld Mock-up Plate P-5

    Energy Technology Data Exchange (ETDEWEB)

    Hubbard, Camden R [ORNL

    2011-09-01

    Oak Ridge National Laboratory (ORNL) has worked with NRC and EPRI to apply neutron and X-ray diffraction methods to characterize the residual stresses in a number of dissimilar metal weld mockups and samples. The design of the Phase IA specimens aimed to enable stress measurements by several methods and computational modeling of the weld residual stresses. The partial groove in the 304L stainless steel plate was filled with weld beads of Alloy 82. A summary of the weld conditions for each plate is provided in Table 1. The plates were constrained along the long edges during and after welding by bolts with spring-loaded washers attached to the 1-inch thick Al backing plate. The purpose was to avoid stress relief due to bending of the welded stainless steel plate. The neutron diffraction method was one of the methods selected by EPRI for non-destructive through thickness strain and stress measurement. Four different plates (P-3 to P-6) were studied by neutron diffraction strain mapping, representing four different welding conditions. Through thickness neutron diffraction strain mappings at NRSF2 for the four plates and associated strain-free d-zero specimens involved measurement along seven lines across the weld and at six to seven depths. The mountings of each plate for neutron diffraction measurements were such that the diffraction vector was parallel to each of the three primary orthogonal directions of the plate: two in-plane directions, longitudinal and transverse, and the direction normal to the plate (shown in left figure within Table 1). From the three orthogonal strains for each location, the residual stresses along the three plate directions were calculated. The principal axes of the strain and stress tensors, however, need not necessarily align with the plate coordinate system. To explore this, plate P-5 was selected for examination of the possibility that the principal axes of strain are not along the sample coordinate system axes. If adequate data could

  10. Measurement of residual stresses in alloy 600 pressurizer penetrations

    International Nuclear Information System (INIS)

    Hall, J.F.; Molkenthin, J.P.; Prevey, P.S.; Pathania, R.S.

    1994-01-01

    Alloy 600 penetrations in several pressurized water reactors have experienced primary water stress corrosion cracking near the partial penetration J-welds between the Alloy 600 and the cladding on the inside diameter of the components. The microstructure and tensile properties indicated that the Alloy 600 was susceptible to primary water stress corrosion cracking (PWSCC) providing that a high tensile stress (applied + residual) was present. The residual stress distributions at the inside diameter surface and at different depths below the surface were measured in Alloy 600 nozzle and heater sleeve mockups. Surface residual stresses on the nozzle mockup ranged from -350 to +830 MPa. For the heater sleeve mockup, the surface residual stresses ranged from -330 to +525 MPa. In the areas of high tensile residual stress, for the most part, the residual stresses decreased with increasing depth below the surface. For the nozzle and heater sleeve mockups, the percent cold-world and yield strength as a function of depth were determined. (authors). 12 figs., 4 refs

  11. Residual stress in polyethylene pipes

    Czech Academy of Sciences Publication Activity Database

    Poduška, Jan; Hutař, Pavel; Kučera, J.; Frank, A.; Sadílek, J.; Pinter, G.; Náhlík, Luboš

    2016-01-01

    Roč. 54, SEP (2016), s. 288-295 ISSN 0142-9418 R&D Projects: GA MŠk LM2015069; GA MŠk(CZ) LQ1601 Institutional support: RVO:68081723 Keywords : polyethylene pipe * residual stress * ring slitting method * lifetime estimation Subject RIV: JL - Materials Fatigue, Friction Mechanics Impact factor: 2.464, year: 2016

  12. Analytical model of stress field in submerged arc welding butt joint with thorough penetration

    Directory of Open Access Journals (Sweden)

    Winczek Jerzy

    2018-01-01

    Full Text Available Analytical model of temporary and residual stresses for butt welding with thorough penetration was described assuming planar section hypothesis and using integral equations of stress equilibrium of the bar and simple Hooke’s law. In solution the effect of phase transformations (structure changes and structural strains has been taken into account. Phase transformations during heating are limited by temperature values at the beginning and at the end of austenitic transformation, depending on chemical composition of steel while the progress of phase transformations during cooling is determined on the basis of TTT-welding diagram. Temperature values at the beginning and at the end of transformation are conditioned by the speed of heating. Kinetics of diffusional transformation is described basing on Johnson-Mehl-Avrami-Kolmogorov equation, while martensitic transformation, basing on Koistinen-Marburger equation. Stresses in elasto-plastic state are determined by iteration, using elastic solutions method with changeable longitudinal modulus of elasticity, conditioned by stress-strain curve. Computations of stress field have been conducted for one-side butt welded of two steel flats made from S235 steel. It has enabled a clear interpretation of influence of temperature field and phase transformation on stresses caused by welding using Submerged Arc Welding (SAW method.

  13. Neutron residual stress measurements in linepipe

    Science.gov (United States)

    Law, Michael; Gnaëpel-Herold, Thomas; Luzin, Vladimir; Bowie, Graham

    2006-11-01

    Residual stresses in gas pipelines are generated by manufacturing and construction processes and may affect the subsequent pipe integrity. In the present work, the residual stresses in eight samples of linepipe were measured by neutron diffraction. Residual stresses changed with some coating processes. This has special implications in understanding and mitigating stress corrosion cracking, a major safety and economic problem in some gas pipelines.

  14. Neutron residual stress measurements in linepipe

    International Nuclear Information System (INIS)

    Law, Michael; Gnaepel-Herold, Thomas; Luzin, Vladimir; Bowie, Graham

    2006-01-01

    Residual stresses in gas pipelines are generated by manufacturing and construction processes and may affect the subsequent pipe integrity. In the present work, the residual stresses in eight samples of linepipe were measured by neutron diffraction. Residual stresses changed with some coating processes. This has special implications in understanding and mitigating stress corrosion cracking, a major safety and economic problem in some gas pipelines

  15. Residual stress measurements in a ferritic steel/In625 superalloy dissimilar metal weldment using neutron diffraction and deep-hole drilling

    International Nuclear Information System (INIS)

    Skouras, A.; Paradowska, A.; Peel, M.J.; Flewitt, P.E.J.; Pavier, M.J.

    2013-01-01

    This paper reports the use of non-invasive and semi-invasive techniques to measure the residual stresses in a large dissimilar weldment. This took the form of a butt weld between two sections of a P92 steel pipe, joined using an In625 welding consumable. Residual stress measurements have been carried out on the 30 mm thick welded pipe using the deep-hole drilling technique to characterise the through wall section residual stress distribution for the weld metal, HAZ and parent material. In addition, neutron diffraction measurements have been carried out within the weld zone. Diffraction patterns presented a high intensity and sharp peaks for the base P92 steel material. However measurements in the weld superalloy material were proven problematic as very weak diffraction patterns were observed. A thorough examination of the weld material suggested that the likely cause of this phenomenon was texture in the weld material created during the solidification phase of the welding procedure. This paper discusses the challenges in the execution and interpretation of the neutron diffraction results and demonstrates that realistic measurements of residual stresses can be achieved, in complex dissimilar metal weldments. Highlights: ► One of the few papers to measure residual stresses on dissimilar metal welds. ► Paper managed to provide realistic measurements of residual stresses using the DHD and ND technique. ► Results of this study have demonstrated the effect of texture during the ND measurements.

  16. Optimization of weld overlay dimensions for butt-welded pipes

    Energy Technology Data Exchange (ETDEWEB)

    Chintapalli, A.; Ku, F.H.; Miessi, G.A., E-mail: achintapalli@structint.com, E-mail: fku@structint.com, E-mail: amiessi@structint.com [Structural Integrity Associates, Inc., San Jose, California (United States); Yee, R.K., E-mail: Raymond.Yee@sjsu.edu [San Jose State Univ., San Jose, California (United States)

    2008-07-01

    Weld overlay technique can be used on a welded pipe with a flaw in the butt weld to prevent it from cracking further. Due to the application of weld overlay on top of the weld, compressive stresses are developed in the pipe wall and the weld. These stresses counteract the effect of the residual stresses from the butt weld and tensile stresses produced in the pipe during normal operation. Existing guidelines in the nuclear industry specify minimum dimensions (length and thickness) of the weld overlay. However, there is no guideline regarding the optimum repair dimensions that should be used to obtain minimum residual stresses induced by the weld overlay technique. The optimum dimensions in this study refer to the minimum material that can be used for the weld overlay. This results in reduced cost, time and exposure to radiation. Hence a size sensitivity study is performed by varying three parameters, the width and thickness of the weld overlay, and the size of the pipe being repaired. The repaired pipe is assumed to be subjected to typical pressurizer water reactor (PWR) operating conditions. The weld overlay process is simulated using an axisymmetric finite element model. The axial and hoop stresses in the region of the butt weld after the weld overlay are compared. The results from this study will be analyzed to establish optimum dimensions of the weld overlay for various pipe sizes to mitigate axial and circumferential crack initiation at the butt weld. (author)

  17. Numerical simulation of residual stress in piping components at Framatome-ANP

    International Nuclear Information System (INIS)

    Gilies, P.; Franco, C.; Cipiere, M.-F.; Ould, P.

    2005-01-01

    Numerous manufacturing processes induce residual stresses and distortions in piping components and associated welds: quenching of cast pipings, machining and welding. In Pressurized Water Reactors, most of the components have a large thickness for sustaining pressure and distortions are a minor source of concern. This is not the case for residual stresses which may have a strong influence on several type of damage such as fatigue, corrosion, brittle fracture. In low toughness components, residual stress fields may contribute to ductile tearing initiation. These potential damages are mitigated after welding by stress relief heat treatment, which is applied in a systematic manner to ferritic components of the primary system in nuclear reactors. This treatment is not applied on austenitic piping for which the heat treatment temperature is limited due to the risk of sensitization and residual stresses are difficult to eliminate completely. Since on site measurements are costly and difficult to perform, numerical simulation appears to be an attractive tool for estimating residual stress distributions. Framatome-ANP is working on modelling manufacturing processes with that purpose in mind. This paper presents three kinds of applications illustrating efforts on welding, quenching and machining simulation. First a comparison is shown between computations and measurements of residual stress induced by welding of a dissimilar weld metal junction. Then numerical simulations of quenching of a cast stainless steel nozzle are presented. Finally quenching followed by machining and grinding of this cast component are considered in a full simulation of the manufacturing process. Computed distortions and residual stresses are compared with experimental measurements at different stages of the manufacturing process. (authors)

  18. Measurements of residual stresses and textures by neutron diffraction

    International Nuclear Information System (INIS)

    Hayashi, Makoto

    2008-01-01

    Many measurement methods of residual stress are compared and characteristic properties of neutron diffraction method are described. The penetration depth of neutron, photon radiation and Cu-Kα ray to metals are compared and the values of neutron are larger than others. Two kinds of measurement methods of residual stress by neutron diffraction, the angular scattering and the time of flight method, are explained. The results of measurement of residual stresses of carbon steel and titanium butt weld joint, Wasploy alloy, aluminum alloy and Incoloy 800 tube in stream generator of nuclear power plant are reported. Neutron diffraction profile of SiCp/Al2024-T6 was measured by TOF method. The textures of Zr-2.5% Nb and SUS316 steel were observed. (S.Y.)

  19. Possible standard specimens for neutron diffraction residual stress measurements

    International Nuclear Information System (INIS)

    Brand, P.C.; Prask, H.J.; Fields, R.J.; Blackburn, J.; Proctor, T.M.

    1995-01-01

    Increasingly, sub-surface residual stress measurements by means of neutron diffraction are being conducted at various laboratories around the world. Unlike X-ray diffraction residual stress measurement setups, neutron instruments in use worldwide vary widely in design, neutron flux, and level of dedication towards residual stress measurements. Although confidence in the neutron technique has increased within the materials science and engineering communities, no demonstration of standardization or consistency between laboratories has been made. One of the steps in the direction of such standardization is the development of standard specimens, that have well characterized residual stress states and which could be examined worldwide. In this paper the authors will examine two options for a neutron stress standard specimen: (1) a steel ring-plug specimen with very well defined diametrical interference; (2) a spot weld in a High Strength Low Alloy steel disk. The results of neutron residual stress measurements on these specimens will be discussed and conclusions as to their usefulness as neutron stress standards will be presented

  20. Experiment and numerical simulation for laser ultrasonic measurement of residual stress.

    Science.gov (United States)

    Zhan, Yu; Liu, Changsheng; Kong, Xiangwei; Lin, Zhongya

    2017-01-01

    Laser ultrasonic is a most promising method for non-destructive evaluation of residual stress. The residual stress of thin steel plate is measured by laser ultrasonic technique. The pre-stress loading device is designed which can easily realize the condition of the specimen being laser ultrasonic tested at the same time in the known stress state. By the method of pre-stress loading, the acoustoelastic constants are obtained and the effect of different test directions on the results of surface wave velocity measurement is discussed. On the basis of known acoustoelastic constants, the longitudinal and transverse welding residual stresses are measured by the laser ultrasonic technique. The finite element method is used to simulate the process of surface wave detection of welding residual stress. The pulsed laser is equivalent to the surface load and the relationship between the physical parameters of the laser and the load is established by the correction coefficient. The welding residual stress of the specimen is realized by the ABAQUS function module of predefined field. The results of finite element analysis are in good agreement with the experimental method. The simple and effective numerical and experimental methods for laser ultrasonic measurement of residual stress are demonstrated. Copyright © 2016. Published by Elsevier B.V.

  1. Variant selection of martensites in steel welded joints with low transformation temperature weld metals

    International Nuclear Information System (INIS)

    Takahashi, Masaru; Yasuda, Hiroyuki Y.

    2013-01-01

    Highlights: ► We examined the variant selection of martensites in the weld metals. ► We also measured the residual stress developed in the butt and box welded joints. ► 24 martensite variants were randomly selected in the butt welded joint. ► High tensile residual stress in the box welded joint led to the strong variant selection. ► We discussed the rule of the variant selection focusing on the residual stress. -- Abstract: Martensitic transformation behavior in steel welded joints with low transformation temperature weld (LTTW) metal was examined focusing on the variant selection of martensites. The butt and box welded joints were prepared with LTTW metals and 980 MPa grade high strength steels. The residual stress of the welded joints, which was measured by a neutron diffraction technique, was effectively reduced by the expansion of the LTTW metals by the martensitic transformation during cooling after the welding process. In the LTTW metals, the retained austenite and martensite phases have the Kurdjumov–Sachs (K–S) orientation relationship. The variant selection of the martensites in the LTTW metals depended strongly on the type of welded joints. In the butt welded joint, 24 K–S variants were almost randomly selected while a few variants were preferentially chosen in the box welded joint. This suggests that the high residual stress developed in the box welded joint accelerated the formation of specific variants during the cooling process, in contrast to the butt welded joint with low residual stress

  2. A strategy for accommodating residual stresses in the assessment of repair weldments based upon measurement of near surface stresses

    International Nuclear Information System (INIS)

    Mcdonald, E.J.; Hallam, K.R.; Flewitt, P.E.J.

    2005-01-01

    On many occasions repairs are undertaken to ferritic steel weldments on plant either during construction or to remove service induced defects. These repaired weldments are subsequently put into service with or without a post-weld heat treatment. In either case, but particularly for the latter, there is a need to accommodate the associated residual stresses in structural integrity assessments such as those based upon the R6 failure avoidance procedure. Although in some circumstances the residual macro-stresses developed within weldments of components and structures can be calculated this is not so readily achieved in the case of residual stresses introduced by repair welds. There is a range of physical and mechanical techniques available to undertake the measurement of macro-residual stresses. Of these X-ray diffraction has the advantage that it is essentially non-destructive and offers the potential for evaluating stresses, which exist in the near surface layer. Although for many structural integrity assessments both the magnitude and distribution of residual stresses have to be accommodated it is not practical to make destructive measurements on weld repaired components and structures to establish the through section distribution of stresses. An approach is to derive a description of the appropriate macro-stresses by a combination of measurement and calculation on trial ferritic steel repair weldments. Surface measurements on the plant can then be made to establish the relationship between the repaired component or structure and the trial weld and thereby improve confidence in predicted stresses and their distribution from the near-surface measured values. Hence X-ray diffraction measurements at the near-surface of the plant weldment can be used to underwrite the quality of the repair by confirming the magnitude and distribution of residual stresses used for the integrity assessment to demonstrate continued safe operation

  3. Assessment of Residual Stresses in 3013 Inner and Outer Containers and Teardrop Samples

    Energy Technology Data Exchange (ETDEWEB)

    Stroud, Mary Ann [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Prime, Michael Bruce [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Veirs, Douglas Kirk [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Berg, John M. [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Clausen, Bjorn [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Worl, Laura Ann [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); DeWald, Adrian T. [Hill Engineering, LLC, Rancho Cordova, CA (United States)

    2015-12-08

    This report is an assessment performed by LANL that examines packaging for plutonium-bearing materials and the resilience of its design. This report discusses residual stresses in the 3013 outer, the SRS/Hanford and RFETS/LLNL inner containers, and teardrop samples used in studies to assess the potential for SCC in 3013 containers. Residual tensile stresses in the heat affected zones of the closure welds are of particular concern.

  4. Influence of residual stresses and loading frequencies on corrosion fatigue crack growth behavior of weldments

    Science.gov (United States)

    Kitsunai, Y.; Tanaka, M.; Yoshihisa, E.

    1998-04-01

    The effect of residual stresses and loading frequencies on corrosion fatigue crack growth behavior under synthetic seawater with a free corrosion potential was examined using center-cracked tension (CCT) and single edge-cracked tension (SECT) specimens machined from mild steel butt-welded joints and the parent material. A series of fatigue crack growth tests were carried out with a sinusoidal loading wave form at a stress ratio of 0.05 with a loading frequency of 0.017 to 6.7 Hz. The results show that the crack growth resistance of a weld metal in the SECT specimen is higher than that in the CCT specimen regardless of testing conditions. The discrepancy is attributed to the differences in residual stress distribution at the crack tip in the two specimen geometries. The crack growth rate of the weld metal in the CCT specimen in seawater increased with decreasing loading frequency. The acceleration of the crack growth rate may be related to the occurrence of brittle striation or cleavage due to hydrogen embrittlement. It was found that the corrosion fatigue crack growth rate of a welded joint with tensile residual stress can be predicted using the effective stress intensity factor range, which takes into account both the residual stress and the loading frequency effects.

  5. Process for measuring residual stresses

    International Nuclear Information System (INIS)

    Elfinger, F.X.; Peiter, A.; Theiner, W.A.; Stuecker, E.

    1982-01-01

    No single process can at present solve all problems. The complete destructive processes only have a limited field of application, as the component cannot be reused. However, they are essential for the basic determination of stress distributions in the field of research and development. Destructive and non-destructive processes are mainly used if investigations have to be carried out on original components. With increasing component size, the part of destructive tests becomes smaller. The main applications are: quality assurance, testing of manufactured parts and characteristics of components. Among the non-destructive test procedures, X-raying has been developed most. It gives residual stresses on the surface and on surface layers near the edges. Further development is desirable - in assessment - in measuring techniques. Ultrasonic and magnetic crack detection processes are at present mainly used in research and development, and also in quality assurance. Because of the variable depth of penetration and the possibility of automation they are gaining in importance. (orig./RW) [de

  6. Modeling of residual stress mitigation in austenitic stainless steel pipe girth weldment

    International Nuclear Information System (INIS)

    Li, M.; Atteridge, D.G.; Anderson, W.E.; West, S.L.

    1994-01-01

    This study provides numerical procedures to model 40-cm-diameter, schedule 40, Type 304L stainless steel pipe girth welding and a newly proposed post-weld treatment. The treatment can be used to accomplish the goal of imparting compressive residual stresses at the inner surface of a pipe girth weldment to prevent/retard the intergranular stress corrosion cracking (IGSCC) of the piping system in nuclear reactors. This new post-weld treatment for mitigating residual stresses is cooling stress improvement (CSI). The concept of CSI is to establish and maintain a certain temperature gradient across the pipe wall thickness to change the final stress state. Thus, this process involves sub-zero low temperature cooling of the inner pipe surface of a completed girth weldment, while simultaneously keeping the outer pipe surface at a slightly elevated temperature with the help of a certain heating method. Analyses to obtain quantitative results on pipe girth welding and CSI by using a thermo-elastic-plastic finite element model are described in this paper. Results demonstrate the potential effectiveness of CSI for introducing compressive residual stresses to prevent/retard IGSCC. Because of the symmetric nature of CSI, it shows great potential for industrial application

  7. The measurement of residual stresses in claddings

    International Nuclear Information System (INIS)

    Hofer, G.; Bender, N.

    1978-01-01

    The ring core method, a variation of the hole drilling method for the measurement of biaxial residual stresses, has been extended to measure stresses from depths of about 5 to 25mm. It is now possible to measure the stress profiles of clad material. Examples of measured stress profiles are shown and compared with those obtained with a sectioning technique. (author)

  8. Residual thermal stresses in injection moulded products

    NARCIS (Netherlands)

    Zoetelief, W.F.; Douven, L.F.A.; Ingen Housz, A.J.; Ingen housz, A.J.

    1996-01-01

    Nonisothermal flow of a polymer melt in a cold mold cavity introduces stresses that are partly frozen-in during solidification. Flow-induced stresses cause anisotropy of mechanical, thermal, and optical properties, while the residual thermal stresses induce warpage and stress-cracking. In this

  9. A utilização da difração de neutrões na determinação do perfil de tensões residuais em revestimentos por soldadura The use of neutron diffraction for the determination of the in-depth residual stresses profile in weld coatings

    Directory of Open Access Journals (Sweden)

    Maria José Marques

    2013-06-01

    Full Text Available A técnica de difração de neutrões é usada neste artigo para estudar amostras ferríticas, revestidas comaços inoxidáveisausteníticos através de soldadura por arco submerso. Este procedimento é frequentemente usado no fabrico de equipamentos de processo para as indústrias química e nuclear, por facilidade de execução e razões económicas. A principal desvantagem deste processo de revestimento é a fissuração que frequentemente ocorre na interface material base/soldadura, potenciada pela presença de tensões residuais resultantes da operação de soldadura, a qual pode ser minimizada com a realização de tratamentos térmicos de relaxação de tensões. As amostras foram produzidas a partir de placas em aço ao carbono, tendo uma das superfícies sido revestida com dois tipos de aço inoxidável. Para a primeira camada foi usado um elétrodo EN 12072 - S 23 12 2 L e para a segunda e a terceira camadas foi usado um elétrodo EN 12072 - S 19 12 3 L. Após a soldadura, as amostras foram submetidas a um tratamento térmico de relaxação de tensões, durante 1 hora, à temperatura de 620ºC. Os perfis de tensões residuais obtidos por difração de neutrões evidenciam a relaxação de tensões residuais após o tratamento térmico realizado. A técnica de difração de neutrões revelou-se muito adequada na avaliação de tensões residuais neste tipo de ligações.The neutron diffraction is a non-destructive technique, particularly suitable for the analysis of residual stress fields in welds. The technique is used in this article to study ferritic samples, coated by submerged arc welding using stainless steel filler metals. This procedure is often used for manufacturing process equipment for chemical and nuclear industries, for ease of implementation and economic reasons. The main disadvantage of that processes is the cracking phenomenon that often occurs at the interface between the base material and coatings, which can be

  10. Neutron diffraction investigations on residual stresses contributing to the fatigue crack growth in ferritic steel tubular bridges

    OpenAIRE

    Acevedo, Claire; Evans, Alexander; Nussbaumer, Alain

    2012-01-01

    Fatigue crack growth observed in tubular K-joint specimens, typical of tubular bridge structures, always initiates at the chord crown toe locations whether the applied stress range is tensile or compressive. Even though other locations around the weld have highest hot-spot stresses, chord crown toe locations are still the most critical. This raises the question about the relevant tensile residual stress level at that location. The results of residual stress investigations, obtained using neut...

  11. Characterization of Phase Transformations and Stresses During the Welding of a Ferritic Mild Steel

    Science.gov (United States)

    Dye, D.; Stone, H. J.; Watson, M.; Rogge, R. B.

    2014-04-01

    The transient stresses and phase evolution have been characterized in the quasi-steady state produced around a gas tungsten arc welding torch in a plain carbon (ASTM 1018) steel using in situ neutron diffraction. A novel method has been developed to isolate the deviatoric or plane stress state in the presence of isotropic contributions to the lattice parameter, such as thermal expansion and solute content. The stress state was found to evolve in the anticipated manner, with compressive stresses ahead of the weld and tensile stresses behind the weld, in the weld and heat-affected zone, and compression in the far field behind the weld. In particular, the region of compression in the heat-affected zone adjacent to and just behind the welding torch expected from weld models was observed. The evolution of phase fraction around the weld was also determined using the technique and the stresses obtained from the ferrite phase.

  12. Residual stress measurement for injection molded components

    Directory of Open Access Journals (Sweden)

    Achyut Adhikari

    2016-07-01

    Full Text Available Residual stress induced during manufacturing of injection molded components such as polymethyl methacrylate (PMMA affects the mechanical and optical properties of these components. These residual stresses can be visualized and quantified by measuring their birefringence. In this paper, a low birefringence polariscope (LBP is used to measure the whole-field residual stress distribution of these injection molded specimens. Detailed analytical and experimental study is conducted to quantify the residual stress measurement in these materials. A commercial birefringence measurement system was used to validate the results obtained to our measurement system. This study can help in material diagnosis for quality and manufacturing purpose and be useful for understanding of residual stress in imaging or other applications.

  13. Welding.

    Science.gov (United States)

    South Carolina State Dept. of Education, Columbia. Office of Vocational Education.

    This curriculum guide is designed for use by South Carolina vocational education teachers as a continuing set of lesson plans for a two-year course on welding. Covered in the individual sections of the guide are the following topics: an orientation to welding, oxyacetylene welding, advanced oxyacetylene welding, shielded metal arc welding, TIG…

  14. Stress redistribution and void growth in butt-welded canisters for spent nuclear fuel

    International Nuclear Information System (INIS)

    Josefson, B.L.; Karlsson, L.; Haeggblad, H.Aa.

    1993-02-01

    The stress-redistribution in Cu-Fe canisters for spent nuclear fuel during waiting for deposition and after final deposition is calculated numerically. The constitutive equation modelling creep deformation during this time period employs values on materials parameters determined within the SKB-project on 'mechanical integrity of canisters for spent nuclear fuel'. The welding residual stresses are redistributed without lowering maximum values during the waiting period, a very low amount of void growth is predicted for this type of copper during the deposition period. This leads to an estimated very large rupture time

  15. Neutron diffraction investigations on residual stresses contributing to the fatigue crack growth in ferritic steel tubular bridges

    International Nuclear Information System (INIS)

    Acevedo, C.; Evans, A.; Nussbaumer, A.

    2012-01-01

    Fatigue crack growth observed in tubular K-joint specimens, typical of tubular bridge structures, always initiates at the chord crown toe locations whether the applied stress range is tensile or compressive. Even though other locations around the weld have highest hot-spot stresses, chord crown toe locations are still the most critical. This raises the question about the relevant tensile residual stress level at that location. The results of residual stress investigations, obtained using neutron diffraction measurements highlight that the direction and location of the maximum tensile residual stresses in K-joints is substantially different from those in the more usual tubular butt joints. Indeed, it is shown that the highest tensile residual stresses are oriented perpendicular to the weld direction, which is also the main orientation of the loading stresses applied in K-joints. This paper demonstrates that it is the complex geometry of the K-joint that causes the superposition of critical stresses, making these joints susceptible to fatigue cracking. Therefore, transverse residual stresses play a crucial part in the fatigue crack growth behaviour that applied stresses alone cannot explain. Highlights: ► We measure the 3D residual stresses in tubular joints using neutron diffraction. ► We identify direction and location of the maximum tensile residual stresses. ► K-joint geometry will induce a non-usual orientation of residual stresses. ► Fatigue crack propagation is affected by this critical stress orientation.

  16. Round Robin Analyses on Stress Intensity Factors of Inner Surface Cracks in Welded Stainless Steel Pipes

    Directory of Open Access Journals (Sweden)

    Chang-Gi Han

    2016-12-01

    Full Text Available Austenitic stainless steels (ASSs are widely used for nuclear pipes as they exhibit a good combination of mechanical properties and corrosion resistance. However, high tensile residual stresses may occur in ASS welds because postweld heat treatment is not generally conducted in order to avoid sensitization, which causes a stress corrosion crack. In this study, round robin analyses on stress intensity factors (SIFs were carried out to examine the appropriateness of structural integrity assessment methods for ASS pipe welds with two types of circumferential cracks. Typical stress profiles were generated from finite element analyses by considering residual stresses and normal operating conditions. Then, SIFs of cracked ASS pipes were determined by analytical equations represented in fitness-for-service assessment codes as well as reference finite element analyses. The discrepancies of estimated SIFs among round robin participants were confirmed due to different assessment procedures and relevant considerations, as well as the mistakes of participants. The effects of uncertainty factors on SIFs were deducted from sensitivity analyses and, based on the similarity and conservatism compared with detailed finite element analysis results, the R6 code, taking into account the applied internal pressure and combination of stress components, was recommended as the optimum procedure for SIF estimation.

  17. Research and application of residual stress monitor based on magneto-elastic effect

    International Nuclear Information System (INIS)

    Luu Vu Nhut; Luong Thi Hong; Vu Xuan Thanh; Nguyen Viet Hung

    2015-01-01

    Residual stresses can play a significant role in explaining of deformation and crack in weld joints. There are many methods of residual stress measurement. Most commonly methods used in industry and academia are considered: X-ray and neutron diffraction, hole drilling, Barkhausen, eddy current and ultrasonic methods. This paper introduces a new method for stress measurement, which is based on magneto-elastic effect, is a nondestructive method, available to assist evaluate and monitor the stress level, concentration and the gradient which are very important parameters for the evaluation and assessment of predicted life of the components and preventive care. The paper also reports on research which involved diagnostics and assessment of stressed state in butt weld plate before and after heat treatment. (author)

  18. Prediction of machining induced residual stresses

    Science.gov (United States)

    Pramod, Monangi; Reddy, Yarkareddy Gopi; Prakash Marimuthu, K.

    2017-07-01

    Whenever a component is machined, residual stresses are induced in it. These residual stresses induced in the component reduce its fatigue life, corrosion resistance and wear resistance. Thus it is important to predict and control the machining-induced residual stress. A lot of research is being carried out in this area in the past decade. This paper aims at prediction of residual stresses during machining of Ti-6Al-4V. A model was developed and under various combinations of cutting conditions such as, speed, feed and depth of cut, the behavior of residual stresses were simulated using Finite Element Model. The present work deals with the development of thermo-mechanical model to predict the machining induced residual stresses in Titanium alloy. The simulation results are compared with the published results. The results are in good agreement with the published results. Future work involves optimization or the cutting parameters that effect the machining induced residual stresses. The results obtained were validated with previous work.

  19. Residual stress field of ballised holes

    International Nuclear Information System (INIS)

    Lai, Man On; He, Zhimin

    2012-01-01

    Ballising, involving pushing a slightly over-sized ball made of hard material through a hole, is a kind of cold working process. Applying ballising process to fastener holes produces compressive residual stress on the edge of the holes, and therefore increases the fatigue life of the components or structures. Quantification of the residual stress field is critical to define and precede the ballising process. In this article, the ballised holes are modeled as cold-expanded holes. Elastic-perfectly plastic theory is employed to analyze the holes with cold expansion process. For theoretical simplification, an axially symmetrical thin plate with a cold expanded hole is assumed. The elasticplastic boundaries and residual stress distribution surrounding the cold expanded hole are derived. With the analysis, the residual stress field can be obtained together with actual cold expansion process in which only the diameters of hole before and after cold expansion need to be measured. As it is a non-destructive method, it provides a convenient way to estimate the elastic-plastic boundaries and residual stresses of cold worked holes. The approach is later extended to the case involving two cold-worked holes. A ballised hole is looked upon as a cold expanded hole and therefore is investigated by the approach. Specimens ballised with different interference levels are investigated. The effects of interference levels and specimen size on residual stresses are studied. The overall residual stresses of plates with two ballised holes are obtained by superposing the residual stresses induced on a single ballised hole. The effects of distance between the centers of the two holes with different interference levels on the residual stress field are revealed

  20. Virtual Welded - Joint Design Integrating Advanced Materials and Processing Technology

    Energy Technology Data Exchange (ETDEWEB)

    Yang, Zhishang; Ludewig, Howard W.; Babu, S. Suresh

    2005-06-30

    Virtual Welede-Joint Design, a systematic modeling approach, has been developed in this project to predict the relationship of welding process, microstructure, properties, residual stress, and the ultimate weld fatique strength. This systematic modeling approach was applied in the welding of high strength steel. A special welding wire was developed in this project to introduce compressive residual stress at weld toe. The results from both modeling and experiments demonstrated that more than 10x fatique life improvement can be acheived in high strength steel welds by the combination of compressive residual stress from the special welding wire and the desired weld bead shape from a unique welding process. The results indicate a technology breakthrough in the design of lightweight and high fatique performance welded structures using high strength steels.

  1. TIG-dressing of high strength butt welded connection - Part 2: physical testing and modelling

    NARCIS (Netherlands)

    Es, S.H.J. van; Kolstein, M.H.; Pijpers, R.J.M.; Bijlaard, F.S.K.

    2013-01-01

    Weld improvement techniques are aimed at reducing the notch effects of welds and generally focus on two aspects: a change of geometry of the weld toe and a change of the weld residual stresses. In this paper, fatigue tests are discussed, performed on butt welded specimens in steel grades ranging

  2. Experimental determination of residual stress by neutron diffraction in a boiling water reactor core shroud

    International Nuclear Information System (INIS)

    Payzant, A.; Spooner, S.; Zhu, Xiaojing; Hubbard, C.R.

    1996-01-01

    Residual strains in a 51 mm (2-inch) thick 304L stainless steel plate have been measured by neutron diffraction and interpreted in terms of residual stress. The plate, measuring (300 mm) in area, was removed from a 6m (20-ft.) diameter unirradiated boiling water reactor core shroud, and included a multiple-pass horizontal weld which joined two of the cylindrical shells which comprise the core shroud. Residual stress mapping was undertaken in the heat affected zone, concentrating on the outside half of the plate thickness. Variations in residual stresses with location appeared consistent with trends expected from finite element calculations, considering that a large fraction of the residual hoop stress was released upon removal of the plate from the core shroud cylinder

  3. Residual stress in Ni-W electrodeposits

    DEFF Research Database (Denmark)

    Mizushima, Io; Tang, Peter Torben; Hansen, Hans Nørgaard

    2006-01-01

    In the present work, the residual stress in Ni–W layers electrodeposited from electrolytes based on NiSO4 and Na2WO4, is investigated. Citrate, glycine and triethanolamine were used as complexing agents, enabling complex formation between the nickel ion and tungstate. The results show that the type...... of complexing agent and the current efficiency have an influence on the residual stress. In all cases, an increase in tensile stress in the deposit with time after deposition was observed. Pulse plating could improve the stress level for the electrolyte containing equal amounts of citrate...

  4. Residual stress measurement at Budapest Neutron Center

    International Nuclear Information System (INIS)

    Gyula, T.

    2005-01-01

    The use of residual stress measurements of different construction element and recent possibilities of Budapest Neutron Centre are presented. The details investigated already: gas turbine wheel, axial compressor blade, turbine blade and plastically deformed stainless steel. We demonstrated the use of a neutron scattering (SANS, residual stress, diffraction) for the materials behavior investigation in order to analyze the processes going on under the different mechanical loading. The direction of possible instrumental development is presented. (author)

  5. Neutron diffraction measurements of residual stress for industrial application

    International Nuclear Information System (INIS)

    Minakawa, Nobuaki

    1999-01-01

    The neutron diffraction method is used to measure the inner strain distribution of material using the penetrating power of neutron as one of the effective use of the research reactor for the study and to evaluate a correct fatigue and a lifetime. Internal residual stress measurements have attracted great interest in material science where it is especially important to know the distribution of the internal stress when we estimated the strength of construction materials or processed goods for the industrial applications. This measurement can be applied to the study of hardening of processed goods, metal fatigue, strain of welding. Conventional techniques to measure strain such as strain gauge method, optical interference fringes method, X-ray diffraction method, Raman spectroscopic analysis method, and magnetostriction method, etc. can measure the strain only near the surface of materials. On the other hand, neutron diffractometer for residual stress analysis, RESA, installed at T2-1 port of JRR-3M enables us to study the internal stress non-destructively. (J.P.N.)

  6. Mapping residual and internal stress in materials by neutron diffraction

    International Nuclear Information System (INIS)

    Withers, Ph.J.

    2007-01-01

    Neutron diffraction provides one of the few means of mapping residual stresses deep within the bulk of materials and components. This article reviews the basic scientific methodology by which internal strains and stresses are inferred from recorded diffraction peaks. Both conventional angular scans and time-of-flight measurements are reviewed and compared. Their complementarity with analogous synchrotron X-ray methods is also highlighted. For measurements to be exploited in structural integrity calculations underpinning the safe operation of engineering components, measurement standards have been defined and the major findings are summarised. Examples are used to highlight the unique capabilities of the method showing how it can provide insights ranging from the basic physics of slip mechanisms in hexagonal polycrystalline materials, through the materials optimisation of stress induced transformations in smart nano-materials, to the industrial introduction of novel friction welding processes exploiting stress residual measurements transferred from prototype sub-scale tests to the joining of full-scale aero-engine assemblies. (author)

  7. Mapping residual and internal stress in materials by neutron diffraction

    Science.gov (United States)

    Withers, Philip J.

    2007-09-01

    Neutron diffraction provides one of the few means of mapping residual stresses deep within the bulk of materials and components. This article reviews the basic scientific methodology by which internal strains and stresses are inferred from recorded diffraction peaks. Both conventional angular scans and time-of-flight measurements are reviewed and compared. Their complementarity with analogous synchrotron X-ray methods is also highlighted. For measurements to be exploited in structural integrity calculations underpinning the safe operation of engineering components, measurement standards have been defined and the major findings are summarised. Examples are used to highlight the unique capabilities of the method showing how it can provide insights ranging from the basic physics of slip mechanisms in hexagonal polycrystalline materials, through the materials optimisation of stress induced transformations in smart nanomaterials, to the industrial introduction of novel friction welding processes exploiting stress residual measurements transferred from prototype sub-scale tests to the joining of full-scale aeroengine assemblies. To cite this article: P.J. Withers, C. R. Physique 8 (2007).

  8. Residual stresses in cold drawn ferritic rods

    International Nuclear Information System (INIS)

    Atienza, J.M.; Martinez-Perez, M.L.; Ruiz-Hervias, J.; Mompean, F.; Garcia-Hernandez, M.; Elices, M.

    2005-01-01

    The residual stress state generated by cold-drawing in a ferritic steel rod has been determined. Stress profiles in the three principal directions were measured by neutron and X-ray diffraction and calculated by 3D finite element simulation. The agreement between the simulations and the experimental data is excellent

  9. Real Structure and Resudal Stresses in Advanced Welds Determined by X-ray and Neutron Diffraction

    Czech Academy of Sciences Publication Activity Database

    Trojan, K.; Hervoches, Charles; Ganev, N.; Mikula, Pavol; Čapek, J.

    2017-01-01

    Roč. 9, SEP (2017), s. 32-38 E-ISSN 2336-5382 R&D Projects: GA MŠk LM2015056; GA ČR GB14-36566G Institutional support: RVO:61389005 Keywords : laser and MAG welding * residual stresses * X-ray diffraction * neutron diffraction Subject RIV: BM - Solid Matter Physics ; Magnetism OBOR OECD: Condensed matter physics (including formerly solid state physics, supercond.) https://ojs.cvut.cz/ojs/index.php/APP/article/view/4401/4298

  10. Half bead welding technique

    International Nuclear Information System (INIS)

    Canonico, D.A.; Holz, P.P.

    1978-05-01

    The ORNL has employed the Section XI half-bead procedure for six repair welds. Table 2 identifies the repairs and the components upon which they were accomplished. The weld repairs were performed to permit us to evaluate material properties, residual stresses, weld repair procedures, and structural behavior of repaired pressure vessels. As a consequence of our study we concluded that when the half bead procedure is correctly applied: (1) there is no metallurgical degradation of the base material, (2) residual stresses of yield point magnitude will be present, and (3) the structural integrity of the pressure vessel is not impaired at Charpy V-notch upper shelf temperatures

  11. Application of secondary and residual stresses to the assessment of the structural integrity of nuclear power-generating plant

    International Nuclear Information System (INIS)

    Banahan, B.D.

    2008-01-01

    Magnox nuclear power stations were built in the 1960s to design codes that, in general, required weldments to be subject to a post-weld heat treatment to remove residual stresses. Implicit in this was the assumption that the heat treatment reduced the stresses significantly such that as stated in the codes 'stresses caused by fabrication and welding are practically annulled'. However, it has since been realised that the stresses remaining, although small, could still be significant when incorporated into the subsequently developed failure avoidance methodologies such as R6. Moreover, either at the time of construction or during the operating life, repairs are undertaken to remove manufacturing or service-induced defects. These repairs can be put into service with or without a post-weld heat treatment. As a consequence of a paucity of data for the two- and three-dimensional distribution of the magnitude of these stresses, extremely conservative values of stresses have been adopted to ensure that the plant is secure against the design intent throughout the service life. In this paper, the requirements of the failure-avoidance methodology R6 Revision 4 are briefly reviewed with respect to the categorisation of secondary and residual stresses and the application of the three approaches for determining the as-welded residual stress distribution at room temperature. These three levels comprise, Level 1, simple estimates, Level 2, bounding profiles, and Level 3, detailed evaluation. Examples are presented where knowledge of the residual stresses has been an important component of the overall integrity assessment. The first relates to multi-pass weldments in superheater headers fabricated from a ferritic steel and the second to the weldments in the standpipes, both at Magnox power stations with concrete pressure vessels. Although in these cases the weldments had been subject to a post-weld heat treatment, the remaining residual stresses presented a significant challenge to

  12. Residual stress measurement on propellant tank of 2219 aluminum alloy and study on its weak spot

    Energy Technology Data Exchange (ETDEWEB)

    Huang, Chaoqun; Li, Huan; Li, Jianxiong; Luo, Chuanguang; Ni, Yanbing [Tianjin University, Tianjin (China)

    2017-05-15

    This paper presented residual stress measurement on two circumferential Variable polarity plasma arc welding (VPPAW) joints and one circular closed Friction stir welding (FSW) joint on the propellant tank of 2219 aluminum alloy using the indentation strain-gauge method. Quite large tensile residual stresses were attached to the center and inner areas of the circular closed FSW joint. There were very large tensile stresses in some points of the two circumferential VPPAW joints, among these points, the maximum value was +253 MPa, which was about 63 % of the yield strength of 410 MPa measured in the base material. In addition, the peak of compressive residual stress was about -160 MPa. Above all, there were two typical peaks of residual stress in the circumferential VPPAW joints, one was located in the middle part while the other one was near the start/end position of the joints. Combining the result of residual stress measurement with the characteristics of the tank structure, it can be concluded that circular closed FSW joint around the flange was a weak spot on the propellant tank. And the most vulnerable point on the circular closed FSW joint has also been found.

  13. Residual stress evaluation by neutron diffraction. Some industrial applications and perspectives

    International Nuclear Information System (INIS)

    Rogante, M.

    2001-01-01

    Materials and components of technological and industrial interest can present Residual Stresses (RS), that can be generated during the manufacturing process - e. g. extruding, welding, and forging -, or as a consequence of plastic deformations or thermal treatments. When RS add to external loads, they can enhance fatigue processes, earlier inducing failure of the component. Examples of RS determination in industrial applications are reported: the one focuses on AA 6082 alloy extruded samples, the other on a 2,25Cr1Mo ferritic steel welded pipe after thermal treatment. Other examples are shown, successively, concerning particular industrial problems which need to be studied also by adopting the same technique. (R.P.)

  14. Numerical investigation on stress corrosion cracking behavior of dissimilar weld joints in pressurized water reactor plants

    Directory of Open Access Journals (Sweden)

    Lingyan Zhao

    2014-07-01

    Full Text Available There have been incidents recently where stress corrosion cracking (SCC observed in the dissimilar metal weld (DMW joints connecting the reactor pressure vessel (RPV nozzle with the hot leg pipe. Due to the complex microstructure and mechanical heterogeneity in the weld region, dissimilar metal weld joints are more susceptible to SCC than the bulk steels in the simulated high temperature water environment of pressurized water reactor (PWR. Tensile residual stress (RS, in addition to operating loads, has a great contribution to SCC crack growth. Limited experimental conditions, varied influence factors and diverging experimental data make it difficult to accurately predict the SCC behavior of DMW joints with complex geometry, material configuration, operating loads and crack shape. Based on the film slip/dissolution oxidation model and elastic-plastic finite element method (EPFEM, an approach is developed to quantitatively predict the SCC growth rate of a RPV outlet nozzle DMW joint. Moreover, this approach is expected to be a pre-analytical tool for SCC experiment of DMW joints in PWR primary water environment.

  15. Methods of measuring residual stresses in components

    International Nuclear Information System (INIS)

    Rossini, N.S.; Dassisti, M.; Benyounis, K.Y.; Olabi, A.G.

    2012-01-01

    Highlights: ► Defining the different methods of measuring residual stresses in manufactured components. ► Comprehensive study on the hole drilling, neutron diffraction and other techniques. ► Evaluating advantage and disadvantage of each method. ► Advising the reader with the appropriate method to use. -- Abstract: Residual stresses occur in many manufactured structures and components. Large number of investigations have been carried out to study this phenomenon and its effect on the mechanical characteristics of these components. Over the years, different methods have been developed to measure residual stress for different types of components in order to obtain reliable assessment. The various specific methods have evolved over several decades and their practical applications have greatly benefited from the development of complementary technologies, notably in material cutting, full-field deformation measurement techniques, numerical methods and computing power. These complementary technologies have stimulated advances not only in measurement accuracy and reliability, but also in range of application; much greater detail in residual stresses measurement is now available. This paper aims to classify the different residual stresses measurement methods and to provide an overview of some of the recent advances in this area to help researchers on selecting their techniques among destructive, semi destructive and non-destructive techniques depends on their application and the availabilities of those techniques. For each method scope, physical limitation, advantages and disadvantages are summarized. In the end this paper indicates some promising directions for future developments.

  16. Residual stresses of water-jet peened austenitic stainless steel

    International Nuclear Information System (INIS)

    Suzuki, Kenji; Shobu, Takahisa; Shiro, Ayumi

    2013-01-01

    The specimen material was austenitic stainless steel, SUS316L. The residual stress was induced by water-jet peening. The residual stress was measured using the 311 diffraction with conventional X-rays. The measured residual stress showed the equi-biaxial stress state. To investigate thermal stability of the residual stress, the specimen was aged thermally at 773K in air to 1000h. The residual stress kept the equi-biaxial stress state against the thermal aging. Lattice plane dependency of the residual stress induced by water-jet peening was evaluated using hard synchrotron X-rays. The residual stress measured by the soft lattice plane showed the equi-biaxial stress state, but the residual stress measured by the hard lattice plane did not. In addition, the distributions of the residual stress in the depth direction were measured using a strain scanning method with hard synchrotron X-rays and neutrons. (author)

  17. Mechanically induced residual stresses: Modelling and characterisation

    Science.gov (United States)

    Stranart, Jean-Claude E.

    Accurate characterisation of residual stress represents a major challenge to the engineering community. This is because it is difficult to validate the measurement and the accuracy is doubtful. It is with this in mind that the current research program concerning the characterisation of mechanically induced residual stresses was undertaken. Specifically, the cold expansion of fastener holes and the shot peening treatment of aerospace alloys, aluminium 7075 and titanium Ti-6Al-4V, are considered. The objective of this study is to characterise residual stresses resulting from cold working using three powerful techniques. These are: (i) theoretical using three dimensional non-linear finite element modelling, (ii) semi-destructive using a modified incremental hole drilling technique and (iii) nondestructive using a newly developed guided wave method supplemented by traditional C-scan measurements. The three dimensional finite element results of both simultaneous and sequential cold expansion of two fastener holes revealed the importance of the separation distance, the expansion level and the loading history upon the development and growth of the plastic zone and unloading residual stresses. It further showed that the commonly adopted two dimensional finite element models are inaccurate and incapable of predicting these residual stresses. Similarly, the dynamic elasto-plastic finite element studies of shot peening showed that the depth of the compressed layer, surface and sub-surface residual stresses are significantly influenced by the shot characteristics. Furthermore, the results reveal that the separation distance between two simultaneously impacting shots governs the plastic zone development and its growth. In the semi-destructive incremental hole drilling technique, the accuracy of the newly developed calibration coefficients and measurement techniques were verified with a known stress field and the method was used to measure peening residual stresses. Unlike

  18. Development and Applications of Residual Stress Measurements Using Neutron Beams

    International Nuclear Information System (INIS)

    2014-01-01

    The deep penetration and selective absorption of neutrons make them a powerful tool for the non-destructive testing of large samples of material or large objects. Residual stress that is formed in a material during manufacturing, welding, utilization or repair can be measured by means of neutron diffraction. In fact, neutron diffraction is the only non-destructive testing method which can facilitate three dimensional mapping of residual stress in a bulk component. Stress measurement using neutron beams is a technique that enables this kind of high quality non-destructive investigation, and provides insight into the material strain and stress state deep within engineering components and structures under various conditions representative of those which might be experienced in service. Such studies are of importance to improve the quality of industrial components in production and to optimize design criteria in applications. Anisotropies in macroscopic properties such as thermal and electrical conductivities, for instance of fuel elements, and mechanical properties of materials depend on the textures developed during their preparation or thermal treatment. Such textures also can be studied using neutron diffraction techniques. There is currently substantial scientific and industrial demand for high quality non-destructive residual stress measurements, and the continuing competitive drive to optimize performance and minimize weight in many applications indicates that this demand will continue to grow. As such, the neutron diffraction technique is an increasingly important tool for mechanical and materials engineering in the search for improved manufacturing processes to reduce stress and distortion. Considering this trend, and in accordance with its purpose of promoting the peaceful use of nuclear applications, in 2006-2009 the IAEA organized a Coordinated Research Project on the Development and Application of the Techniques of Residual Stress Measurements in Materials

  19. Neutron diffraction study of residual strains across electron beam welds in AISI 316L stainless steel

    International Nuclear Information System (INIS)

    Braham, C.; Ceretti, M.; Coppola, R.; Lodini, A.; Rustichelli, F.; Tosto, S.

    1995-01-01

    The results of neutron diffraction investigation of the strains produced across an electron-beam (EB) weld in SA AISI 316L reference steel for NET are presented. The sample size was 10 x 5 x 3 cm 3 and the measurements have been carried out at different distances from the weld plane with a spatial resolution of approximately 8 mm 3 in the bulk of the material. Grain size and crystallographic texture effects were investigated, on the same sample, by means of X-ray diffraction and metallography. A method to determine the stress field from the neutron diffraction data even in the presence of strong texture is discussed. (orig.)

  20. Residual stress measurement by neutron diffraction

    International Nuclear Information System (INIS)

    Akita, Koichi; Suzuki, Hiroshi

    2010-01-01

    Neutron diffraction method has great advantages, allowing us to determine the residual stress deep present within the bulk materials and components nondestructively. Therefore, the method has been applied to confirm the structural integrity of the actual mechanical components and structures and to improve the manufacturing process and strength reliability of the products. This article reviews the residual stress measurement methodology of neutron diffraction. It also refers to the appropriate treatments of diffraction plane, stress-free lattice spacing, coarse grain and surface error to obtain reliable results. Finally, a few applications are introduced to show the capabilities of the neutron stress measurement method for the studies on the strength and elasto-plastic behaviors of crystalline materials. (author)

  1. Residual stress in ceramics and ceramic composites

    International Nuclear Information System (INIS)

    Oden, M.

    1992-01-01

    Residual stresses in Si 3 N 4 and SiC have been measured with X-ray diffraction after grinding and thermal shock. The produced surface stresses are compressive after both treatments. The stresses show a strong dependence on the quenching temperature up to a certain temperature when cracks relax the stresses. The influence of the amount of reinforcing phase on the residual stress state in a Al 2 O 3 /SiC whisker composite was investigated and correlated to a modified Eshelby model. The agreement is excellent. The composite was quenched in liquid He (4K) and the stress state measured after show no relaxation of stresses, indicating elastic behaviour. An in situ strain measurement as a function of temperature conducted on a Al 2 O 3 /SiC whisker composite and a SiC/TiB 2 particle composite show very good agreement with the Eshelby model for the Al 2 O 3 /SiC system but not agreement for the SiC/TiB 2 system. The reason is believed to be stress relaxation during sample preparation. (au) (53 refs., 24 figs., 14 tabs.)

  2. A countermeasure for external stress corrosion cracking in piping components by means of residual stress improvement on the outer surface

    International Nuclear Information System (INIS)

    Tanaka, Yasuhiro; Umemoto, Tadahiro

    1988-01-01

    Many techniques have been proposed as countermeasures for the External Stress Corrosion Cracking (ESCC) on austenitic stainless steel piping caused by sea salt particles. However, not one seems perfect. The method proposed here is an expansion of IHSI (Induction Heating Stress Improvement) which has been successfully implemented in many nuclear power plants as a remedy for Intergranular Stress Corrossion Cracking. The proposed method named EIHSI (External IHSI) can make the residual stress compressive on the outer surface of the piping components. In order to confirm the effectiveness of EIHSI, one series of tests were conducted on a weld joint between the pipe flange and the straight pipe. The measured residual stresses and also the results of the cracking test revealed that EIHSI is a superior method to suppress the ESCC. The outline of EIHSI and the verification tests are presented in this paper. (author)

  3. Improving Fatigue Performance of AHSS Welds

    Energy Technology Data Exchange (ETDEWEB)

    Feng, Zhili [ORNL; Yu, Xinghua [ORNL; ERDMAN III, DONALD L [ORNL; Wang, Yanli [ORNL; Kelly, Steve [ArcelorMittal USA; Hou, Wenkao [ArcelorMittal USA; Yan, Benda [ArcelorMittal USA; Wang, Zhifeng [Colorado School of Mines, Golden; Yu, Zhenzhen [Colorado School of Mines, Golden; Liu, Stephen [Colorado School of Mines, Golden

    2015-03-01

    Reported herein is technical progress on a U.S. Department of Energy CRADA project with industry cost-share aimed at developing the technical basis and demonstrate the viability of innovative in-situ weld residual stresses mitigation technology that can substantially improve the weld fatigue performance and durability of auto-body structures. The developed technology would be costeffective and practical in high-volume vehicle production environment. Enhancing weld fatigue performance would address a critical technology gap that impedes the widespread use of advanced high-strength steels (AHSS) and other lightweight materials for auto body structure light-weighting. This means that the automotive industry can take full advantage of the AHSS in strength, durability and crashworthiness without the concern of the relatively weak weld fatigue performance. The project comprises both technological innovations in weld residual stress mitigation and due-diligence residual stress measurement and fatigue performance evaluation. Two approaches were investigated. The first one was the use of low temperature phase transformation (LTPT) weld filler wire, and the second focused on novel thermo-mechanical stress management technique. Both technical approaches have resulted in considerable improvement in fatigue lives of welded joints made of high-strength steels. Synchrotron diffraction measurement confirmed the reduction of high tensile weld residual stresses by the two weld residual stress mitigation techniques.

  4. The reliability of untempered end plug welds on HT9-clad IFR fuel elements

    Energy Technology Data Exchange (ETDEWEB)

    Crawford, D C; Porter, D L

    1987-02-01

    Welding generally leaves residual stresses in transformed weld zones, which can initiate cracks from flaws already present in the weld zones. When HT9 cools from welding temperatures, a martensite phase forms in the weld fusion zone and heat-affected zone. Because this martensite phase is hard and brittle, it is particularly susceptible to cracking aggravated by residual stresses. This causes concern over the use of untempered welds on HT9-clad fuel elements. To determine if residual stresses present in end-plug weld zones would affect fuel pin performance, HT9 capsules with prototypic TIG- and CD-welded end plugs (in the tempered and as-welded conditions) were pressurized to failure at room temperature, 550{sup 0}C, and 600{sup 0}C. None of the capsules failed in a weld zone. To determine the effects of reactor operating temperatures on untempered welds, prototypic TIG welds were tempered at reactor bulk sodium temperature and an expected sodium outlet temperature for various lengths of time. Subsequent tensile and burst tests of these specimens proved that any embrittling effects that may have been induced in these welds were of no consequence. Hardness tests on longitudinal sections of welds indicated the amount of tempering a weld will receive inreactor after relatively short lengths of time. The pressure burst tests proved that untemperted welds on HT9-clad fuel elements are as reliable as tempered welds; any residual stresses in untempered weld zones were of no consequence. The tempering test showed that welds used in the as-welded condition will sufficiently temper in 7 days at 550{sup 0}C, but will not, sufficiently temper in 7 days at bulk sodium temperature. A comparison of the structure of laser welds to those of CD and TIG welds indicated that untempered laser welds will perform and temper in a manner similar to the TIG welds tested in this effort.

  5. Virtual Welded-Joint Design Integrating Advanced Materials and Processing Technologies

    Energy Technology Data Exchange (ETDEWEB)

    Yang, Z.; Dong, P.; Liu, S.; Babu, S.; Olson, G.; DebRoy, T.

    2005-04-15

    The primary goal of this project is to increase the fatigue life of a welded-joint by 10 times and to reduce energy use by 25% through product performance and productivity improvements using an integrated modeling approach. The fatigue strength of a welded-joint is currently the bottleneck to design high performance and lightweight welded structures using advanced materials such as high strength steels. In order to achieve high fatigue strength in a welded-joint it is necessary to manage the weld bead shape for lower stress concentration, produce preferable residual stress distribution, and obtain the desired microstructure for improved material toughness and strength. This is a systems challenge that requires the optimization of the welding process, the welding consumable, the base material, as well as the structure design. The concept of virtual welded-joint design has been proposed and established in this project. The goal of virtual welded-joint design is to develop a thorough procedure to predict the relationship of welding process, microstructure, property, residual stress, and the ultimate weld fatigue strength by a systematic modeling approach. The systematic approach combines five sub-models: weld thermal-fluid model, weld microstructure model, weld material property model, weld residual stress model, and weld fatigue model. The systematic approach is thus based on interdisciplinary applied sciences including heat transfer, computational fluid dynamics, materials science, engineering mechanics, and material fracture mechanics. The sub-models are based on existing models with further development. The results from modeling have been validated with critical experiments. The systematic modeling approach has been used to design high fatigue resistant welds considering the combined effects of weld bead geometry, residual stress, microstructure, and material property. In particular, a special welding wire has been developed in this project to introduce

  6. Residual stress measurements on steel using neutron high resolution powder diffractometer (HRPD)

    International Nuclear Information System (INIS)

    Inawati Tanto

    1996-01-01

    Stress analysis by neutron diffraction is based on the determination of lattice strains by precise measurements of the d spacing. Residual stress measurements were made on 0.7 mm of a rolled thin steel and on 1.65 mm of a galvanized flat steel. The neutron measurements in the vertical and horizontal directions were made in transmission and reflection geometry using HRPD on the Hifar Reactor at Lucas Heights, Australia. It can be concluded that the stress arise on the weld section of the galvanized flat steel was compression. On rolled thin steel stresses were measured at the rolled and unrolled section. Datas collected were not consistent with the expectations for example the horizontal rolled measurement was expected to show compressive residual stress, however the opposite was observed. (author), 4 refs, 2 tabs, 1 figs

  7. Estudo das tensões residuais em juntas soldadas de materiais dissimilares e determinação dos limites de resistência à fadiga dos metais de base Study of residual stress in welds of dissimilar material and determination of fatigue strength limits of base metals

    Directory of Open Access Journals (Sweden)

    Tanius Rodrigues Mansur

    2011-09-01

    in design, choice of manufacturing process, choice of consumables and obviously in the preservation and integrity of the equipment. This paper presents results achieved for the residual stresses in dissimilar welds and SNP curves relating tension with the number of cycles and the failure probability for four metals: electrolytic copper, austenitic AISI 304 and AISI 316L stainless steels and A36 carbon steel which were subsequently welded together.

  8. Residual stress measurements in laser clad repaired low pressure turbine blades for the power industry

    Energy Technology Data Exchange (ETDEWEB)

    Bendeich, P. [Australian Nuclear Science and Technology Organisation, Lucas Heights, Menai, NSW 2234 (Australia)]. E-mail: pbx@ansto.gov.au; Alam, N. [CSIRO Manufacturing Science and Technology, 32 Audley St., Woodville, SA 5011 (Australia); Brandt, M. [IRIS Swinburne University of Technology, 533-545 Burwood Rd., Hawthorne, Vic. 3122 (Australia); Carr, D. [Australian Nuclear Science and Technology Organisation, Lucas Heights, Menai, NSW 2234 (Australia); Short, K. [Australian Nuclear Science and Technology Organisation, Lucas Heights, Menai, NSW 2234 (Australia); Blevins, R. [Australian Nuclear Science and Technology Organisation, Lucas Heights, Menai, NSW 2234 (Australia); Curfs, C. [Australian Nuclear Science and Technology Organisation, Lucas Heights, Menai, NSW 2234 (Australia); Kirstein, O. [Australian Nuclear Science and Technology Organisation, Lucas Heights, Menai, NSW 2234 (Australia); Atkinson, G. [Australian Nuclear Science and Technology Organisation, Lucas Heights, Menai, NSW 2234 (Australia); Holden, T. [Northern Stress Technologies, 20, Pine Point Rd., Deep River, Ont., K0J 1P0 (Canada); Rogge, R. [National Research Council, Neutron Program for Materials Research, Chalk River Laboratories, Chalk River, Ont., KOJ 1JO (Canada)

    2006-11-10

    Low pressure turbine blades in power stations suffer from leading edge erosion damage due to water impingement. In an effort to extend the life of these blades, repair of the eroded regions has been proposed using laser cladding with Stellite material. However, the addition of Stellite results in residual stresses being generated in the parent metal due to contraction during cooling and differences in thermal expansion between the two materials. In this work test coupons and laser clad blades were examined for residual stresses using both the L3 diffractometer at the NRU reactor, Chalk River, Canada and the TASS strain scanner at ANSTO's HIFAR reactor, Lucas Heights, Australia. In addition XRD results were used to measure residual stresses on the surface of the blade to complement the neutron measurements. An FEA model of a simplified weld was used to explain some of the results.

  9. Residual Stress Induced by Nitriding and Nitrocarburizing

    DEFF Research Database (Denmark)

    Somers, Marcel A.J.

    2005-01-01

    The present chapter is devoted to the various mechanisms involved in the buildup and relief of residual stress in nitrided and nitrocarburized cases. The work presented is an overview of model studies on iron and iron-based alloys. Subdivision is made between the compound (or white) layer......, developing at the surfce and consisting of iron-based (carbo)nitrides, and the diffusion zone underneath, consisting of iron and alloying element nitrides dispersed in af ferritic matrix. Microstructural features are related directly to the origins of stress buildup and stres relief....

  10. Residual stress distribution in extruded polypropylene pipes

    Czech Academy of Sciences Publication Activity Database

    Poduška, Jan; Kučera, J.; Hutař, Pavel; Ševčík, Martin; Křivánek, J.; Sadílek, J.; Náhlík, Luboš

    2014-01-01

    Roč. 2014, č. 40 (2014), s. 88-98 ISSN 0142-9418 R&D Projects: GA ČR(CZ) GAP108/12/1560 Institutional support: RVO:68081723 Keywords : polypropylene * extruded polymer pipe * residual stress * curved beam methodology * numerical simulations Subject RIV: JL - Materials Fatigue, Friction Mechanics Impact factor: 2.240, year: 2014 http://www.sciencedirect.com/science/article/pii/S0142941814001809

  11. Effect of stress concentration on the fatigue strength of A7N01S-T5 welded joints

    Science.gov (United States)

    Zhang, Mingyue; Gou, Guoqing; Hang, Zongqiu; Chen, Hui

    2017-07-01

    Stress concentration is a key factor that affects the fatigue strength of welded joints. In this study, the fatigue strengths of butt joints with and without the weld reinforcement were tested to quantify the effect of stress concentration. The fatigue strength of the welded joints was measured with a high-frequency fatigue machine. The P-S-N curves were drawn under different confidence levels and failure probabilities. The results show that butt joints with the weld reinforcement have much lower fatigue strength than joints without the weld reinforcement. Therefore, stress concentration introduced by the weld reinforcement should be controlled.

  12. The effect of hardening laws and thermal softening on modeling residual stresses in FSW of aluminum alloy 2024-T3

    DEFF Research Database (Denmark)

    Sonne, Mads Rostgaard; Tutum, Cem Celal; Hattel, Jesper Henri

    2013-01-01

    In the present paper, a numerical model consisting of a heat transfer analysis based on the Thermal Pseudo Mechanical (TPM) model for heat generation, and a sequentially coupled quasi-static stress analysis with a built-in metallurgical softening model was implemented in ABAQUS. Both isotropic...... or kinematic hardening together with the metallurgical softening model were applied in order to give a first impression of the tendencies in residual stresses in friction stir welds when choosing different hardening and softening behaviors. Secondly, real friction stir butt welding of aluminum alloy 2024-T3...

  13. Characteristic and principle of the residual stress measurement by neutron diffraction method

    International Nuclear Information System (INIS)

    Akiniwa, Yoshiaki

    2016-01-01

    Although X-ray method has been widely used as the nondestructive measurement method of residual stress, the object to be measured with laboratory X-ray was limited to the vicinity of surface, and the nondestructive measurement of stress inside an essential component could not be performed. Since the neutron method utilizes the wave characteristics of electrically neutral particles, the penetrability is excellent so that information up to the inside of a material can be obtained sufficiently. As the feature of neutron stress measurement, it is suitable for measurement inside metals such as iron and aluminum, which cannot be measured with X-rays. For the measurement of residual stress in localized region, the use of high energy synchrotron radiation is advantageous. In the stress measurement utilizing diffraction phenomena, there is the strain calculated from a change in diffraction lattice spacing. The measured strain is converted into stress using Hooke's Law. As the measurement examples of neutron stress evaluation, the following are introduced: (1) residual stress distribution around the ferrite steel (50 mm thick) welded joint of a large-sized structure, (2) residual stress due to the heat treatment of aluminum alloy with a plate thickness of 20 to 140 mm, and (3) change in the strain of aluminum die block in the vicinity of a cast iron cylinder liner of engine, when heating/cooling up to 470degC. (A.O.)

  14. The method for measuring residual stress in stainless steel pipes

    International Nuclear Information System (INIS)

    Shimov, Georgy; Rozenbaum, Mikhail; Serebryakov, Alexandr; Serebryakov, Andrey

    2016-01-01

    The main reason of appearance and growth of corrosion damages of the nuclear steam generator heat exchanger tubes is the process of stress-corrosion cracking of metal under the influence of residual tensile stress. Methods used in the production for estimating residual stresses (such as a method of ring samples) allow measuring only the average tangential stress of the pipe wall. The method of ring samples does not allow to assess the level of residual stress in the surface layer of the pipe. This paper describes an experimental method for measuring the residual stresses on the pipe surface by etching a thin surface layer of the metal. The construction and working principle of a trial installation are described. The residual stresses in the wall of the tubes 16 × 1.5 mm (steel AISI 321) for nuclear steam generators is calculated. Keywords: heat exchange pipes, stress corrosion cracking, residual stresses, stress distribution, stress measurement.

  15. Experimental evaluation of residual stresses produced by plain dents in pipelines

    Energy Technology Data Exchange (ETDEWEB)

    Pascotto, Jorge [PETROBRAS Transporte S.A. (TRANSPETRO), Rio de Janeiro, RJ (Brazil); Marques, Altino; Fonseca, Maria Cindra [Universidade Federal Fluminense (UFF), Niteroi, RJ (Brazil)

    2009-07-01

    A dent means a permanent plastic deformation of the circular cross-section of the pipe. Dents are potentially danger for structural integrity of onshore and offshore pipelines, because it causes a local stress and strain concentration. It is also expected that residual stresses are introduced by the non-uniform plastic deformation. A plain dent is a dent which causes a smooth change in the curvature of the pipe wall that contains no wall thickness reductions (such as a gouge or a crack) or other defects or imperfections (such as a weld). This work presents an experimental evaluation of residual stresses intensification due to plain dents introduced through the same indentation process, in samples made of the same steel line pipe, commonly used in the pipeline industry. The residual stresses were measured in the longitudinal and circumferential directions in preselected points by X-ray diffraction technique, before indentation. After the samples have been dented, the residual stresses were measured once more at the same points, for comparison. All samples presented a similar behavior of the residual stresses due to induced plain dents, and the X-ray diffraction technique shows itself as an efficient methodology of stress measurement in pipelines. (author)

  16. Evaluations of stress concentration at girth butt weld joint between straight pipe and elbow

    International Nuclear Information System (INIS)

    Mizuno, S.

    1983-01-01

    The design of class 1 piping for nuclear plants is performed in accordance with the ASME B and PV Code Sec. Ill by rising stress index which have been defined at the center portion of elbow, since it has been generally believed that the highest stress will occur at this point. Consequently the stress evaluations at girth weld joint is riot recognized contrary to tire high stress concentration due to the weld irregularities. However, for LMFBR piping, especially under high temperature conditions the stress evaluations based on the index at the center portion of the elbow will not always provide conservative results from the piping design point of view, especially for fatigue, because it requires to evaluate the stress or strain range by multiplying the square of the stress or strain concentration factor. For thin wall and large diameter LMFBR piping the following four items provide significant effects on the stress and strain at the girth weld joint between straight pipe and elbow: stresses in weld joint due to ovalization of elbow, represented by 'carry over factor'; stress concentration due to weld Irregularities between straight pipe and elbow; gross structural discontinuity due to radial deflection caused by weld shrinkage at joint; increase of nominal stress due to decrease of nominal pipe wall thickness caused by counter bore machining. This report presents proposed design factors of above four items with the aim to use them in Monju FBR PHTS main piping and verify the structural integrity

  17. Thermomechanical conditions and stresses on the friction stir welding tool

    Science.gov (United States)

    Atthipalli, Gowtam

    Friction stir welding has been commercially used as a joining process for aluminum and other soft materials. However, the use of this process in joining of hard alloys is still developing primarily because of the lack of cost effective, long lasting tools. Here I have developed numerical models to understand the thermo mechanical conditions experienced by the FSW tool and to improve its reusability. A heat transfer and visco-plastic flow model is used to calculate the torque, and traverse force on the tool during FSW. The computed values of torque and traverse force are validated using the experimental results for FSW of AA7075, AA2524, AA6061 and Ti-6Al-4V alloys. The computed torque components are used to determine the optimum tool shoulder diameter based on the maximum use of torque and maximum grip of the tool on the plasticized workpiece material. The estimation of the optimum tool shoulder diameter for FSW of AA6061 and AA7075 was verified with experimental results. The computed values of traverse force and torque are used to calculate the maximum shear stress on the tool pin to determine the load bearing ability of the tool pin. The load bearing ability calculations are used to explain the failure of H13 steel tool during welding of AA7075 and commercially pure tungsten during welding of L80 steel. Artificial neural network (ANN) models are developed to predict the important FSW output parameters as function of selected input parameters. These ANN consider tool shoulder radius, pin radius, pin length, welding velocity, tool rotational speed and axial pressure as input parameters. The total torque, sliding torque, sticking torque, peak temperature, traverse force, maximum shear stress and bending stress are considered as the output for ANN models. These output parameters are selected since they define the thermomechanical conditions around the tool during FSW. The developed ANN models are used to understand the effect of various input parameters on the total

  18. Analysis of Factors Affecting Fractures of Rails Welded by Alumino-Thermic Welding

    OpenAIRE

    Sergejevs, D; Mihailovs, S

    2008-01-01

    On Latvian Railway, the use of the thermic welding is widespread using the ELECTRO-THERMIT Company technology. Today it is a basic method for rail joints. Experience of the operation of rails welded by the thermic welding showed that every year occur from 2 to 3 fractures of thermic joints on the main tracks between stations of Latvian Railway.Such emergence of cracks in the weld joint alongside the scores indicates of great residual stresses in the weld joints made by the thermic welding.

  19. Correlation of Stress Concentration Factors for T-Welded Connections – Finite Element Simulations and Fatigue Behavior

    Directory of Open Access Journals (Sweden)

    Gerardo Terán Méndez

    Full Text Available Abstract The stress concentration factors (SCFs in welded connections usually occur at zones with high stress levels. Stress concentrations reduce the fatigue behavior of welded connections in offshore structures and cracking can develop. By using the grinding technique, cracking can be eliminated. Stress concentration factors are defined as a ratio of maximum stress at the intersection to nominal stress on the brace. Defining the stress concentration factor is an important stage in the fatigue behavior of welded connections. Several approaches have evolved for designing structures with the classical S-N approach for estimating total life. This work correlates to the stress concentration factors of T-welded connections and the fatigue behavior. Stress concentration factors were computed with the finite element employing 3D T-welded connections with intact and grinding depth conditions. Then, T-welded connections were constructed with A36 plate steel and welded with E6013 electrodes to obtain the stress-life (S-N approach. The methodology from previous works was used to compute the SCF and fabricate the T-welded connections. The results indicated that the grinding process could restore the fatigue life of the T-welded connections for SCFs values in the range of 1.29. This value can be considered to be a low SCF value in T-welded connection. However, for higher SCF values, the fatigue life decreased, compromising and reducing the structural integrity of the T-welded connections.

  20. Three dimensional finite element analysis of weld overlay application on a plastically formed feeder tube

    Energy Technology Data Exchange (ETDEWEB)

    Ku, F.H.; Riccardella, P.C.; Lashley, M.S. [Structural Integrity Associates Inc., California (United States); Chen, Y. [Structural Integrity Associates, Inc., Ontario (Canada); Yee, R.K. [San Jose State Univ., California (United States)

    2010-07-01

    This paper presents a finite element analysis (FEA) model to predict the residual stresses in a tight-radius warm bend feeder tube in a CANDU nuclear reactor coolant system throughout the various stages of the manufacturing and welding processes, including feeder tube forming, Grayloc hub weld, and weld overlay application. The FEA employs 3-D elastic-plastic technology with large deformation capability to predict the residual stresses due to the feeder tube forming and various welding processes. The results demonstrate that the FEA method captures the residual stress trends resulted from warm bending and weld overlay with acceptable accuracy. (author)

  1. Effects of microstructure and local mechanical fields on intergranular stress corrosion cracking of a friction stir welded aluminum–copper–lithium 2050 nugget

    International Nuclear Information System (INIS)

    Dhondt, Matthieu; Aubert, Isabelle; Saintier, Nicolas; Olive, Jean Marc

    2014-01-01

    Highlights: • Applied stress changes the corrosion mode from pitting to intergranular cracking. • Residual stresses are sufficient to induce intergranular stress corrosion cracking. • Effect of crystallographic texture on the development of IGSCC evidenced by EBSD. • Cubic elasticity drives the local orientation of the intergranular cracking. • Tomography observations show the 3D nature of the corrosion development. - Abstract: The effects of the microstructure and mechanical fields on intergranular stress corrosion cracking (IGSCC) of the nugget zone of heat treated welds obtained by friction stir welding in the AA2050 aluminum alloy have been investigated at different scales. At low strain rate, in 1.0 NaCl aqueous solution, IGSCC develops in the microstructure, whereas only pitting corrosion is observed without any mechanical stress. Based on surface observations, EBSD analysis and X-ray tomography, the key role of sub-millimetric textured bands (induced by the welding process) on the IGSCC is demonstrated. Analyses at a more local scale show the grain boundary (low angle boundary, special coincident site lattice boundary or high angle boundary) do not have a significant effect on crack initiation. Crystal plasticity finite element calculations show that the threshold normal stress at grain boundaries for IGSCC development is about 80% of the macroscopic stress. It is also highlighted by crystal plasticity calculations that there is a drastic effect of the local stress field on the shape of cracks. Finally, it is shown that plasticity induced residual stresses are sufficient for the formation of IGSCC

  2. Modelling of the Residual Stress State in a new Type of Residual Stress Specimen

    DEFF Research Database (Denmark)

    Jakobsen, Johnny; Andreasen, Jens Henrik

    2014-01-01

    The paper presents a study on a new type residual stress specimen which is proposed as a simple way to conduct experimental validation for model predictions. A specimen comprising of a steel plate with circular hole embedded into a stack of CSM glass fibre and further infused with an epoxy resin...... forms the experimental case which is analysed. A FE model of the specimen is used for analysing the curing history and the residual stress build up. The model is validated against experimental strain data which are recorded by a Fibre Brag Grating sensor and good agreement has been achieved....

  3. Modelling of the Residual Stress State in a new Type of Residual Stress Specimen

    DEFF Research Database (Denmark)

    Jakobsen, Johnny; Andreasen, Jens Henrik

    2014-01-01

    forms the experimental case which is analysed. A FE model of the specimen is used for analysing the curing history and the residual stress build up. The model is validated against experimental strain data which are recorded by a Fibre Brag Grating sensor and good agreement has been achieved.......The paper presents a study on a new type residual stress specimen which is proposed as a simple way to conduct experimental validation for model predictions. A specimen comprising of a steel plate with circular hole embedded into a stack of CSM glass fibre and further infused with an epoxy resin...

  4. Welding Curriculum.

    Science.gov (United States)

    Alaska State Dept. of Education, Juneau. Div. of Adult and Vocational Education.

    This competency-based curriculum guide is a handbook for the development of welding trade programs. Based on a survey of Alaskan welding employers, it includes all competencies a student should acquire in such a welding program. The handbook stresses the importance of understanding the principles associated with the various elements of welding.…

  5. Minimization and Mitigation of Wire EDM Cutting Errors in the Application of the Contour Method of Residual Stress Measurement

    Science.gov (United States)

    Ahmad, Bilal; Fitzpatrick, Michael E.

    2016-01-01

    The contour method of residual stress measurement relies on the careful application of wire electro-discharge machining (WEDM) for the cutting stage. Changes in material removal rates during the cut lead to errors in the final calculated values of residual stress. In this study, WEDM cutting parameters have been explored to identify the optimum conditions for contour method residual stress measurements. The influence of machine parameters on the surface roughness and cutting artifacts in the contour cut is discussed. It has been identified that the critical parameter in improving the surface finish is the spark pulse duration. A typical cutting artifact and its impact on measured stress values have been identified and demonstrated for a contour cut in a welded marine steel. A procedure is presented to correct contour displacement data from the influence of WEDM cutting artifacts, and is demonstrated on the correction of a measured weld residual stress. The corrected contour method improved the residual stress magnitude up to 150 MPa. The corrected contour method results were validated by X-ray diffraction, incremental center hole drilling, and neutron diffraction.

  6. Laser Peening for Mitigation of Stress Corrosion Cracking at Welds in Marine Aluminum

    Science.gov (United States)

    2011-06-01

    and propagate in other alloys systems, such as austenitic Alloys 600, 800, and AISI type 304 stainless steel. Potential zones of susceptibility for...MITIGATION OF STRESS CORROSION CRACKING AT WELDS IN MARINE ALUMINUM by Heather R. Mattern June 2011 Thesis Advisor: Luke N. Brewer...REPORT TYPE AND DATES COVERED Master’s Thesis 4. TITLE AND SUBTITLE Laser Peening for Mitigation of Stress Corrosion Cracking at Welds in Marine

  7. Comparison of residual stress in martensitic alloys by nondestructive techniques

    International Nuclear Information System (INIS)

    Roy, A.K.; Bandyopadhyay, S.; Suresh, S.B.; Wells, D.

    2006-01-01

    Three martensitic materials, namely Alloys EP-823, HT-9 and 422 were subjected to tensile loading at ambient temperature. The cylindrical specimens tested at different levels of tensile loading were analyzed for characterization of residual stress resulting from plastic deformation corresponding to the applied loads between the yield strength and the ultimate tensile strength. The extent of residual stress developed at these applied stresses was analyzed by nondestructive positron annihilation spectroscopy, activation, and neutron diffraction techniques. The results indicate that the residual stresses characterized by all three techniques exhibited a consistent pattern showing a gradual enhancement in residual stress with increasing applied load

  8. Welding.

    Science.gov (United States)

    Cowan, Earl; And Others

    The curriculum guide for welding instruction contains 16 units presented in six sections. Each unit is divided into the following areas, each of which is color coded: terminal objectives, specific objectives, suggested activities, and instructional materials; information sheet; transparency masters; assignment sheet; test; and test answers. The…

  9. A study on the fatigue strength characteristics of ship structural steel with gusset welds

    Directory of Open Access Journals (Sweden)

    Sung-Jo Park

    2012-06-01

    Full Text Available This study aims to assess fatigue property by the static overload and average load in the fillet welded joints which is on the ship structural steel having gusset welds. To this end, a small specimen was made, to which the same welding condition for the actual ship structure was applied, to perform fatigue tests. In this study, a method to simply assess changes in welding residual stress according to different static overload was suggested. By measuring actual strain at the weld toe, the weld stress concentration factor and property which is determined by recrystallization in the process of welding were estimated to investigate the relation between overload and fatigue strength.

  10. Stress corrosion crack initiation of alloy 182 weld metal in primary coolant - Influence of chemical composition

    Energy Technology Data Exchange (ETDEWEB)

    Calonne, O.; Foucault, M.; Steltzlen, F. [AREVA (France); Amzallag, C. [EDF SEPTEN (France)

    2011-07-01

    Nickel-base alloys 182 and 82 have been used extensively for dissimilar metal welds. Typical applications are the J-groove welds of alloy 600 vessel head penetrations, pressurizer penetrations, heater sleeves and bottom mounted instrumented nozzles as well as some safe end butt welds. While the overall performance of these weld metals has been good, during the last decade, an increasing number of cases of stress corrosion cracking of Alloy 182 weld metal have been reported in PWRs. In this context, the role of weld defects has to be examined. Their contribution in the crack initiation mechanism requires laboratory investigations with small scale characterizations. In this study, the influence of both alloy composition and weld defects on PWSCC (Stress Corrosion Cracking in Primary Water) initiation was investigated using U-bend specimens in simulated primary water at 320 C. The main results are the following: -) the chemical compositions of the weld deposits leading to a large propensity to hot cracking are not the most susceptible to PWSCC initiation, -) macroscopically, superficial defects did not evolve during successive exposures. They can be included in large corrosion cracks but their role as 'precursors' is not yet established. (authors)

  11. Accelerated crack growth, residual stress, and a cracked zinc coated pressure shell

    Science.gov (United States)

    Dittman, Daniel L.; Hampton, Roy W.; Nelson, Howard G.

    1987-01-01

    During a partial inspection of a 42 year old, operating, pressurized wind tunnel at NASA-Ames Research Center, a surface connected defect 114 in. long having an indicated depth of a 0.7 in. was detected. The pressure shell, constructed of a medium carbon steel, contains approximately 10 miles of welds and is cooled by flowing water over its zinc coated external surface. Metallurgical and fractographic analysis showed that the actual detect was 1.7 in. deep, and originated from an area of lack of weld penetration. Crack growth studies were performed on the shell material in the laboratory under various loading rates, hold times, and R-ratios with a simulated shell environment. The combination of zinc, water with electrolyte, and steel formed an electrolytic cell which resulted in an increase in cyclic crack growth rate by as much as 500 times over that observed in air. It was concluded that slow crack growth occurred in the pressure shell by a combination of stress corrosion cracking due to the welding residual stress and corrosion fatigue due to the cyclic operating stress.

  12. Measurement of internal stresses in a welded assembly made of 20 MND 53 ferritic steel. Stress relaxation

    International Nuclear Information System (INIS)

    Baron, J.L.

    1981-05-01

    An assembly consisting of two flanged plates welded end to end was realized, the plates being made of 20 MND 53 ferritic steel. This grade of steel is used to fabricate PWR reactor vessels. At each important stage in the realization of the assembly, internal stresses were measured by X-ray diffraction techniques. These measurements showed that the finished realization manifested compression stresses in the main parts of its structure and large amplitude tensile stresses in the central weld seam. A heat treatment was performed (615 0 C - 17 hours). Stresses levels almost every where in the assembly dropped to practically zero. Although stress relaxation kinetics are probably slower in voluminous parts, this result and most of the results published in literature on this subject, indicate that such treatment notably diminishes internal welding stress even in thick parts [fr

  13. Application of X-rays and Synchrotron X Rays to Residual Stress Evaluation Near Surfaces

    International Nuclear Information System (INIS)

    Pyzalla, Anke

    1999-01-01

    A nondestructive residual stress analysis can be performed using diffraction methods. The easiest accessible radiation is characteristic X radiation that has a penetration depth of ∼10 microm suitable for the determination of the residual stresses in near-surface layers. Special techniques have been developed, e.g., with respect to in situ analyses of the stress state in oxide layers and the residual stress analysis in coarse grained zones of steel welds or annealed Ni-base alloys. Depending on the size of the gauge volume, neutron diffraction can provide information at depths of tens of millimetres of steel and many tens of millimetres of Al. An alternative to the use of the characteristic synchrotron radiation is the use of a high-energy polychromatic beam in an energy dispersive arrangement, which gives access to higher penetration depths at still gauge volumes as small as 100 microm x 100 microm x 1 mm in steel rods of 15-mm diameter. The combination of neutrons with conventional X rays and monochromatic and polychromatic synchrotron radiation allows for a comprehensive investigation of the phase composition, the texture, and the residual stresses

  14. Impact of the Weld Geometry on the Stress Intensity Factor of the Welded T-Joint Exposed to the Tensile Force and the Bending Moment

    Directory of Open Access Journals (Sweden)

    Djoković Jelena M.

    2015-12-01

    Full Text Available In this paper it is analyzed the welded T-joint exposed to the axial tensile force and the bending moment, for determining the impact of the weld geometry on the fracture mechanics parameters. The stress intensity factor was calculated analytically, based on the concept of the linear elastic fracture mechanics (LEFM, by application of the Mathematica® programming routine. The presence of the weld was taken into account through the corresponding correction factors. The results show that increase of the size of the triangular welds leads to decrease of the stress intensity factor, while the SIF increases with increase of the welds’ width. The ratio of the two welded plates’ thicknesses shows that plate thicknesses do not exhibit significant influence on the stress intensity factor behavior.

  15. Moire interferometry and hole drilling system for residual stress measurement

    Science.gov (United States)

    Ya, Min; Dai, Fulong; Lu, Jian

    2003-04-01

    A combined system of four beams moire interferometer and incremental hole-driling machine was designed and applied for residual stress measurement. Two typical experiments were done using this system: non-uniform in-depth residual stress measurement of an ultrasonic shot-peening Aluminum plate; non-uniform in-plane residual stress measurement of an elastic-plastic Aluminum bent beam. Experiments results show good accordant with other measurement results and theory analysis results.

  16. Residual stresses analysis by X-ray and neutrons diffraction

    International Nuclear Information System (INIS)

    Lodini, A.; Perrin, M.

    1996-04-01

    This conference is composed of 17 papers grouped in 13 chapters which main themes are: advantages of neutrons and synchrotron radiation for material characterization; residual stress evaluation from micro-deformation measurements in polycrystalline materials; X-ray and neutron diffractometry; residual stress evaluation by X-ray diffraction in extreme surfaces; residual stress diffraction evaluation in monocrystalline nickel base alloys, in polyphasic materials, composite materials, thin films, multilayers and joints; application to thermonuclear reactor components

  17. Modelling and Analysis of Phase Transformations and Stresses in Laser Welding Process / Modelowanie I Analiza Przemian Fazowych I Naprężeń W Procesie Spawania Laserowego

    Directory of Open Access Journals (Sweden)

    Piekarska W.

    2015-12-01

    Full Text Available The work concerns the numerical modelling of structural composition and stress state in steel elements welded by a laser beam. The temperature field in butt welded joint is obtained from the solution of heat transfer equation with convective term. The heat source model is developed. Latent heat of solid-liquid and liquid-gas transformations as well as latent heats of phase transformations in solid state are taken into account in the algorithm of thermal phenomena. The kinetics of phase transformations in the solid state and volume fractions of formed structures are determined using classical formulas as well as Continuous-Heating-Transformation (CHT diagram and Continuous-Cooling-Transformation (CCT diagram during welding. Models of phase transformations take into account the influence of thermal cycle parameters on the kinetics of phase transformations during welding. Temporary and residual stress is obtained on the basis of the solution of mechanical equilibrium equations in a rate form. Plastic strain is determined using non-isothermal plastic flow with isotropic reinforcement, obeying Huber-Misses plasticity condition. In addition to thermal and plastic strains, the model takes into account structural strain and transformation plasticity. Changing with temperature and structural composition thermophysical parameters are included into constitutive relations. Results of the prediction of structural composition and stress state in laser butt weld joint are presented.

  18. Analytical and Experimental Study of Residual Stresses in CFRP

    Directory of Open Access Journals (Sweden)

    Chia-Chin Chiang

    2013-01-01

    Full Text Available Fiber Bragg Grating sensors (FBGs have been utilized in various engineering and photoelectric fields because of their good environment tolerance. In this research, residual stresses of carbon fiber reinforced polymer composites (CFRP were studied using both experimental and analytical approach. The FBGs were embedded inside middle layers of CFRP to study the formation of residual stress during curing process. Finite element analysis was performed using ABAQUS software to simulate the CFRP curing process. Both experimental and simulation results showed that the residual stress appeared during cooling process and the residual stresses could be released when the CFRP was machined to a different shape.

  19. Analysis of Overlay Weld Effect on Preventing PWSCC in Dissimilar Metal Weld

    Energy Technology Data Exchange (ETDEWEB)

    Lee, Seung Gun; Oh, Chang Kyun; Park, Heung Bae; Jin, Tae Eun [Korea Power Engineering Company, Daejeon (Korea, Republic of)

    2010-01-15

    PWSCC(Primary Stress Corrosion Cracking) in Alloy 82/182 butt welds is the problem affecting safety and integrity of nuclear power plant. PWSCC can be occurred in the area that is at high magnitude of tensile residual stress, such as Alloy 82/182 dissimilar metal welds in PZR(pressurizer) nozzles. There have been a number of incidents recently at the dissimilar metal welds in overseas nuclear power plants. Overlay weld is the one of the effective methods to decrease tensile residual stress of inside surface, which will result in preventing PWSCC. In this paper, overlay weld conditions on the purpose of preventing PWSCC was explained and the benefit of the overlay weld was confirmed performing finite element analysis.

  20. Analysis of overlay weld effect on preventing PWSCC in dissimilar metal weld

    Energy Technology Data Exchange (ETDEWEB)

    Lee, Seung Gun; Oh, Chang Kyun; Jin, Tae Eun [Korea Power Engineering Co., Inc., Yongin (Korea, Republic of); Kim, Yong Tae [Korea Plant Service and Engineering Co., Ltd., Seongnam (Korea, Republic of); Yoo, Sung Soo [Korea Hydro and Nuclear Power Co., Ltd., Seoul (Korea, Republic of)

    2009-07-01

    PWSCC(Primary Stress Corrosion Cracking) in Alloy 82/182 butt welds is the problem affecting safety and integrity of nuclear power plant. PWSCC can be occurred in high magnitude of tensile residual stress, such as Alloy 82/182 dissimilar metal welds in Pressurizer(PZR) nozzles. There have been related incidents recently at the dissimilar metal welds in overseas nuclear power plants. Overlay weld is the one of the effective methods to decrease tensile residual stress of inside surface, which will result in preventing PWSCC. In this paper, overlay weld conditions on the purpose of preventing PWSCC was explained and the benefit of the overlay weld was confirmed performing finite element analysis.

  1. Investigation on the effects of geometric variables on the residual stresses and PWSCC growth in the RPV BMI penetration nozzles

    International Nuclear Information System (INIS)

    Kim, Jong Sung; Ra, Myoung Soo; Lee, Kyoung Soo

    2015-01-01

    This study investigated the effects of various geometric variables on the residual stresses and PWSCC growth of RPV BMI penetration nozzles. An FE residual stress analysis procedure was developed and validated from the viewpoint of FFS assessment. The validated FE residual stress analysis procedure and the PWSCC growth assessment procedure in the ASME B and PV Code, Sec.XI were applied to the BMI penetration nozzles with specified ranges of the geometric variables. The total stresses at steady state during normal operation including welding residual stresses increase with increasing inclination angle of the BMI nozzles, and with tilt angle, depth, and root width of the J-groove weld. The lifetime from the assumed initial crack to the acceptance criteria according to the ASME B and PV Code, Sec.XI also decreases under these conditions. The total stresses decrease and the lifetime increases with increasing nozzle thickness, but outer radius of the BMI nozzles has an insignificant effect on both of these factors.

  2. Assessment of Stress Corrosion Cracking Resistance of Activated Tungsten Inert Gas-Welded Duplex Stainless Steel Joints

    Science.gov (United States)

    Alwin, B.; Lakshminarayanan, A. K.; Vasudevan, M.; Vasantharaja, P.

    2017-12-01

    The stress corrosion cracking behavior of duplex stainless steel (DSS) weld joint largely depends on the ferrite-austenite phase microstructure balance. This phase balance is decided by the welding process used, heat input, welding conditions and the weld metal chemistry. In this investigation, the influence of activated tungsten inert gas (ATIG) and tungsten inert gas (TIG) welding processes on the stress corrosion cracking (SCC) resistance of DSS joints was evaluated and compared. Boiling magnesium chloride (45 wt.%) environment maintained at 155 °C was used. The microstructure and ferrite content of different weld zones are correlated with the outcome of sustained load, SCC test. Irrespective of the welding processes used, SCC resistance of weld joints was inferior to that of the base metal. However, ATIG weld joint exhibited superior resistance to SCC than the TIG weld joint. The crack initiation and final failure were in the weld metal for the ATIG weld joint; they were in the heat-affected zone for the TIG weld joint.

  3. Residual Stress Analysis Based on Acoustic and Optical Methods

    Directory of Open Access Journals (Sweden)

    Sanichiro Yoshida

    2016-02-01

    Full Text Available Co-application of acoustoelasticity and optical interferometry to residual stress analysis is discussed. The underlying idea is to combine the advantages of both methods. Acoustoelasticity is capable of evaluating a residual stress absolutely but it is a single point measurement. Optical interferometry is able to measure deformation yielding two-dimensional, full-field data, but it is not suitable for absolute evaluation of residual stresses. By theoretically relating the deformation data to residual stresses, and calibrating it with absolute residual stress evaluated at a reference point, it is possible to measure residual stresses quantitatively, nondestructively and two-dimensionally. The feasibility of the idea has been tested with a butt-jointed dissimilar plate specimen. A steel plate 18.5 mm wide, 50 mm long and 3.37 mm thick is braze-jointed to a cemented carbide plate of the same dimension along the 18.5 mm-side. Acoustoelasticity evaluates the elastic modulus at reference points via acoustic velocity measurement. A tensile load is applied to the specimen at a constant pulling rate in a stress range substantially lower than the yield stress. Optical interferometry measures the resulting acceleration field. Based on the theory of harmonic oscillation, the acceleration field is correlated to compressive and tensile residual stresses qualitatively. The acoustic and optical results show reasonable agreement in the compressive and tensile residual stresses, indicating the feasibility of the idea.

  4. Steel research using neutron beam techniques. In-situ neutron diffraction, small-angle neutron scattering and residual stress analysis

    International Nuclear Information System (INIS)

    Sueyoshi, Hitoshi; Ishikawa, Nobuyuki; Yamada, Katsumi; Sato, Kaoru; Nakagaito, Tatsuya; Matsuda, Hiroshi; Arakaki, Yu; Tomota, Yo

    2014-01-01

    Recently, the neutron beam techniques have been applied for steel researches and industrial applications. In particular, the neutron diffraction is a powerful non-destructive method that can analyze phase transformation and residual stress inside the steel. The small-angle neutron scattering is also an effective method for the quantitative evaluation of microstructures inside the steel. In this study, in-situ neutron diffraction measurements during tensile test and heat treatment were conducted in order to investigate the deformation and transformation behaviors of TRIP steels. The small-angle neutron scattering measurements of TRIP steels were also conducted. Then, the neutron diffraction analysis was conducted on the high strength steel weld joint in order to investigate the effect of the residual stress distribution on the weld cracking. (author)

  5. Tensiones residuales en uniones soldadas por FSW en aluminio 7075-T651 Residual stresses in 7075-T651 FSW joint

    Directory of Open Access Journals (Sweden)

    Leonardo N. Tufaro

    2012-12-01

    the structural integrity of a component in service and usually have a major influence on their fatigue life, among other failure mechanisms. In recent years Friction-Stir Welding (FSW has revolutionized the welding technology. Its main application has been given in aluminum alloys, but nowadays can be applicable to different materials. One of the several advantages of this process is a lower level of residual stresses, because the thermal gradients introduced during welding are lower. Among aluminum alloys used for structural applications, 7XXX strain-aged series are usually employed in the aerospace industry, because of their high strength. The aim of this paper is to analyze the effect of welding speed of FSW on residual stresses in aluminum AA7075-T651 joints, using sectioning technique. Coupons were welded AA7075-T651 FSW of 150x150x4 mm by varying the welding speed between 51 and 206 mm.min-1. During the welding thermal cycles were acquired. Subsequently, longitudinal residual stresses measured at different distances from the weld, in each case. Based on the acquired thermal cycling thermal gradients were obtained in the measurement area. Maximum residual stresses ranged from 52 to 78 MPa, corresponding to a range of 10 and 15% of the yield strength. They increased with increasing welding speed, consistent with an increase in the thermal gradient observed. These residual stresses values are lower than those obtained for the welding of these materials by type GMAW processes.

  6. Study of post-weld heat treatment cracking of Nickel base super alloy (Udimet 520) in gas tungsten arc welding method

    International Nuclear Information System (INIS)

    Kokabi, A. H.; Nematzadeh, F.

    2003-01-01

    In this paper, the mechanism and the cause and the ways for eliminating the decrease of post-weld heat treatment cracking in welding of Nickel base super alloy (Udimet 520) in gas tungsten arc welding method has been studied. For this study, X-ray diffraction machine and quantometery has been used. Increasing of Al, Ti percentage and residual stress are the main causes of cracking post-weld heat treatment. The results from quantometery tests demonstrate that decreasing tendency to post-weld heat treatment cracking is due to the decrease of Al, Ti percentage of welding. Result of X-ray diffraction tests show the tendency toward increasing of post-weld heat treatment cracking for existing of strenghed residual stresses. Finally, it is illustrated that alloy welding Udimet 520 in Ti G method is not sensitive to post-weld heat treatment cracking

  7. Validations of Computational Weld Models: Comparison of Residual Stresses

    Science.gov (United States)

    2010-08-01

    valider la capacité du modèle informatique de calculer les contraintes résiduelles dans des structures réparées par ce type de soudage de rechargement...modèle informatique . Les mesures de la dureté de la plaque laissent supposer que cette propriété varie grandement dans l’espace, c.-à-d. qu’elle est

  8. Effect of Microstructure on Stress Corrosion Cracking Behaviour of High Nitrogen Stainless Steel Gas Tungsten Arc Welds

    Science.gov (United States)

    Mohammed, Raffi; Srinivasa Rao, K.; Madhusudhan Reddy, G.

    2018-03-01

    Present work is aimed to improve stress corrosion cracking resistance of high nitrogen steel and its welds. An attempt to weld high nitrogen steel of 5 mm thick plate using gas tungsten arc welding (GTAW) with three high strength age hardenable fillers i.e., 11-10 PH filler, PH 13- 8Mo and maraging grade of MDN 250 filler is made. Welds were characterized by optical microscopy and scanning electron microscopy. Vickers hardness testing of the welds was carried out to study the mechanical behaviour of welds. Potentio-dynamic polarization studies were done to determine pitting corrosion resistance in aerated 3.5% NaCl solution. Stress corrosion cracking (SCC) testing was carried out using constant load type machine with applied stress of 50% yield strength and in 45% MgCl2 solution boiling at 155°C. The results of the present investigation established that improvement in resistance to stress corrosion cracking was observed for PH 13- 8Mo GTA welds when compared to 11-10 PH and MDN 250 GTA welds. However, All GTA welds failed in the weld interface region. This may be attributed to relatively lower pitting potential in weld interface which acts as active site and the initiation source of pitting.

  9. Numerical investigation on the variation of welding stresses after material removal from a thick titanium alloy plate joined by electron beam welding

    International Nuclear Information System (INIS)

    Liu, Chuan; Zhang, Jianxun; Wu, Bing; Gong, Shuili

    2012-01-01

    Highlights: → After less materials removal from the top, stresses on the bottom remain unchanged. → The transverse stress within the weld decreases significantly with material removal. → Local material removal does not influence the longitudinal stress significantly. -- Abstract: The stress modification after material removal from a 50 mm thick titanium alloy plate jointed by electron beam welding (EBW) was investigated through the finite element method (FEM). The welding experiment and milling process were carried out to experimentally determine the stresses induced by EBW and their modification after local material removal. The modification of as-welded stresses due to the local material removal method and the whole layer removal method was discussed with the finite element analysis. Investigated results showed that with less materials removal from the top, the stresses on the bottom surface remain almost unchanged; after material removal from the top and bottom part, the transverse stress on the newly-formed surface decreases significantly as compared to the as-welded stresses at the same locations; however, the stress modification only occurs at the material removal region in the case of local region removal method; the longitudinal stress decreases with the whole layer removal method while remains almost unchanged with the local region removal method.

  10. Computer modeling of the stress-strain state of a linear friction welded disk

    Directory of Open Access Journals (Sweden)

    V. Bychkov

    2015-09-01

    Full Text Available The paper is dedicated to design issues of tooling for linear friction welding (LFW machine. Computer model of a LFW machine was built. As a result of computer simulation, the stress-strain state of the machine and disk module for linear friction welding of aluminum alloy blisks also was obtained. On the basis of the results of computer simulation a module with a replaceable unit and a new variant fixing of disc in the module were designed.

  11. Effect of applied stress on the compressive residual stress introduced by laser peening

    International Nuclear Information System (INIS)

    Sumiya, Rie; Tazawa, Toshiyuki; Narazaki, Chihiro; Saito, Toshiyuki; Kishimoto, Kikuo

    2016-01-01

    Peening is the process which is able to be generated compressive residual stress and is known to be effective for preventing SCC initiation and improvement of fatigue strength. Laser peening is used for the nuclear power plant components in order to prevent SCC initiation. Although it is reported that the compressive residual stress decreases due to applied stresses under general operating condition, the change of residual stress might be large under excessive loading such as an earthquake. The objectives of this study are to evaluate the relaxation behavior of the compressive residual stress due to laser peening and to confirm the surface residual stress after loading. Therefore laser peened round bar test specimens of SUS316L which is used for the reactor internals of nuclear power plant were loaded at room temperature and elevated temperature and then surface residual stresses were measured by X-ray diffraction method. In the results of this test, it was confirmed that the compressive residual stress remained after applying uniform stress larger than 0.2% proof stress, and the effect of cyclic loading on the residual stress was small. The effect of applying compressive stress on the residual stress relaxation was confirmed to be less than that of applying tensile stress. Plastic deformation through a whole cross section causes the change in the residual stress distribution. As a result, the surface compressive residual stress is released. It was shown that the effect of specimen size on residual stress relaxation and the residual stress relaxation behavior in the stress concentration region can be explained by assumed stress relaxation mechanism. (author)

  12. Vibration stress relief treatment in welded samples of ST-3 steel

    International Nuclear Information System (INIS)

    Suarez, J.C.; Fernandez, L.M.; Echevarria, J.F.; Estevez, A.; Perez, A.; Aragon, B.

    1996-01-01

    The presented work is aimed to find the optimal vibration frequency and treatment duration for ST-3 steel welded test pieces. In the experiment transversal stresses were not virtually relieved by the application of vibrations at the three natural frecuencies. With regard to the optimal frequency for our system, the firths natural frequency appears to be most effective one, wherewith a maximum 35-70 % longitudinal stress relief was obtained. The influence of the propagation direction (transversal or longitudinal) of vibrations on stress relief in a welded joint was confirmed

  13. Simulation of Residual Stresses at Holes in Tempered Glass

    DEFF Research Database (Denmark)

    Nielsen, Jens Henrik; Olesen, John Forbes; Poulsen, Peter Noe

    2010-01-01

    This work presents a full 3D numerical study of the residual stresses in tempered (toughened) glass near holes using Narayanaswamy’s model for the tempering process. It is the objective of the paper to elucidate the influence on the minimal residual compressive stresses at holes from variations in...

  14. Frontline and future of residual stress measurement by neutron diffraction

    International Nuclear Information System (INIS)

    Hayashi, Makoto

    2007-01-01

    Neutron diffraction method is very much effective for measurements of residual stress and texture. In this paper the present techniques for measurements of residual stress and texture are reviewed and plans of improvement of RESA in JRR-3 and Ibaraki Prefecture's Material Design Diffractometer to be installed in J-PARC are introduced. (author)

  15. Stress corrosion cracking tests on electron beam welded carbon steel specimens in carbonate-bicarbonate solution

    International Nuclear Information System (INIS)

    Parkins, R.N.

    1985-04-01

    Stress corrosion cracking tests have been performed on tapered carbon steel test pieces containing electron beam welds with a view to defining susceptibility to such cracking in a carbonate-bicarbonate solution at 90 C and an appropriate electrode potential. The tests involved applying cyclic loads to the specimens and it is shown that the threshold stress for cracking reduces linearly with increase in the magnitude of the cyclic load component. Extrapolation of these trends to zero fluctuating stress indicates static load threshold stresses in the vicinity of the yield stress (i.e. about 300 N/mm 2 for parent plate without a weld, 400 N/mm 2 for specimens with welds on one side only and 600 N/mm 2 for specimens having welds penetrating through the thickness of the specimen). The averages of the maximum crack velocities observed were least for parent plate material and greatest for weld metal, the former being essentially intergranular in morphology and the latter mostly transgranular, with heat affected zone material being intermediate between these extremes. (author)

  16. Effect of residual stresses on hydrogen permeation in iron

    International Nuclear Information System (INIS)

    Mouanga, M.; Bercot, P.; Takadoum, J.

    2010-01-01

    The effect of residual stresses on electrochemical permeation in iron membrane was investigated. Four thermal and mechanical treatments were chosen to obtain different surface states in relation to the residual stresses. Residual stresses were determined by X-ray diffraction (XRD) using the Macherauch and Mueller method. The results were completed by the microhardness measurements. For all iron membranes, compressive residual stresses were obtained. Electrochemical permeation experiments using a Devanathan and Stachurski cell were employed to determine the hydrogen permeation behaviour of the various iron membranes. The latter was charged with hydrogen by galvanostatic cathodic polarization in 0.1 M NaOH at 25 deg. C. The experimental results revealed that hydrogen permeation rate increases with increasing residual stresses introduced in iron membranes.

  17. Experience with the Notch Stress Approach for Fatigue Assessment of Welded Joints

    DEFF Research Database (Denmark)

    Pedersen, Mikkel Melters; Mouritsen, Ole Ø.; Hansen, Michael Rygaard

    2010-01-01

    In this paper, fatigue assessment using the notch stress approach is discussed based on re-analysis of many fatigue test results and experience from practical application. Three topics are treated; evaluation of the fatigue strength for as-welded details (FAT225) in the notch stress system...

  18. Image Processing of Welding Procedure Specification and Pre-process program development for Finite Element Modelling

    International Nuclear Information System (INIS)

    Kim, K. S.; Lee, H. J.

    2009-11-01

    PRE-WELD program, which generates automatically the input file for the finite element analysis on the 2D butt welding at the dissimilar metal weld part, was developed. This program is pre-process program of the FEM code for analyzing the residual stress at the welding parts. Even if the users have not the detail knowledge for the FEM modelling, the users can make the ABAQUS INPUT easily by inputting the shape data of welding part, the weld current and voltage of welding parameters. By using PRE-WELD program, we can save the time and the effort greatly for preparing the ABAQUS INPUT for the residual stress analysis at the welding parts, and make the exact input without the human error

  19. Residual stresses in a composite steel tube measured by neutron diffraction

    International Nuclear Information System (INIS)

    Taran, Yu.V.; Balagurov, A.M.; Zlokazov, V.B.; Schreiber, J.; Stuhr, U.; Kockelmann, H.

    2006-01-01

    The triaxial residual stresses in a composite tube from an austenitic stainless steel with a welded ferritic steel cladding were measured by the time-of-flight neutron diffraction method on the POLDI instrument at the PSI SINQ facility. The POLDI results are compared to the results obtained by the destructive turning out method and theoretical predictions of calculations by the finite element method. Only for the tangential component of the stress tensor the semiquantitative agreement of all used methods was observed. There is a clear discrepancy between the results of the different methods in the axial component. For the radial component all methods reveal quite small stresses, however, with some distinct differences in their distributions

  20. Improving fatigue performance of rail thermite welds

    Directory of Open Access Journals (Sweden)

    Winiar L.

    2010-06-01

    Full Text Available Rail transport development offers economic and ecological interests. Nevertheless, it requires heavy investments in rolling material and infrastructure. To be competitive, this transportation means must rely on safe and reliable infrastructure, which requires optimization of all implemented techniques and structure. Rail thermite (or aluminothermic welding is widely used within the railway industry for in-track welding during re-rail and defect replacement. The process provides numerous advantages against other welding technology commonly used. Obviously, future demands on train traffic are heavier axle loads, higher train speeds and increased traffic density. Thus, a new enhanced weld should be developed to prevent accidents due to fracture of welds and to lower maintenance costs. In order to improve such assembly process, a detailed metallurgical study coupled to a thermomechanical modelling of the phenomena involved in the thermite welding process is carried out. Obtained data enables us to develop a new improved thermite weld (type A. This joint is made by modifying the routinely specified procedure (type B used in a railway rail by a standard gap alumino-thermic weld. Joints of type A and B are tested and compared. Based on experimental temperature measurements, a finite element analysis is used to calculate the thermal residual stresses induced. In the vicinity of the weld, the residual stress patterns depend on the thermal conditions during welding as it also shown by litterature [1, 2]. In parallel, X-Ray diffraction has been used to map the residual stress field that is generated in welded rail of types A and B. Their effect on fatigue crack growth in rail welds is studied. An experimental study based on fatigue tests of rails welded by conventional and improved processes adjudicates on the new advances and results will be shown.

  1. Improving fatigue performance of rail thermite welds

    Science.gov (United States)

    Jezzini-Aouad, M.; Flahaut, P.; Hariri, S.; Winiar, L.

    2010-06-01

    Rail transport development offers economic and ecological interests. Nevertheless, it requires heavy investments in rolling material and infrastructure. To be competitive, this transportation means must rely on safe and reliable infrastructure, which requires optimization of all implemented techniques and structure. Rail thermite (or aluminothermic) welding is widely used within the railway industry for in-track welding during re-rail and defect replacement. The process provides numerous advantages against other welding technology commonly used. Obviously, future demands on train traffic are heavier axle loads, higher train speeds and increased traffic density. Thus, a new enhanced weld should be developed to prevent accidents due to fracture of welds and to lower maintenance costs. In order to improve such assembly process, a detailed metallurgical study coupled to a thermomechanical modelling of the phenomena involved in the thermite welding process is carried out. Obtained data enables us to develop a new improved thermite weld (type A). This joint is made by modifying the routinely specified procedure (type B) used in a railway rail by a standard gap alumino-thermic weld. Joints of type A and B are tested and compared. Based on experimental temperature measurements, a finite element analysis is used to calculate the thermal residual stresses induced. In the vicinity of the weld, the residual stress patterns depend on the thermal conditions during welding as it also shown by litterature [1, 2]. In parallel, X-Ray diffraction has been used to map the residual stress field that is generated in welded rail of types A and B. Their effect on fatigue crack growth in rail welds is studied. An experimental study based on fatigue tests of rails welded by conventional and improved processes adjudicates on the new advances and results will be shown.

  2. Behavior of a crack within a Dissimilar Metal Weld Part by using an Overlay Weld

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Kang Soo; Lee, Ho Jin; Lee, Bong Sang [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

    2009-05-15

    In recent years, the dissimilar metal welds, Alloy 82/182 welds, used to connect the stainless steel piping and low alloy steel or carbon steel components in a nuclear reactor piping system have experienced a cracking due to a primary water stress corrosion (PWSCC).It is well known that one reason for the cracking is the residual stress by the weld. But, it is difficult to estimate the weld residual stress exactly due to the many parameters for the welding process. In this paper, a Butt model weld specimen was manufactured and the residual stresses of the weld specimen were measured by the X-Ray method and a Hole Drilling Technique. These results were compared with the results of the Butt FEM Model to confirm the confidence of the FEM input. Also, an analysis of the Crack FEM models made by the ABAQUS Code was performed to estimate the behavior of a crack within a Dissimilar Metal Weld Part (DMWP) when an overlay weld on the DMWP was done.

  3. Yield strength mapping in the cross section of ERW pipes considering kinematic hardening and residual stress

    Science.gov (United States)

    Kim, Dongwook; Quagliato, Luca; Lee, Wontaek; Kim, Naksoo

    2017-09-01

    In the ERW (electric resistance welding) pipe manufacturing, material properties, process conditions and settings strongly influences the mechanical performances of the final product, as well as they can make them to be not uniform and to change from point to point in the pipe. The present research work proposes an integrated numerical model for the study of the whole ERW process, considering roll forming, welding and sizing stations, allowing to infer the influence of the process parameters on the final quality of the pipe, in terms of final shape and residual stress. The developed numerical model has been initially validated comparing the dimensions of the pipe derived from the simulation results with those of industrial production, proving the reliability of the approach. Afterwards, by varying the process parameters in the numerical simulation, namely the roll speed, the sizing ratio and the friction factor, the influence on the residual stress in the pipe, at the end of the process and after each station, is studied and discussed along the paper.

  4. Re-analysis of fatigue data for welded joints using the notch stress approach

    DEFF Research Database (Denmark)

    Pedersen, Mikkel Melters; Mouritsen, Ole Ø.; Hansen, Michael Rygaard

    2010-01-01

    Experimental fatigue data for welded joints have been collected and subjected to re-analysis using the notch stress approach according to IIW recommendations. This leads to an overview regarding the reliability of the approach, based on a large number of results (767 specimens). Evidently, there ......-welded joints agree quite well with the FAT 225 curve; however a reduction to FAT 200 is suggested in order to achieve approximately the same safety as observed in the nominal stress approach.......Experimental fatigue data for welded joints have been collected and subjected to re-analysis using the notch stress approach according to IIW recommendations. This leads to an overview regarding the reliability of the approach, based on a large number of results (767 specimens). Evidently...

  5. Acoustic emission monitoring during welding

    International Nuclear Information System (INIS)

    Prine, D.W.

    1980-01-01

    Weld repair is a major cost item, particularly in the fabrication of heavy section weldments such as pressure vessels. A heavy section repair can frequently leave the weld with worse problems than the original flaw. These problems may include damage to weld microstructure as well as added residual stress. The removal of flaws through in-process repair can minimize these problems and certainly, the removal of one or two passes and their replacement with automatic welding procedure is considerably cheaper than a heavy section post weld repair. The major barrier to application of in-process repair is the lack of an effective in-process inspection procedure. In-process monitoring of Acoustic Emission shows great promise for providing this much needed tool. The successful application of acoustic emission to in-process weld monitoring requires that advanced signal processing and pattern recognition techniques be applied if the flaw related acoustic emission is to be separated from the overwhelming amount of background noise present in welding. GARD, INC. has studied the problem of applying in-process acoustic emission monitoring to weld inspection for over 9 years and has empirically developed AE signal processing techniques which allow typical weld flaws to be detected, located, and characterized. This paper discusses these techniques and describes a recent successful field test of a microcomputer based AE weld monitor in a nuclear fabrication plant. (author)

  6. Ceramic laminates with tailored residual stresses

    Directory of Open Access Journals (Sweden)

    Baudín, C.

    2009-12-01

    Full Text Available Severe environments imposed by new technologies demand new materials with better properties and ensured reliability. The intrinsic brittleness of ceramics has forced scientists to look for new materials and processing routes to improve the mechanical behaviour of ceramics in order to allow their use under severe thermomechanical conditions. The laminate approach has allowed the fabrication of a new family of composite materials with strength and reliability superior to those of monolithic ceramics with microstructures similar to those of the constituent layers. The different ceramic laminates developed since the middle 1970´s can be divided in two large groups depending on whether the development of residual stresses between layers is the main design tool. This paper reviews the developments in the control and tailoring of residual stresses in ceramic laminates. The tailoring of the thickness and location of layers in compression can lead to extremely performing structures in terms of strength values and reliability. External layers in compression lead to the strengthening of the structure. When relatively thin and highly compressed layers are located inside the material, threshold strength, crack bifurcation and crack arrest during fracture occur.

    Las severas condiciones de trabajo de las nuevas aplicaciones tecnológicas exigen el uso de materiales con mejores propiedades y alta fiabilidad. La potencialidad de uso de materiales frágiles, como los cerámicos, en estas aplicaciones exige el desarrollo de nuevos materiales y métodos de procesamiento que mejoren su comportamiento mecánico. El concepto de material laminado ha permitido la fabricación de una nueva familia de materiales con tensiones de fractura y fiabilidad superiores a las de materiales monolíticos con microestructuras similares a las de las láminas que conforman el laminado. Los distintos materiales laminados desarrollados desde mediados de los años 70 se pueden

  7. Measurement of through-thickness residual stress in T-butt weldments of offshore steel by high resolution neutron diffraction

    International Nuclear Information System (INIS)

    Allen, A.J.; Hutchings, M.T.; Rainey, V.S.

    1988-01-01

    The use of high resolution neutron diffraction to measure, nondestructively, the residual strain and hence the residual stress variation through the heat affected zone and into the plate beneath the toe of a T-butt is described. The effects on the strain variation of post weld heat treatment, and of fatigue loading until a crack is formed in the plate, have been investigated. The results indicate the power of the neutron diffraction technique to obtain unique information on the strain distribution with a weldment. (author)

  8. The behavior of welded joint in steel pipe members under monotonic and cyclic loading

    International Nuclear Information System (INIS)

    Chang, Kyong-Ho; Jang, Gab-Chul; Shin, Young-Eui; Han, Jung-Guen; Kim, Jong-Min

    2006-01-01

    Most steel pipe members are joined by welding. The residual stress and weld metal in a welded joint have the influence on the behavior of steel pipes. Therefore, to accurately predict the behavior of steel pipes with a welded joint, the influence of welding residual stress and weld metal on the behavior of steel pipe must be investigated. In this paper, the residual stress of steel pipes with a welded joint was investigated by using a three-dimensional non-steady heat conduction analysis and a three-dimensional thermal elastic-plastic analysis. Based on the results of monotonic and cyclic loading tests, a hysteresis model for weld metal was formulated. The hysteresis model was proposed by the authors and applied to a three-dimensional finite elements analysis. To investigate the influence of a welded joint in steel pipes under monotonic and cyclic loading, three-dimensional finite elements analysis considering the proposed model and residual stress was carried out. The influence of a welded joint on the behavior of steel pipe members was investigated by comparing the analytical result both steel pipe with a welded joint and that without a welded joint

  9. Evaluation Of Residual Stresses In Inner Ring Of The Bearings

    Science.gov (United States)

    Malotová, Šárka; Hemžský, Pavel; Pitela, David; Nicielnik, Henryk; Šoková, Dagmar; Kyncl, Ladislav; Mrázik, Jozef

    2015-12-01

    Residual stresses are undesirable and it should not be underestimated. They occur in many components and it is necessary to identify and try to avoid them. For detection the Residual stresses, there are many methods, but not all are suitable, because they can completely destroy of the components. The article deals with the evaluation of Residual stresses in the inner rings of Bearings, which are made from steel 100Cr6 (ČSN 14 109.4. The surfaces were turning at different cutting parameters and subsequently are evaluated Residual stresses. The stresses have been evaluated by non - destructive method X - Ray. The experiment was realized in cooperation Faculty of Mechanical Engineering VSB - TU Ostrava and Faculty of Mechanical Engineering of ZU Zilina - machining in the laboratories of ZU Žilina, Slovak Republic.

  10. Fatigue strength assessment of the cruciform fillet welded joints using hot-spot stress approach

    International Nuclear Information System (INIS)

    Kim, Dae Jin; Koo, Jae Mean; Seok, Chang Sung; Seo, Jung Won; Goo, Byeong Choon

    2005-01-01

    In this study, fatigue tests to obtain S-N curves and FE analyses to obtain structural stress concentration factors were conducted for the two types of cruciform fillet welded joints, that is, load-carrying and non load-carrying types. Then we changed the obtained S-N curve of load-carrying joint to that based on hot-spot stress. As a result, the S-N curve of load-carrying joint based on hot-spot stress was almost exactly coincided with that of non load-carrying joint based on nominal stress. So we have concluded that the fatigue strength of a welded joint with different geometry from the non load-carrying cruciform joint could be estimated by the structural stress concentration factor obtained by considering the stress distributions along the expected crack path

  11. Stress indices for ANSI standard B16.11 socket-welding fittings

    International Nuclear Information System (INIS)

    Rodabaugh, E.C.; Moore, S.E.

    1975-08-01

    Stress indices for ANSI standard B16.11 socket-welding tees, 45 0 elbows, 90 0 elbows, and couplings are developed for intended use with the Class-1 piping system design rules of Section III--Division 1 of the ASME Boiler and Pressure Vessel Code. Indices are given for the evaluation of appropriate primary stresses, primary-plus-secondary stresses, and peak stresses due to internal pressure, bending-moment loads, and thermal gradients between the fitting and the attached pipe. The proposed indices are based on the dimensional and pressure-burst requirements of the B16.11 standard, the apparent shapes of B16.11 fittings as indicated from a random sampling taken off-the-shelf, the standard pressure-temperature ratings of the fittings, and on current stress indices now in the Code for similar butt-welding fittings. Specific recommendations are made for issuing the new stress indices in a Code case. (auth)

  12. Nonlinear morphoelastic plates I: Genesis of residual stress

    KAUST Repository

    McMahon, J.

    2011-04-28

    Volumetric growth of an elastic body may give rise to residual stress. Here a rigorous analysis is given of the residual strains and stresses generated by growth in the axisymmetric Kirchhoff plate. Balance equations are derived via the Global Constraint Principle, growth is incorporated via a multiplicative decomposition of the deformation gradient, and the system is closed by a response function. The particular case of a compressible neo-Hookean material is analyzed, and the existence of residually stressed states is established. © SAGE Publications 2011.

  13. Stress corrosion cracking of alloy 182 weld in a PWR water environment

    International Nuclear Information System (INIS)

    Lima, Luciana Iglesias Lourenco; Schvartzman, Monica Maria de Abreu Mendonca; Quinan, Marco Antonio Dutra; Soares, Antonio Edicleto Gomes; Piva, Stephano P.T.

    2011-01-01

    The weld used to connect two different metals is known as dissimilar metal welds (DMW). In the nuclear power plant, this weld is used to join stainless steel nipples to low alloy carbon steel components on the nuclear pressurized water reactor (PWR). In most cases, nickel alloys are used to joint these materials. These alloys are known to accommodate the differences in composition and thermal expansion of the two materials. The stress corrosion cracking (SCC) is a phenomenon that occurs in nuclear power plants metallic components where susceptibility materials are subjected to the simultaneously effect of mechanical stress and an aggressive media with different compositions. SCC is one of degradation process that gradually introduces damage of components, change their characteristics with the operation time. The nickel alloy 600, and their weld metals (nickel alloys 82 and 182), originally selected due to its high corrosion resistance, it exhibit after long operation period (20 years), susceptibility to the SCC. This study presents a comparative work between the SCC in the Alloy 182 filler metal weld in two different temperatures (303 deg C and 325 deg C) in primary water. The susceptibility to stress corrosion cracking was assessed using the slow strain rate tensile (SSRT) test. The results of the SSRT tests indicated that SCC is a thermally-activated mechanism and that brittle fracture caused by the corrosion process was observed at 325 deg C. (author)

  14. Stellite failure on a P91 HP valve - failure investigation and modelling of residual stresses

    DEFF Research Database (Denmark)

    Thorborg, Jesper; Hald, John; Hattel, Jesper Henri

    2006-01-01

    The sequence of the primary welding process and the following secondary processes of machining, and heat treatment has been modelled to predict the residual conditions in a Stellite 6 overlay weld on a P91 steam turbine valve. The different process steps are coupled in order to transfer the resid...

  15. Measuring depth profiles of residual stress with Raman spectroscopy

    Energy Technology Data Exchange (ETDEWEB)

    Enloe, W.S.; Sparks, R.G.; Paesler, M.A.

    1988-12-01

    Knowledge of the variation of residual stress is a very important factor in understanding the properties of machined surfaces. The nature of the residual stress can determine a part`s susceptibility to wear deformation, and cracking. Raman spectroscopy is known to be a very useful technique for measuring residual stress in many materials. These measurements are routinely made with a lateral resolution of 1{mu}m and an accuracy of 0.1 kbar. The variation of stress with depth; however, has not received much attention in the past. A novel technique has been developed that allows quantitative measurement of the variation of the residual stress with depth with an accuracy of 10nm in the z direction. Qualitative techniques for determining whether the stress is varying with depth are presented. It is also demonstrated that when the stress is changing over the volume sampled, errors can be introduced if the variation of the stress with depth is ignored. Computer aided data analysis is used to determine the depth dependence of the residual stress.

  16. Recent studies on the welding of austenitic stainless steel piping for BWR service

    International Nuclear Information System (INIS)

    Childs, W.J.

    1986-01-01

    The incidence of intergranular stress corrosion cracking (IGSCC) in stainless steel piping in BWR power plants has led to the development of various countermeasures. Replacement of the susceptible Type 304 stainless steel with Type 316 nuclear grade stainless steel has been done by a number of plants. In order to minimize radiation exposure to welding personnel, automatic GTA welding has been used wherever possible when we make the field welds. Studies have shown that the residual stresses in the welded butt joints are affected by the welding process, weld joint design and welding procedures. A new weld joint design has been developed which minimizes the volume of deposited metal while providing adequate access for welding. It also minimizes axial and radial shrinkage and the resulting residual stresses. Other countermeasures, which have been used, include stress modifications such as induction heating stress improvement (IHSI) and last pass heat sink welding (LPHSW). It has been shown that these remedies must be process adjusted to account for the welding process employed. In some cases where UT cracking indication have been detected or where through wall cracking has occurred, weld surfacing has been used to extend life. A further approach to preventing IGSCC in the weld HAZ has been through improvement of the water chemistry by injecting hydrogen to reduce the oxygen level and by keeping the impurity level low

  17. Stress corrosion cracking of austenitic weld deposits in a salt spray environment

    International Nuclear Information System (INIS)

    Cai, J.B.; Yu, C.; Shiue, R.K.; Tsay, L.W.

    2015-01-01

    ER 308L and 309LMo were utilized as the filler metals for the groove and overlay welds of a 304L stainless steel substrate, which was prepared via a gas tungsten arc-welding process in multiple passes. U-bend and weight-loss tests were conducted by testing the welds in a salt spray containing 10 wt% NaCl at 120 °C. The dissolution of the skeletal structure in the fusion zone (FZ) caused the stress corrosion cracking (SCC) of the weld. The FZ in the cold-rolled condition showed the longest single crack length in the U-bend tests. Moreover, sensitization treatment at 650 °C for 10 h promoted the formation of numerous fine cracks, which resulted in a high SCC susceptibility. The weight loss of the deposits was consistent with the SCC susceptibility of the welds in a salt spray. The 309LMo deposit was superior to the 308L deposit in the salt spray. - Highlights: • ER 308L and 309LMo were utilized as fillers for the groove and overlay welds of a 304L SS. • U-bend and weight-loss tests in a salt spray containing 10 wt% NaCl at 120 °C were performed. • The dissolution of solidified structure caused the SCC of the welds in a salt spray. • Sensitization treatment increased the weight loss and SCC susceptibility of the deposits. • The weight loss of the weld deposits was related to their SCC susceptibility in a salt spray.

  18. The nev diffractometer ARES for the analysis of residual stresses

    Czech Academy of Sciences Publication Activity Database

    Staron, P.; Ruhnau, H. U.; Marmotti, M.; Mikula, Pavol; Kampmann, R.

    276/278, - (2000), s. 158-159 ISSN 0921-4526 Institutional research plan: CEZ:AV0Z1048901 Keywords : neutron instruments * residual stress Subject RIV: BM - Solid Matter Physics ; Magnetism Impact factor: 0.893, year: 2000

  19. Neutron diffractometer RSND for residual stress analysis at CAEP

    Science.gov (United States)

    Li, Jian; Wang, Hong; Sun, Guangai; Chen, Bo; Chen, Yanzhou; Pang, Beibei; Zhang, Ying; Wang, Yun; Zhang, Changsheng; Gong, Jian; Liu, Yaoguang

    2015-05-01

    Residual Stress Neutron Diffractometer (RSND) has been built at China Academy of Engineering Physics (CAEP) in Mianyang. Due to its excellent flexibility, the residual stress measurement on different samples, as well as in-situ study for materials science, can be carried out through RSND. The basic tests on its intensity and resolution and some preliminary experimental results under mechanical load, demonstrate the high quality of RSND.

  20. Residual stresses and structural integrity in nuclear structural materials: recent developments and results from neutron and synchrotron x-ray diffraction experiments

    International Nuclear Information System (INIS)

    Steuwer, A.; Daniels, JE

    2008-01-01

    Over the last few years, significant progress has been made in the investigation of residual stresses over a variety of length scales in nuclear structural materials, ranging from stainless steels to hydrided zirconium alloys. In this manuscript we review some of these developments, such as, in-situ characterization of stresses at crack tips in steels and zirconium alloys, residual stresses around welds, and the characterization of hydrided zirconium alloys. Neutron and synchrotron X-ray diffraction are essential and complementary tools in this approach, and their applicability to structural integrity issues is discussed in view of existing and future large-scale research facilities. (au)

  1. Residual stresses in a cast iron automotive brake disc rotor

    Science.gov (United States)

    Ripley, Maurice I.; Kirstein, Oliver

    2006-11-01

    Runout, and consequent juddering and pulsation through the brake pedal, is a multi-million dollar per year warranty problem for car manufacturers. There is some suspicion that the runout can be caused by relaxation of residual casting stresses when the disc is overheated during severe-braking episodes. We report here neutron-diffraction measurements of the levels and distribution of residual strains in a used cast iron brake disc rotor. The difficulties of measuring stresses in grey cast iron are outlined and three-dimensional residual-strain distributions are presented and their possible effects discussed.

  2. Residual stresses in a cast iron automotive brake disc rotor

    International Nuclear Information System (INIS)

    Ripley, Maurice I.; Kirstein, Oliver

    2006-01-01

    Runout, and consequent juddering and pulsation through the brake pedal, is a multi-million dollar per year warranty problem for car manufacturers. There is some suspicion that the runout can be caused by relaxation of residual casting stresses when the disc is overheated during severe-braking episodes. We report here neutron-diffraction measurements of the levels and distribution of residual strains in a used cast iron brake disc rotor. The difficulties of measuring stresses in grey cast iron are outlined and three-dimensional residual-strain distributions are presented and their possible effects discussed

  3. In-situ neutron diffraction measurements of temperature and stresses during friction stir welding of 6061-T6 aluminum alloy

    International Nuclear Information System (INIS)

    Woo, Wan Chuck; Feng, Zhili; Wang, Xun-Li; Brown, D.W.; Clausen, B.; An, Ke; Choo, Hahn; Hubbard, Camden R.; David, Stan A.

    2007-01-01

    The evolution of temperature and thermal stresses during friction stir welding of Al6061-T6 was investigated by means of in-situ, time-resolved neutron diffraction technique. A method is developed to deconvolute the temperature and stress from the lattice spacing changes measured by neutron diffraction. The deep penetration capability of neutrons made it possible for the first time to obtain the temperature and thermal stresses inside a friction stir weld

  4. Repeatability of Contour Method Residual Stress Measurements for a Range of Material, Process, and Geometry (Preprint)

    Science.gov (United States)

    2017-09-19

    stainless steel plate with a dissimilar metal slot-filled weld, a stainless steel forging, a titanium plate with an electron beam slot-filled weld, and a...stress 16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT: SAR 18. NUMBER OF PAGES 27 19a. NAME OF RESPONSIBLE PERSON (Monitor) a...include: an aluminum T-section, a stainless steel plate with a dissimilar metal slot-filled weld, a stainless steel forging, a titanium plate with an

  5. Finite element analysis and simulation of welding - an addendum: a bibliography (1996-2001)

    Science.gov (United States)

    Mackerle, Jaroslav

    2002-05-01

    This paper gives a bibliographical review of the finite element methods applied to the analysis and simulation of welding processes. The bibliography is an addendum to the finite element analysis and simulation of welding: a bibliography (1976-96) published in Modelling Simul. Mater. Sci. Eng. (1996) 4 501-33. The added bibliography at the end of this paper contains approximately 550 references to papers and conference proceedings on the subject that were published in 1996-2001. These are classified in the following categories: modelling of welding processes in general; modelling of specific welding processes; influence of geometrical parameters; heat transfer and fluid flow in welds; residual stresses and deformations in welds; fracture mechanics and welding; fatigue of welded structures; destructive and non-destructive evaluation of weldments and cracks; welded tubular joints, pipes and pressure vessels/components; welds in plates and other structures/components.

  6. Experience of Application of EBW in Producing Welded VT41 Alloy Drums in the Design of an HPC in an Advanced Engine

    Science.gov (United States)

    Bykov, Yu. G.; Fomichev, E. O.; Kashapov, O. S.; Kyaramyan, K. A.

    2017-12-01

    The conditions of electron-beam welding (EBW) of ring samples made of a VT41 alloy are adjusted to produce large welded joints of this alloy for a high-pressure compressor (HPC) of an advanced engine. The problems of quality control of a welded joint, the level of residual stresses in the near-weld zone, the microstructure of the welded joint, and its properties are considered.

  7. Acoustoelastic evaluation of welding and heat treatment stress relieving of pressure vessel steel for Angra 3

    Energy Technology Data Exchange (ETDEWEB)

    Moraes, Bruno C. de, E-mail: bruno.cesar@nuclep.gov.br [Nuclebras Equipamentos Pesados S.A (NUCLEP), Itaguai, RJ (Brazil); Bittencourt, Marcelo de S.Q., E-mail: bruno.cesar@nuclep.gov.br, E-mail: bittenc@ien.gov.br [Instituto de Engenharia Nuclear (IEN/CNEN-RJ), Rio de Janeiro, RJ (Brazil)

    2015-07-01

    Currently the knowledge of non-destructive techniques allows to evaluate the stresses on components and mechanical structures, aiming at physical security, preservation of the environment and avoid financial losses associated with the construction and operation of industrial plants. The search for new techniques, especially applied in the nuclear industry to assess status more accurately, voltage safety and to ensure structural integrity, for example, core components of the primary circuit, such as the reactor pressure vessel and steam generator has become of great importance within the community of non-destructive testing .This paper aims to contribute to the non-destructive technique development in order to ensure the structural integrity of nuclear components. One acoustoelastic evaluation of steel 20 MnMoNi 55, used in pressure vessels of nuclear power plants were performed. The acoustic birefringence technique was use to evaluate the acoustoelastic behavior of the test material in the as received condition, after welding and after the stress relief heat treatment. The constant acoustoelastic material was obtained by an uniaxial loading test. It was found a slight anisotropy in the material as received. After welding, a marked variation of acoustic birefringence in the region near the weld bead was observed. The heat treatment indicated a new change of acoustic birefringence. Obtaining the acoustoelastic constant allowed the evaluation of stress in the different conditions of the weld and treated material. (author)

  8. Weld Magnification Factor Approach in Cruciform Joints Considering Post Welding Cooling Medium and Weld Size

    Directory of Open Access Journals (Sweden)

    Oscar Araque

    2018-01-01

    Full Text Available The objective of this research is to develop an experimental-theoretical analysis about the influence of the cooling medium and the geometry of the welding bead profile in fatigue life and the associated parameters with structural integrity of welded joints. A welded joint with cruciform geometry is considered using SMAW (Shielded Metal ArcWelding, plates in structural steel ASTM A36 HR of 8 mm of thickness, and E6013 electrode input. A three-dimensional computational model of the cruciform joint was created using the finite element method. For this model, the surface undulation of the cord and differentiation in the mechanical properties of the fusion zone were considered, the heat-affected zone (HAZ and base material, respectively. In addition, an initial residual stress field, which was established experimentally, was considered. The results were a set of analytical expressions for the weld magnification factor Mk. It was found that values for the latter decrease markedly in function of the intensity of the cooling medium used in the post welding cooling phase, mainly due to the effect of the residual compressive stresses. The obtained models of behavior of the weld magnification factor are compared with the results from other researchers with some small differences, mainly due to the inclusion of the cooling effect of the post weld and the variation of the leg of the weld bead. The obtained analytical equations in the present research for Mk can be used in management models of life and structural integrity for this type of welded joint.

  9. Residual stress analysis of drive shafts after induction hardening

    Energy Technology Data Exchange (ETDEWEB)

    Lemos, Guilherme Vieira Braga; Rocha, Alexandre da Silva; Nunes, Rafael Menezes, E-mail: lemos_gl@yahoo.com.br [Universidade Federal do Rio Grande do Sul (UFRS), Porto Algre, RS (Brazil); Hirsch, Thomas Karl [Stiftung Institut für Werkstofftechnik (IWT), Bremen (Germany)

    2014-08-15

    Typically, for automotive shafts, shape distortion manifests itself in most cases after the induction hardening by an effect known as bending. The distortion results in a boost of costs, especially due to machining parts in the hardened state to fabricate its final tolerances. In the present study, residual stress measurements were carried out on automotive drive shafts made of DIN 38B3 steel. The samples were selected in consequence of their different distortion properties by an industrial manufacturing line. One tested shaft was straightened, because of the considerable dimensional variation and the other one not. Firstly, the residual stress measurements were carried out by using a portable diffractometer, in order to avoid cutting the shafts and evaluate the original state of the stresses, and afterwards a more detailed analysis was realized by a conventional stationary diffractometer. The obtained results presented an overview of the surface residual stress profiles after induction hardening and displayed the influence of the straightening process on the redistribution of residual stresses. They also indicated that the effects of the straightening in the residual stresses cannot be neglected. (author)

  10. The Numerical and Experimental Investigation of the Multi-layer Laser-MIG Hybrid Welding for Fe36Ni Invar Alloy

    Science.gov (United States)

    Zhan, Xiaohong; Liu, Yun; Ou, Wenmin; Gu, Cheng; Wei, Yanhong

    2015-12-01

    Numerical and experimental investigations of multi-layer laser-MIG hybrid welding for Fe36Ni Invar alloy were presented in this paper. The multi-layer laser-MIG hybrid welding experiments with different parameters were conducted for the 19.5-mm-thick Invar plates. A finite element (FE) model was established to predict the temperature field, residual stress, and deformation distribution during and after welding. A plane-conical combined heat source model was used to simulate the laser-MIG hybrid welding process. Different numbers of welding layers were chosen to study the effect of welding layer on the temperature field, residual stress, and deformation distribution. It was found that the maximum residual stress of Invar plates after laser-MIG hybrid welding is 300 MPa and maximum deformation is 0.4 mm, so that laser-MIG hybrid welding can be used in actual manufacture of Invar moulds.

  11. CRADA Final Report: Weld Predictor App

    Energy Technology Data Exchange (ETDEWEB)

    Billings, Jay Jay [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

    2018-01-25

    Welding is an important manufacturing process used in a broad range of industries and market sectors, including automotive, aerospace, heavy manufacturing, medical, and defense. During welded fabrication, high localized heat input and subsequent rapid cooling result in the creation of residual stresses and distortion. These residual stresses can significantly affect the fatigue resistance, cracking behavior, and load-carrying capacity of welded structures during service. Further, additional fitting and tacking time is often required to fit distorted subassemblies together, resulting in non-value added cost. Using trial-and-error methods to determine which welding parameters, welding sequences, and fixture designs will most effectively reduce distortion is a time-consuming and expensive process. For complex structures with many welds, this approach can take several months. For this reason, efficient and accurate methods of mitigating distortion are in-demand across all industries where welding is used. Analytical and computational methods and commercial software tools have been developed to predict welding-induced residual stresses and distortion. Welding process parameters, fixtures, and tooling can be optimized to reduce the HAZ softening and minimize weld residual stress and distortion, improving performance and reducing design, fabrication and testing costs. However, weld modeling technology tools are currently accessible only to engineers and designers with a background in finite element analysis (FEA) who work with large manufacturers, research institutes, and universities with access to high-performance computing (HPC) resources. Small and medium enterprises (SMEs) in the US do not typically have the human and computational resources needed to adopt and utilize weld modeling technology. To allow an engineer with no background in FEA and SMEs to gain access to this important design tool, EWI and the Ohio Supercomputer Center (OSC) developed the online weld

  12. On machine surface to the unit event causing residual stress

    International Nuclear Information System (INIS)

    Arunachalama, R.M.; Mannanb, M.A.; Spowageca, A.

    2005-01-01

    Integrity and reduce overall costs. Within the framework of surface integrity investigations, special emphasis is given to the measurement of residual stresses because they contribute directly to premature failure of components. Since the highest residual stresses are to be found in surface layers, these deserve special attention when dealing with dynamically, heavily loaded machine parts such as gas turbine components used in aero engines. Of the many techniques available for the measurement of residual stresses, the most highly developed and widely used non-destructive method is based on X-ray diffraction (XRD). However, it is not possible to use this technique for inspection of all the components, since it is time consuming, complicated as well as expensive. In this paper, a method is being proposed that augments the XRD method but at the same time capable of inspecting all the components. A non-destructive, visual inspection technique has been developed that can correlate the characteristic features on the surface to the unit event causing the residual stress and the type of residual stress generated on the machined surface. Pictures of the machined surfaces have been taken using a digital video microscope at a magnification of 500 and the surface feature correlated to the unit event causing the residual stress. Sharp and well defined long grooves indicate that the plastic deformation is dominated by a mechanical unit event while appearance of streaks and small areas of smeared material indicate that the plastic deformation is dominated by a thermal unit event. These trends have been confirmed by measuring the residual stresses using XRD. The proposed technique is an attempt at establishing a simple methodology that would be useful to industries manufacturing aerospace and other components that require good surface integrity. (Author)

  13. Characterization of 2.25Cr1Mo welded ferritic steel plate by using diffractometric and ultrasonic techniques

    International Nuclear Information System (INIS)

    Cernuschi, F.; Ghia, S.; Albertini, G.; Ceretti, M.; Rustichelli, F.

    1995-12-01

    Four different techniques (X-ray and neutron diffraction, ultrasonic birefringence and incremental hole drilling method) were applied for evaluating residual stress in a butt-welded ferritic steel palte. Measurements were carried out both before and after welding. Effects of post-welding heat treatment is also considered. A comparison between results obtained by using four different techniques is done

  14. Numerical analysis of residual stresses reconstruction for axisymmetric glass components

    Science.gov (United States)

    Tao, Bo; Xu, Shuang; Yao, Honghui

    2018-01-01

    A non-destructive measurement method for 3D stress state in a glass cylinder using photoelasticity has been analyzed by simulation in this research. Based on simulated stresses in a glass cylinder, intensity of the cylinder in a circular polariscope can be calculated by Jones calculus. Therefore, the isoclinic angle and optical retardation can be obtained by six steps phase shifting technique. Through the isoclinic angle and optical retardation, the magnitude and distribution of residual stresses inside the glass cylinder in cylindrical coordinate system can be reconstructed. Comparing the reconstructed stresses with numerical simulated stresses, the results verify this non-destructive method can be used to reconstruct the 3D stresses. However, there are some mismatches in axial stress, radial stress and circumferential stress.

  15. Residual stresses estimation in tubes after rapid heating of surface

    International Nuclear Information System (INIS)

    Serikov, S.V.

    1992-01-01

    Results are presented on estimation of residual stresses in tubes of steel types ShKh15, EhP836 and 12KIMF after heating by burning pyrotechnic substance inside tubes. External tube surface was heated up to 400-450 deg C under such treatment. Axial stresses distribution over tube wall thickness was determined for initial state, after routine heat treatment and after heating with the use of fireworks. Inner surface heating was shown to essentially decrease axial stresses in tubes

  16. Prediction of residual stress using explicit finite element method

    Directory of Open Access Journals (Sweden)

    W.A. Siswanto

    2015-12-01

    Full Text Available This paper presents the residual stress behaviour under various values of friction coefficients and scratching displacement amplitudes. The investigation is based on numerical solution using explicit finite element method in quasi-static condition. Two different aeroengine materials, i.e. Super CMV (Cr-Mo-V and Titanium alloys (Ti-6Al-4V, are examined. The usage of FEM analysis in plate under normal contact is validated with Hertzian theoretical solution in terms of contact pressure distributions. The residual stress distributions along with normal and shear stresses on elastic and plastic regimes of the materials are studied for a simple cylinder-on-flat contact configuration model subjected to normal loading, scratching and followed by unloading. The investigated friction coefficients are 0.3, 0.6 and 0.9, while scratching displacement amplitudes are 0.05 mm, 0.10 mm and 0.20 mm respectively. It is found that friction coefficient of 0.6 results in higher residual stress for both materials. Meanwhile, the predicted residual stress is proportional to the scratching displacement amplitude, higher displacement amplitude, resulting in higher residual stress. It is found that less residual stress is predicted on Super CMV material compared to Ti-6Al-4V material because of its high yield stress and ultimate strength. Super CMV material with friction coefficient of 0.3 and scratching displacement amplitude of 0.10 mm is recommended to be used in contact engineering applications due to its minimum possibility of fatigue.

  17. Residual Stress Measurement of Titanium Casting Alloy by Neutron Diffraction

    Science.gov (United States)

    Nishida, M.; Jing, T.; Muslih, M. R.; Hanabusa, T.

    2008-03-01

    Neutron stress measurement can detect strain and stress information in deep region because of large penetration ability of neutron beams. The present paper describes procedure and results in the residual stress measurement of titanium casting alloy by neutron diffraction. In this study, the three axial method using Hooke's equation was employed for neutron stress measurement. This method was applied to the cylindrical shape sample of titanium casting alloy (Ti-6Al-4V). Form the results of this study, this sample has large crystal grain in the inside whole position, it is assumed this large grain was grown up during casting manufacture process. Furthermore, the peak profile used to the stress measurement appears in very weak because of the HCP crystal system of titanium character and effect of large crystal grain. These conditions usually make difficult to measure the accuracy values of residual stresses. Therefore, it had to spend a long time to measure the satisfied data from titanium sample. Regarding to the results of stress measurement, the stress values in the cylindrical sample of three directions is almost same tendency, and residual stresses change from the compressive state in the outer part to the tensile state in the inner part gradually.

  18. Thermomechanical history measurements on Type 304L stainless steel pipe girth welds

    International Nuclear Information System (INIS)

    Li, Ming; Atteridge, D.G.; Anderson, W.E.; Turpin, R.; West, S.L.

    1993-01-01

    Thermal and strain histories were recorded for three 40-cm-diameter (16 inch), Type 304L stainless steel (SS), schedule 40 (1.27 cm thickness) pipe girth welds. Two weld groove preparations were standard V grooves while the third was a narrow groove configuration. The welding parameters for the three pipe welds simulated expected field practice as closely as possible. The narrow gap weld was completed in four continuous passes while the other two welds required six and nine (discontinuous) passes, due to the use of different weld wire diameters. Thermomechanical history measurements were taken on the inner counterbore surface, encompassing the weld centerline and heat-affected zone (HAZ), as well as 10 cm of inner counterbore surface on either side of the weld centerline; a total of 47 data acquisition instruments were used for each weld. These instruments monitored: (1) weld shrinkages parallel to the pipe axis; (2) surface temperatures; (3) surface strains parallel to weld centerline; and (4) radial deformations. Results show that the weld and HAZ experienced cyclic deformation in the radial direction during welding, indicating that the final residual stress distribution in multi-pass pipe weldments is not axisymmetric. Measured radial and axial deformations were smaller for the narrow gap groove than for the standard V grooves, suggesting that the narrow gap groove weldment may have lower residual stress levels than the standard V groove weldments. This study provides the experimental database and a guideline for further computational modeling work

  19. Application of the Mathar Method to Identify Internal Stress Variation in Steel as a Welding Process Result

    Science.gov (United States)

    Kowalski, Dariusz

    2017-06-01

    The paper deals with the method to identify internal stresses in two-dimensional steel members. Steel members were investigated in the delivery stage and after assembly, by means of electric-arc welding. In order to perform the member assessment two methods to identify the stress variation were applied. The first is a non-destructive measurement method employing local external magnetic field and to detecting the induced voltage, including Barkhausen noise The analysis of the latter allows to assess internal stresses in a surface layer of the material. The second method, essential in the paper, is a semi-trepanation Mathar method of tensometric strain variation measurement in the course of a controlled void-making in the material. Variation of internal stress distribution in the material led to the choice of welding technology to join. The assembly process altered the actual stresses and made up new stresses, triggering post-welding stresses as a response for the excessive stress variation.

  20. Numerical simulation and experimental validation of arc welding of DMR-249A steel

    Directory of Open Access Journals (Sweden)

    Rishi Pamnani

    2016-08-01

    Full Text Available The thermo-mechanical attributes of DMR-249A steel weld joints manufactured by shielded metal arc welding (SMAW and activated gas tungsten arc