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)

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

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)

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)

Features of residual stresses in duplex stainless steel butt welds

Science.gov (United States)

Um, Tae-Hwan; Lee, Chin-Hyung; Chang, Kyong-Ho; Nguyen Van Do, Vuong

2018-04-01

Duplex stainless steel finds increasing use as an alternative to austenitic stainless steel, particularly where chloride or sulphide stress corrosion cracking is of primary concern, due to the excellent combination of strength and corrosion resistance. During welding, duplex stainless steel does not create the same magnitude or distribution of weld-induced residual stresses as those in welded austenitic stainless steel due to the different physical and mechanical properties between them. In this work, an experimental study on the residual stresses in butt-welded duplex stainless steel is performed utilizing the layering technique to investigate the characteristics of residual stresses in the weldment. Three-dimensional thermos-mechanical-metallurgical finite element analysis is also performed to confirm the residual stress measurements.

Effect of the weld groove shape and pass number on residual stresses in butt-welded pipes

International Nuclear Information System (INIS)

Sattari-Far, I.; Farahani, M.R.

2009-01-01

This study used finite element techniques to analyze the thermo-mechanical behaviour and residual stresses in butt-welded pipes. The residual stresses were also measured in some welds by using the Hole-Drilling method. The results of the finite element analysis were compared with experimentally measured data to evaluate the accuracy of the finite element modelling. Based on this study, a finite element modelling procedure with reasonable accuracy was developed. The developed FE modelling was used to study the effects of weld groove shape and weld pass number on welding residual stresses in butt-welded pipes. The hoop and axial residual stresses in pipe joints of 6 and 10 mm thickness of different groove shapes and pass number were studied. It is shown that these two parameters may have significant effects on magnitude and distribution of residual stresses in welded pipes.

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.

Residual stresses due to weld repairs, cladding and electron beam welds and effect of residual stresses on fracture behavior. Annual report, September 1, 1977--November 30, 1978

International Nuclear Information System (INIS)

Rybicki, E.F.

1978-11-01

The study is divided into three tasks. Task I is concerned with predicting and understanding the effects of residual stresses due to weld repairs of pressure vessels. Task II examines residual stresses due to an electron beam weld. Task III addresses the problem of residual stresses produced by weld cladding at a nozzle vessel intersection. The objective of Task I is to develop a computational model for predicting residual stress states due to a weld repair of pressure vessel and thereby gain an understanding of the mechanisms involved in the creation of the residual stresses. Experimental data from the Heavy Section Steel Technology (HSST) program at Oak Ridge National Laboratories (ORNL) is used to validate the computational model. In Task II, the residual stress model is applied to the case of an electron beam weld of a compact tension freacture specimen. The results in the form of residual stresses near the weld are then used to explain unexpected fracture behavior which is observed in the testing of the specimen. For Task III, the residual stress model is applied to the cladding process used in nozzle regions of nuclear pressure vessels. The residual stresses obtained from this analysis are evaluated to determine their effect on the phenomena of under-clad cracking

Fatigue life evaluation based on welding residual stress relaxation and notch strain approach for cruciform welded joint

International Nuclear Information System (INIS)

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

2003-01-01

The fatigue strength of welded joint is influenced by the welding residual stress which is relaxed depending on local stress distributed in vicinity of stress raisers, eg. under cut, overlap and blow hole. To evaluate its fatigue life the geometry of the stress raisers and the welding residual stress should be taken into account. The several methods based on notch strain approach have been proposed in order to consider the two factors above mentioned. These methods, however, have shown considerable differences between analytical and experimental results. It is due to the fact that the amount of the relaxed welding residual stress evaluated by the cyclic stress-strain relationship do not correspond with that occurred in reality. In this paper the residual stress relaxation model based on experimental results was used in order to reduce the discrepancy of the estimated amount of the relaxed welding residual stress. Under an assumption of the superimposition of the relaxed welding residual stress and the local stress, a modified notch strain approach was proposed and verified to the cruciform welded joint

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

Design of specimen for weld residual stress simulation

International Nuclear Information System (INIS)

Kim, Jin Weon; Park, Jong Sun; Lee, Kyung Soo

2008-01-01

The objective of this study is to design a laboratory specimen for simulating residual stress of circumferential butt welding of pipe. Specimen type and method for residual stress generation were proposed based on the review of prior studies and parametric finite element simulation. To prove the proposed specimen type and loading method, the residual stress was generated using the designed specimen by applying proposed method and was measured. The measured residual stress using X-ray diffraction reasonably agreed with the results of finite element simulation considered in the specimen design. Comparison of residual strains measured at several locations of specimen and given by finite element simulation also showed good agreement. Therefore, it is indicated that the designed specimen can reasonably simulate the residual stress of circumferential butt welding of pipe

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

International Nuclear Information System (INIS)

Song, Tae Kwang; Kim, Yun Jae; Lee, Kyoung Soo; Park, Chi Yong; Kim, Jong Sung; Kim, Jin Weon

2007-01-01

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

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.

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

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

Estimation of stress intensity factors for circumferential cracked pipes under welding residual stress filed

International Nuclear Information System (INIS)

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

2012-01-01

Recently, stress corrosion cracking(SCC) have been found in dissimilar metal welds of nozzles in some pressurized water reactors and on low carbon stainless steel piping systems of boiling water reactors. The important factor of SCC is the residual stress field caused by weld. For the evaluation of crack growth analysis due to SCC, stress intensity factor under a residual stress field should be estimated. Several solutions for stress intensity factor under residual stress field were recommended in flaw assessment codes such as the American Society of Mechanical Engineers (ASME) Section XI, R6, American Petroleum Institute (API579). Some relevant works have been studied. Dong et al. evaluated stress intensity factors in welded structures. Miyazaki et al. estimated stress intensity factors of surface crack in simple stress fields. This paper presents a simple method to estimate stress intensity factors in welding residual stress field. For general application, results of structure integrity assessment codes KI solutions were compared Finite element analyses of welding simulation and cracked pipes are described. Comparison results of KI solutions and proposed simplified solution are presented in the works

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

Residual stress measurement in socket welded joints by neutron diffraction

International Nuclear Information System (INIS)

Hayashi, Makoto; Ishiwata, Masayuki; Minakawa, Noriaki; Funahashi, Satoru.

1995-01-01

Neutron diffraction measurements of lattice spacings provide the spatial map of residual stress near welds in ferritic steel socket joints. The high tensile stress greater than 200 MPa was found in the fusion and heat-affected zones in the hoop direction. However, the highest tensile stress in the axial direction at the weld root was about 110 MPa relatively lower than the expected value from the fatigue test results. The balancing compressive stress was found near the surface of the socket weld fusion zone. Heat treatment at 625degC for 2 hours was sufficient for the relief of residual stress in socket welds. (author)

Residual stresses determination in an 8 mm Incoloy 800H weld via neutron diffraction

International Nuclear Information System (INIS)

Chen, Xizhang; Zhang, Shu Yan; Wang, Jingjun; Kelleher, Joe F.

2015-01-01

Highlights: • Stress through thickness at 5 mm from weld centerline indicates a “U” distribution. • Declining of tensile stress through thickness occurred at weld centerline. • Residual stress between layers is the lowest. - Abstract: To investigate the distribution of residual stresses, the 8 mm 800H alloy was joined by multi-layer butt TIG process. Residual stresses in the longitudinal, transverse and normal directions were measured via neutron diffraction. These residual stress measurements were taken at a series of points 2 mm below the top surface, covering the fusion zone, heat affected zone (HAZ) and base metal. In addition, two lines of longitudinal residual stress values at the weld centerline and 5 mm from weld centerline through thickness were measured. Results show that both the longitudinal and transverse stresses from the weld centerline to base metal are mainly tensile stresses. The longitudinal residual stress is the largest, with a maximum value of 330 MPa. As for the normal residual stress, the weld zone shows tensile stress, while the HAZ shows compressive stress. The middle of the thickness shows compressive residual stress along the thickness direction. The longitudinal stress at weld centerline through thickness reveals the interlayer heat treat effects leads to a declining of tensile stress. While the stress at 5 mm from weld centerline indicates a “U” distribution due to the mixed microstructure close to fusion line. With the increasing distance from weld seam, the residual stress decreases gradually

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

Evaluation of residual stress on pipe welded joints using laser interferometry

Energy Technology Data Exchange (ETDEWEB)

Chang, Ho Seob; Na, Man Gyun; Kim, Koung Suk [Chosun University, Gwangju (Korea, Republic of)

2014-02-15

Residual stresses that occur during the welding process, are the main cause of failure and defects in welded structures. This paper, presents the use of an electronic processing laser speckle interferometer to measure the residual stress of a welded pipe for a nuclear power plant. A tensile testing machine was used to evaluate a welded pipe that failed in compression. The inform plane deformation and modulus of elasticity of the base metal and welds were measured using an interferometer. Varying the load on the welded pipe had a larger effect on the deformation of the base metal the other properties of the base metal and welds. The elastic moduli of the base metal and weld of the welded pipe were 202.46 and 212.14 GPa, respectively, the residual stress was measured to be 6.29 MPa.

Influence of Welding Strength Matching Coefficient and Cold Stretching on Welding Residual Stress in Austenitic Stainless Steel

Science.gov (United States)

Lu, Yaqing; Hui, Hu; Gong, Jianguo

2018-05-01

Austenitic stainless steel is widely used in pressure vessels for the storage and transportation of liquid gases such as liquid nitrogen, liquid oxygen, and liquid hydrogen. Cryogenic pressure vessel manufacturing uses cold stretching technology, which relies heavily on welding joint performance, to construct lightweight and thin-walled vessels. Residual stress from welding is a primary factor in cases of austenitic stainless steel pressure vessel failure. In this paper, on the basis of Visual Environment 10.0 finite element simulation technology, the residual stress resulting from different welding strength matching coefficients (0.8, 1, 1.2, 1.4) for two S30408 plates welded with three-pass butt welds is calculated according to thermal elastoplastic theory. In addition, the stress field was calculated under a loading as high as 410 MPa and after the load was released. Path 1 was set to analyze stress along the welding line, and path 2 was set to analyze stress normal to the welding line. The welding strength matching coefficient strongly affected both the longitudinal residual stress (center of path 1) and the transverse residual stress (both ends of path 1) after the welding was completed. However, the coefficient had little effect on the longitudinal and transverse residual stress of path 2. Under the loading of 410 MPa, the longitudinal and transverse stress decreased and the stress distribution, with different welding strength matching coefficients, was less diverse. After the load was released, longitudinal and transverse stress distribution for both path 1 and path 2 decreased to a low level. Cold stretching could reduce the effect of residual stress to various degrees. Transverse strain along the stretching direction was also taken into consideration. The experimental results validated the reliability of the partial simulation.

Welding induced residual stress evaluation using laser-generated Rayleigh waves

Science.gov (United States)

Ye, Chong; Zhou, Yuanlai; Reddy, Vishnu V. B.; Mebane, Aaron; Ume, I. Charles

2018-04-01

Welding induced residual stress could affect the dimensional stability, fatigue life, and chemical resistance of the weld joints. Ultrasonic method serves as an important non-destructive tool for the residual stress evaluation due to its easy implementation, low cost and wide application to different materials. Residual stress would result in the ultrasonic wave velocity variation, which is the so called acoustoelastic effect. In this paper, Laser/EMAT ultrasonic technique was proposed to experimentally study the relative velocity variation ΔV/V of Rayleigh wave, which has the potential to evaluate surface/subsurface longitudinal residual stress developed during the Gas Metal Arc Welding process. Broad band ultrasonic waves were excited by pulsed Q-Switched Nd: YAG laser. An electromagnetic acoustic transducer (EMAT) attached to the welded plates was used to capture the Rayleigh wave signals propagating along the weld seam direction. Different time of flight measurements were conducted by varying the distance between the weld seam and Rayleigh wave propagating path in the range of 0 to 45 mm. The maximum relative velocity difference was found on the weld seam. With the increasing distance away from the weld seam, the relative velocity difference sharply decreased to negative value. With further increase in distance, the relative velocity difference slowly increased and approached zero. The distribution of relative velocity variations indicates that tensile stress appears in the melted zone as it becomes compressive near the heat-affected zone.

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

Improvement and Validation of Weld Residual Stress Modelling Procedure

Energy Technology Data Exchange (ETDEWEB)

Zang, Weilin; Gunnars, Jens (Inspecta Technology AB, Stockholm (Sweden)); Dong, Pingsha; Hong, Jeong K. (Center for Welded Structures Research, Battelle, Columbus, OH (United States))

2009-06-15

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

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)

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

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

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)

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.

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

International Nuclear Information System (INIS)

Bae, Hong Yeol; Song, Tae Kwang; Chun, Yun Bae; Oh, Chang Young; Kim, Yun Jae; Lee, Kyoung Soo; Park, Chi Yong

2008-01-01

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

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

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

International Nuclear Information System (INIS)

Song, Tae Kwang; Bae, Hong Yeol; Chun, Yun Bae; Oh, Chang Young; Kim, Yun Jae; Lee, Kyoung Soo; Park, Chi Yong

2008-01-01

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

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.

Influence of weld-induced residual stresses on the hysteretic behavior of a girth-welded circular stainless steel tube

Science.gov (United States)

Lee, Chin-Hyung; Nguyen Van Do, Vuong; Chang, Kyong-Ho; Jeon, Jun-Tai; Um, Tae-Hwan

2018-04-01

The present study attempts to characterize the relevance of welding residual stresses to the hysteretic behaviour of a girth-welded circular stainless steel tube under cyclic mechanical loadings. Finite element (FE) thermal simulation of the girth butt welding process is first performed to identify the weld-induced residual stresses by using the one-way coupled three-dimensional (3-D) thermo-mechanical FE analysis method. 3-D elastic-plastic FE analysis equipped with the cyclic plasticity constitutive model capable of describing the cyclic response is next carried out to scrutinize the effects that the residual stresses have on the hysteretic performance of the girth-welded steel tube exposed to cyclic axial loading, which takes the residual stresses and plastic strains calculated from the preceding thermo-mechanical analysis as the initial condition. The analytical results demonstrate that the residual stresses bring about premature yielding and deterioration of the load carrying capacity in the elastic and the transition load ranges, whilst the residual stress effect is wiped out quickly in the plastic load domain since the residual stresses are nearly wholly relaxed after application of the cyclic plastic loading.

Investigation of residual stress in laser welding dissimilar materials

International Nuclear Information System (INIS)

Mirim, Denilson de Camargo; Oliveira, Rene Ramos de; Berretta, Jose Roberto; Rossi, Wagner de; Lima, Nelson Batista de; Delijaicov, Sergio; Gomes, Diego Oliva

2010-01-01

One of the most critical problems found in the different materials welding is the residual stress formation, that happens mainly for the fact of those materials they possess coefficients of thermal expansion and different thermal conductivities. Like this in this work the residual tension was evaluated in the technique of welding laser among the steel low carbon, AISI 1010 and AISI 304. The materials were united for it welds autogenous of top with a laser of continuous Nd:YAG in that they were varied the potency, speed and the focus of the laser stayed constant in relation to surface of the sample. The main objective of the study went identification and to analysis of the residual stress in HAZ on both sides of seem. Um planning factorial of two factors at two levels each it was executed for optimization the combination of the factors potency and speed. The obtained answers were the residual stress in different depths in HAZ. In the surface of the sample measures of residual stress were accomplished by the technique of X-ray diffraction. The hole drilling strain gage method it was applied to measure the residual stress on both sides of the union. The results were analyzed using the variance analysis and the statistical regression based on the different influences of the entrance and combination of the factors in the residual stress generated in that union. The results indicate that the development of models can foresee the answers satisfactorily. (author)

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

Different finite element techniques to predict welding residual stresses in aluminum alloy plates

International Nuclear Information System (INIS)

Moein, Hadi; Sattari-Far, Iradj

2014-01-01

This study is a 3D thermomechanical finite element (FE) analysis of a single-pass and butt-welded work-hardened aluminum (Al) 5456 plates. It aims to validate the use of FE welding simulations to predict residual stress states in assessing the integrity of welded components. The predicted final residual stresses in the plate from the FE simulations are verified through comparison with experimental measurements. Three techniques are used to simulate the welding process. In the first two approaches, welding deposition is applied by using element birth and interaction techniques. In the third approach, the entire weld zone is simultaneously deposited. Results show a value at approximately the yield strength for longitudinal residual stresses of the welded center of the butt-welded Al alloy plates with a thickness of 2 mm. Considering the application of a comprehensive heat source, along with heat loss modeling and the temperature dependent properties of the material, the approach without deposition predicts a reasonable distribution of residual stresses. However, the element birth and interaction techniques, compared with the no-deposit technique, provide more accurate results in calculating residual stresses. Furthermore, the element interaction technique, compared with the element birth technique, exhibits higher efficiency and flexibility in modeling the deposition of welded metals as well as less modeling cost.

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.

Predictions and measurements of residual stress in repair welds in plates

Energy Technology Data Exchange (ETDEWEB)

Brown, T.B. [Mitsui Babcock Energy Limited, Technology and Engineering, Porterfield Road, Renfrew, PA4 8DJ, Scotland (United Kingdom)]. E-mail: bbrown@mitsuibabcock.com; Dauda, T.A. [Mitsui Babcock Energy Limited, Technology and Engineering, Porterfield Road, Renfrew, PA4 8DJ, Scotland (United Kingdom); Truman, C.E. [Department of Mechanical Engineering, University of Bristol, Bristol BS8 1TR, England (United Kingdom); Smith, D.J. [Department of Mechanical Engineering, University of Bristol, Bristol BS8 1TR (United Kingdom); Memhard, D. [Fraunhofer-Institut fuer Werkstoffmechanik, Freiburg (Germany); Pfeiffer, W. [Fraunhofer-Institut fuer Werkstoffmechanik, Freiburg (Germany)

2006-11-15

This paper presents the work, from the European Union FP-5 project ELIXIR, on a series of rectangular repair welds in P275 and S690 steels to validate the numerical modelling techniques used in the determination of the residual stresses generated during the repair process. The plates were 1,000 mm by 800 mm with thicknesses of 50 and 100 mm. The repair welds were 50%, 75% and 100% through the plate thickness. The repair welds were modelled using the finite element method to make predictions of the as-welded residual stress distributions. These predictions were compared with surface-strain measurements made on the parent plates during welding and found to be in good agreement. Through-thickness residual stress measurements were obtained from the test plates through, and local to, the weld repairs using the deep hole drilling technique. Comparisons between the measurements and the finite element predictions generally showed good agreement, thus providing confidence in the method.

Predictions and measurements of residual stress in repair welds in plates

International Nuclear Information System (INIS)

Brown, T.B.; Dauda, T.A.; Truman, C.E.; Smith, D.J.; Memhard, D.; Pfeiffer, W.

2006-01-01

This paper presents the work, from the European Union FP-5 project ELIXIR, on a series of rectangular repair welds in P275 and S690 steels to validate the numerical modelling techniques used in the determination of the residual stresses generated during the repair process. The plates were 1,000 mm by 800 mm with thicknesses of 50 and 100 mm. The repair welds were 50%, 75% and 100% through the plate thickness. The repair welds were modelled using the finite element method to make predictions of the as-welded residual stress distributions. These predictions were compared with surface-strain measurements made on the parent plates during welding and found to be in good agreement. Through-thickness residual stress measurements were obtained from the test plates through, and local to, the weld repairs using the deep hole drilling technique. Comparisons between the measurements and the finite element predictions generally showed good agreement, thus providing confidence in the method

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

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.

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

International Nuclear Information System (INIS)

Noh, Byeong Wook; Chung, Sung Ho; Lee, Jung Hun; Kim, Oak Sug

2008-01-01

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)

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)

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)

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)

Calculation of residual stresses by means of a 3D numerical weld simulation

International Nuclear Information System (INIS)

Nicak, Tomas; Huemmer, Matthias

2008-01-01

The numerical weld simulation has developed very fast in recent years. The problem complexity has increased from simple 2D models to full 3D models, which can describe the entire welding process more realistically. As recent research projects indicate, a quantitative assessment of the residual stresses by means of a 3D analysis is possible. The structure integrity can be assessed based on the weld simulation results superimposed with the operating load. Moreover, to support the qualification of welded components parametric studies for optimization of the residual stress distribution in the weld region can be performed. In this paper a full 3D numerical weld simulation for a man-hole drainage nozzle in a steam generator will be presented. The residual stresses are calculated by means of an uncoupled transient thermal and mechanical FE analysis. The paper will present a robust procedure allowing reasonable predictions of the residual stresses for complex structures in industrial practice. (authors)

Prediction of retained residual stresses in laboratory fracture mechanics specimens extracted from welded components

International Nuclear Information System (INIS)

Hurlston, R.G.; Sherry, A.H.; James, P.; Sharples, J.K.

2015-01-01

The measurement of weld material fracture toughness properties is important for the structural integrity assessment of engineering components. However, welds can contain high levels of residual stress and these can be retained in fracture mechanics specimens, particularly when machined from non-stress relieved welds. Retained residual stresses can make the measurement of valid fracture toughness properties difficult. This paper describes the results of analytical work undertaken to investigate factors that can influence the magnitude and distribution of residual stresses retained in fracture mechanics specimen blanks extracted from as-welded ferritic and austenitic stainless steel plates. The results indicate that significant levels of residual stress can be retained in specimen blanks prior to notching, and that the magnitude and distribution of stress is dependent upon material properties, specimen geometry and size, and extraction location through the thickness of the weld. Finite element modelling is shown to provide a useful approach for estimating the level and distributions of retained residual stresses. A new stress partitioning approach has been developed to estimate retained stress levels and results compare favourably with FE analysis and available experimental data. The approach can help guide the selection of specimen geometry and machining strategies to minimise the level of residual stresses retained in fracture mechanics specimen blanks extracted from non stress-relieved welds and thus improve the measurement of weld fracture toughness properties. - Highlights: • A simplified method for generating realistic weld residual stresses has been developed. • It has been shown that significant levels of residual stress can be retained within laboratory fracture mechanics specimens. • The level and distribution is dependant upon material, specimen type, specimen size and extraction location. • A method has been developed to allow estimates of the

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)

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.

Influence of Hardening Model on Weld Residual Stress Distribution

Energy Technology Data Exchange (ETDEWEB)

Mullins, Jonathan; Gunnars, Jens (Inspecta Technology AB, Stockholm (Sweden))

2009-06-15

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

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

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.

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

The numerical high cycle fatigue damage model of fillet weld joint under weld-induced residual stresses

Science.gov (United States)

Nguyen Van Do, Vuong

2018-04-01

In this study, a development of nonlinear continuum damage mechanics (CDM) model for multiaxial high cycle fatigue is proposed in which the cyclic plasticity constitutive model has been incorporated in the finite element (FE) framework. T-joint FE simulation of fillet welding is implemented to characterize sequentially coupled three-dimensional (3-D) of thermo-mechanical FE formulation and simulate the welding residual stresses. The high cycle fatigue damage model is then taken account into the fillet weld joints under the various cyclic fatigue load types to calculate the fatigue life considering the residual stresses. The fatigue crack initiation and the propagation in the present model estimated for the total fatigue is compared with the experimental results. The FE results illustrated that the proposed high cycle fatigue damage model in this study could become a powerful tool to effectively predict the fatigue life of the welds. Parametric studies in this work are also demonstrated that the welding residual stresses cannot be ignored in the computation of the fatigue life of welded structures.

The effect of tensioning and sectioning on residual stresses in aluminium AA7749 friction stir welds

International Nuclear Information System (INIS)

Altenkirch, J.; Steuwer, A.; Peel, M.; Richards, D.G.; Withers, P.J.

2008-01-01

Using synchrotron X-ray diffraction the residual stress distribution has been measured in a series of AA7449-W51 aluminium friction stir welds that had been tensioned to different loads during welding. By modifying the stress accumulation path, the application of a tensioning stress has reduced the tensile magnitude of the final residual weld stresses. In the present case the residual stresses were minimised when the applied load is ∼35% of the room temperature yield stress of the parent material. Subsequent sectioning of the weld into shorter test lengths, as might be necessary for weld testing, resulted in a progressive and significant relaxation of the residual stress field. The effect of tensioning on the weld component distortion also has been investigated

Influence of repair length on residual stress in the repair weld of a clad plate

International Nuclear Information System (INIS)

Jiang Wenchun; Xu, X.P.; Gong, J.M.; Tu, S.T.

2012-01-01

Highlights: ► Residual stress in the repair weld of a stainless steel clad plate is investigated. ► The effect of repair length on residual stress has been studied. ► Large tensile residual stress is generated in the repair weld and heat affected zone. ► With the increase of repair length, transverse stress is decreased. ► Repair length has little effect on longitudinal stress. - Abstract: A 3-D sequential coupling finite element simulation is performed to investigate the temperature field and residual stress in the repair weld of a stainless steel clad plate. The effect of repair length on residual stress has been studied, aiming to provide a reference for repairing the cracked clad plate. The results show that large tensile residual stresses are generated in the repair weld and heat affected zone (HAZ), and then decrease gradually away from the weld and HAZ. The residual stresses through thickness in the clad layer are relative uniform, while they are non-uniform in the base metal. A discontinuous stress distribution is generated across the interface between weld metal and base metal. The repair length has a great effect on transverse stress. With the increase of repair length, the transverse stress is decreased. When the repair length is increased to 14 cm, the peak of transverse stress has been decreased below yield strength, and the transverse stress in the weld and HAZ has also been greatly decreased. But the repair length has little effect on longitudinal stress.

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.

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

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.

Weld residual stress according to the ways of heat input in the simulation of weld process using finite element analysis

International Nuclear Information System (INIS)

Yang, Jun Seog; Lee, Kyoung Soo; Park, Chi Yong

2008-01-01

This paper is to discuss distribution of welding residual stresses of a ferritic low alloy steel nozzle with dissimilar metal weld using Alloy 82/182. Two Dimensional (2D) thermo-mechanical finite element analyses are carried out to simulate multi-pass welding process on the basis of the detailed and fabrication data. On performing the welding analysis generally, the characteristics on the heat input and heat transfer of weld are affected on the weld residual stress analyses. Thermal analyses in the welding heat cycle process is very important process in weld residual stress analyses. Therefore, heat is rapidly input to the weld pass material, using internal volumetric heat generation, at a rate which raises the peak weld metal temperature to 2200 .deg. C and the base metal adjacent to the weld to about 1400 .deg. C. These are approximately the temperature that the weld metal and surrounding base materials reach during welding. Also, According to the various ways of applying the weld heat source, the predicted residual stress results are compared with measured axial, hoop and radial through-wall profiles in the heat affected zone of test component. Also, those results are compared with those of full 3-dimensional simulation

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)

Prediction of residual stresses in electron beam welded Ti-6Al-4V plates

Energy Technology Data Exchange (ETDEWEB)

Xu, Lianyong; Ge, Keke; Jing, Hongyang; Zhao, Lei; Lv, Xiaoqing [Tianjin Univ. (China); Han, Yongdian [Tianjin Univ. (China). Key Lab. of Advanced Joining Technology

2017-05-01

A thermo-metallurgical procedure based on the SYSWELD code was developed to predict welding temperature field, microstructure and residual stress in butt-welded Ti-6Al-4V plate taking into account phase transformation. The formation of martensite was confirmed by the CCT diagram and microstructure in the weld joint, which significantly affects the magnitude of residual stress. The hole drilling procedure was utilized to measure the values of residual stress at the top surface of the specimen, which are in well agreement with the numerical results. Both simulated and test results show that the magnitude and distribution of residual stress on the surface of the plate present a large gradient feature from the weld joint to the base metal. Moreover, the distribution law of residual stresses in the plate thickness was further analyzed for better understanding of its generation and evolution.

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

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.

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.

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

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.

A neutron diffraction study of residual stress and plastic strain in welded beryllium rings

Energy Technology Data Exchange (ETDEWEB)

Brown, D.W.; Varma, R.; Bourke, M.A.M.; Holden, T.M. [Los Alamos National Lab., Los Alamos, NM (United States); Ely, T.; Spooner, S. [Oak Ridge National Lab., Oak Ridge, TN (United States)

2002-07-01

We present a study of residual stresses associated with the welding of beryllium rings. Using novel analysis techniques, information about residual stresses and plastic deformation of the base metal were obtained. In the post-welded state, the rings have a strong tensile circumferential residual stress and show evidence of significant plastic deformation. (orig.)

Effects of microstructure and residual stress on fatigue crack growth of stainless steel narrow gap welds

International Nuclear Information System (INIS)

Jang, Changheui; Cho, Pyung-Yeon; Kim, Minu; Oh, Seung-Jin; Yang, Jun-Seog

2010-01-01

The effects of weld microstructure and residual stress distribution on the fatigue crack growth rate of stainless steel narrow gap welds were investigated. Stainless steel pipes were joined by the automated narrow gap welding process typical to nuclear piping systems. The weld fusion zone showed cellular-dendritic structures with ferrite islands in an austenitic matrix. Residual stress analysis showed large tensile stress in the inner-weld region and compressive stress in the middle of the weld. Tensile properties and the fatigue crack growth rate were measured along and across the weld thickness direction. Tensile tests showed higher strength in the weld fusion zone and the heat affected zone compared to the base metal. Within the weld fusion zone, strength was greater in the inner weld than outer weld region. Fatigue crack growth rates were several times greater in the inner weld than the outer weld region. The spatial variation of the mechanical properties is discussed in view of weld microstructure, especially dendrite orientation, and in view of the residual stress variation within the weld fusion zone. It is thought that the higher crack growth rate in the inner-weld region could be related to the large tensile residual stress despite the tortuous fatigue crack growth path.

Joining U.S. NRC international round robin for weld residual stress analysis. Stress analysis and validation in PWSCC mitigation program

International Nuclear Information System (INIS)

Maekawa, Akira; Serizawa, Hisashi; Murakawa, Hidekazu

2012-01-01

It is necessary to establish properly reliable weld residual stress analysis methods for accurate crack initiation and growth assessment of primary water stress corrosion cracking (PWSCC), which may occur in nickel-based dissimilar metal welds in pressurized water reactors. The U.S. Nuclear Regulatory Commission conducted an international round robin for weld residual stress analysis to improve stress analysis methods and to examine the uncertainties involved in the calculated stress values. In this paper, the results from the authors' participation in the round robin were reported. In the round robin, the weld residual stress in a nickel-based dissimilar metal weld of a pressurizer surge nozzle mock-up was computed under various analysis conditions. Based on these residual stress analysis results, a welding simulation code currently being developed that uses the iterative substructure method was validated and affecting factors on the analysis results were identified. (author)

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

A Study on Fatigue Design Automation of Plug- and Ring-type Gas-welded Joints of STS301L Taking Welded Residual Stress into Account

International Nuclear Information System (INIS)

Baek, Seung yeb; Yun, Ki Ho

2010-01-01

This paper presents a fatigue design method for plug- and ring-type gas-welded joints, which takes into account the effects of welding residual stress. To develop this method, we simulated the gas-welding process by performing nonlinear finite element analysis (FEA) To validate the FEA results, numerically calculated residual stresses in the gas welds were then compared with experimental results obtained by the hole-drilling method. To evaluate the fatigue strength of plug- and ring-type gas-welded joints influenced by welding residual stresses, the use of stress amplitude (σ a )R, which includes the welding residual stress in gas welds, is proposed (σ a )R on the basis of a modified Goodman equation that includes the residual stress effects. Using the stress amplitude (σ a )R at the hot spot point of gas weld, the relations obtained as the fatigue test results for plug and ring type gas welded joints having various dimensions and shapes were systematically rearranged to obtain the (σ a )R-N f relationship. It was found that more systematic and accurate evaluation of the fatigue strength of plug- and ring-type gas-welded joints can be achieved by using (σ a )R

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

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.)

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)

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.

Study of residual stresses in welded joints of dual phase HSLA steel used in automotive industry

International Nuclear Information System (INIS)

Barbato, D.S.; Fonseca, M.P. Cindra; Marques Junior, A.S.; Chuvas, T.C.; Pardal, J.M.

2010-01-01

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 Crκα 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)

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

Welding-induced residual tensile stresses and distortion have become a major concern in relation to the structural integrity of welded structures within the offshore wind industry. The stresses have a negative impact on the integrity of the welded joint, as they promote distortion, reduce fatigue...... leading to a better understanding of the distribution and development of the welding residual stresses. This can later be used to optimize the fatigue design, providing a more efficient and improved design. In this context, the current research is expected to benefit the offshore industry by leading...... 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...

Development of residual stress analysis procedure for fitness-for-service assessment of welded structure

International Nuclear Information System (INIS)

Kim, Jong Sung; Jin, Tae Eun; Dong, P.; Prager, M.

2003-01-01

In this study, a state of art review of existing residual stress analysis techniques and representative solutions is presented in order to develop the residual stress analysis procedure for Fitness-For-Service(FFS) assessment of welded structure. Critical issues associated with existing residual stress solutions and their treatments in performing FFS are discussed. It should be recognized that detailed residual stress evolution is an extremely complicated phenomenon that typically involves material-specific thermomechanical/metallurgical response, welding process physics, and structural interactions within a component being welded. As a result, computational procedures can vary significantly from highly complicated numerical techniques intended only to elucidate a small part of the process physics to cost-effective procedures that are deemed adequate for capturing some of the important features in a final residual stress distribution. Residual stress analysis procedure for FFS purposes belongs to the latter category. With this in mind, both residual stress analysis techniques and their adequacy for FFS are assessed based on both literature data and analyses performed in this investigation

Influences of lumped passes on welding residual stress of a thick-walled nuclear rotor steel pipe by multipass narrow gap welding

Energy Technology Data Exchange (ETDEWEB)

Tan, Long, E-mail: mse.longtan@gmail.com [State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, Xi’an Jiaotong University, Xi’an 710049 (China); Zhang, Jianxun; Zhuang, Dong [State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, Xi’an Jiaotong University, Xi’an 710049 (China); Liu, Chuan [Provincial Key Lab of Advanced Welding Technology, Jiangsu University of Science and Technology, Zhenjiang 212003 (China)

2014-07-01

Highlights: • The internal residual stress of the thick-walled pipe is measured by using the local removal blind hole method. • Two lumped-pass models are developed to reduce computational cost. • The effect of lumped passes on the welding residual stress is discussed. • Reasonable lumped-pass model can guarantee the accuracy and improve the computational efficiency. - Abstract: The purpose of this study is to investigate the effect of the lumped passes simulation on the distribution of residual stresses before and after heat treatment in a thick-walled nuclear power rotor pipe with a 89-pass narrow gap welding process. The local removal blind hole method was used to measure internal residual stress of the thick-walled pipe after post weld heat treatment (PWHT). Based on the ANSYS software, a two-dimensional axisymmetric finite element model is employed. Two lumped-pass models of M-5th model (five weld beads as one lumped pass) and M-10th model (ten weld beads as one lumped pass) were developed to reduce computational cost. Based on the results in this study, the distributions of residual stresses of a thick-walled welded pipe before and after PWHT are developed. Meanwhile, the distribution of the through-wall axial residual stress along the weld center line is demonstrated to be a self-equilibrating type. In addition, the investigation results show that reasonable and reliable lumped-pass model can not only guarantee the accuracy of the simulated results, but also improve the computational efficiency in the thermo-elastic–plastic FE analysis procedure. Therefore, from the viewpoint of engineering application the developed lumped-pass computational procedure is a promising and useful method to predict residual stress of large and complex welded structures.

Influences of lumped passes on welding residual stress of a thick-walled nuclear rotor steel pipe by multipass narrow gap welding

International Nuclear Information System (INIS)

Tan, Long; Zhang, Jianxun; Zhuang, Dong; Liu, Chuan

2014-01-01

Highlights: • The internal residual stress of the thick-walled pipe is measured by using the local removal blind hole method. • Two lumped-pass models are developed to reduce computational cost. • The effect of lumped passes on the welding residual stress is discussed. • Reasonable lumped-pass model can guarantee the accuracy and improve the computational efficiency. - Abstract: The purpose of this study is to investigate the effect of the lumped passes simulation on the distribution of residual stresses before and after heat treatment in a thick-walled nuclear power rotor pipe with a 89-pass narrow gap welding process. The local removal blind hole method was used to measure internal residual stress of the thick-walled pipe after post weld heat treatment (PWHT). Based on the ANSYS software, a two-dimensional axisymmetric finite element model is employed. Two lumped-pass models of M-5th model (five weld beads as one lumped pass) and M-10th model (ten weld beads as one lumped pass) were developed to reduce computational cost. Based on the results in this study, the distributions of residual stresses of a thick-walled welded pipe before and after PWHT are developed. Meanwhile, the distribution of the through-wall axial residual stress along the weld center line is demonstrated to be a self-equilibrating type. In addition, the investigation results show that reasonable and reliable lumped-pass model can not only guarantee the accuracy of the simulated results, but also improve the computational efficiency in the thermo-elastic–plastic FE analysis procedure. Therefore, from the viewpoint of engineering application the developed lumped-pass computational procedure is a promising and useful method to predict residual stress of large and complex welded structures

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

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.

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

Coping with residual stresses in the integrity assessment of an as-welded repair

International Nuclear Information System (INIS)

Knee, N.

1989-11-01

One of a series of large scale tests on pressure vessels is described, in which a defect was deliberately introduced into an as-welded (i.e. not stress relieved) repair weld. The behaviour of the vessel during pressurization to failure was carefully monitored and the actual performance compared with theoretical predictions. The influence of residual welding stresses on ductile crack growth from pre-existing defects is discussed in the light of the results of this test and of previous tests in the series. The tests have confirmed that residual stresses can exert a significant effect on the growth of fatigue cracks. However, in tests for which the failure mechanism is predominantly controlled by collapse of the remaining ligament, the development of plasticity during pressurization to failure will tend to remove any local residual stresses. (author)

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

International Nuclear Information System (INIS)

Kim, Kang Soo; Lee, Ho Jin; Woo, Wan Chuck; Seong, Baek Seok; Byeon, Jin Gwi; Park, Kwang Soo; Jung, In Chul

2010-01-01

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

Residual stress measurements in coil, linepipe and girth welded pipe

International Nuclear Information System (INIS)

Law, M.; Prask, H.; Luzin, V.; Gnaeupel-Herold, T.

2006-01-01

Residual stresses in gas pipelines come from forming operations in producing the coil and pipe, seam welding the pipe, and girth welding pipes together to form a gas pipeline. Welding is used extensively in gas pipelines, the welds are made without post weld heat treatment. The three normal stresses were measured by neutron diffraction for three types of sample: coil, unwelded rings cut from the pipe made from this coil, and girth welded rings cut from linepipe. All three specimens came from three thicknesses of manufacture (5.4, 6.4, and 7.1 mm). The welds are manual metal arc cellulosic electrode welds made in X70 linepipe, these were measured at 5 through-thickness positions at 19 locations (from the center of the weld up to 35 mm away from the weld) with a spatial resolution of 1 mm 3 . The coil and unwelded rings were measured at the same five through-thickness positions

Dissimilar friction stir welds in AA5083-AA6082: The effect of process parameters on residual stress

International Nuclear Information System (INIS)

Steuwer, A.; Peel, M.J.; Withers, P.J.

2006-01-01

The effect of tool traverse and rotation speeds on the residual stresses are quantified for welds between non-age-hardening AA5083 and age-hardening AA6082 and compared to single alloy joints made from each of the two constituents. The residual stresses have been characterised non-destructively by neutron diffraction and synchrotron X-ray diffraction. The region around the weld line was characterised by significant tensile residual stress fields which are balanced by compressive stresses in the parent material. The rotation speed of the tool has been found to have a substantially greater influence than the transverse speed on the properties and residual stresses in the welds, particularly on the AA5083 side where the location of the peak stress moves from the stir zone to beyond the edge of the tool shoulder. The changes in residual stress are related to microstructural and hardness changes as determined in a previous study . In particular the larger stresses under the weld tool on the AA5083 side compared to the AA6082 side are related to a transient reduction in yield stress due to dissolution of the hardening precipitates during welding prior to natural aging after welding

Effect of Trailing Intensive Cooling on Residual Stress and Welding Distortion of Friction Stir Welded 2060 Al-Li Alloy

Science.gov (United States)

Ji, Shude; Yang, Zhanpeng; Wen, Quan; Yue, Yumei; Zhang, Liguo

2018-04-01

Trailing intensive cooling with liquid nitrogen has successfully applied to friction stir welding of 2 mm thick 2060 Al-Li alloy. Welding temperature, plastic strain, residual stress and distortion of 2060 Al-Li alloy butt-joint are compared and discussed between conventional cooling and trailing intensive cooling using experimental and numerical simulation methods. The results reveal that trailing intensive cooling is beneficial to shrink high temperature area, reduce peak temperature and decrease plastic strain during friction stir welding process. In addition, the reduction degree of plastic strain outside weld is smaller than that inside weld. Welding distortion presents an anti-saddle shape. Compared with conventional cooling, the reductions of welding distortion and longitudinal residual stresses of welding joint under intense cooling reach 47.7 % and 23.8 %, respectively.

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.

Analysis of residual stresses in girth welded type 304 stainless steel pipes

International Nuclear Information System (INIS)

Brust, F.W.; Kanninen, M.F.

1981-01-01

Intergranular stress corrosion cracking (IGSCC) in boiling water reactor (BWR) piping is a problem for the nuclear power industry. Tensile residual stresses induced by welding are an important factor in IGSCC of Type 304 stainless steel pipes. Backlay and heat sink welding can retard IGSCC. 17 refs

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

Effect of process parameters on the residual stresses in AA5083-H321 friction stir welds

Energy Technology Data Exchange (ETDEWEB)

Lombard, H. [NMMU, Gardham Avenue, PO Box 77000, 6031 Port Elizabeth (South Africa); University of Plymouth, Drake Circus, Plymouth PL4 8AA (United Kingdom); Hattingh, D.G. [NMMU, Gardham Avenue, PO Box 77000, 6031 Port Elizabeth (South Africa); Steuwer, A. [NMMU, Gardham Avenue, PO Box 77000, 6031 Port Elizabeth (South Africa); FaME38 at the ILL-ESRF, 6 rue J Horowitz, 38042 Grenoble (France); University of Plymouth, Drake Circus, Plymouth PL4 8AA (United Kingdom)], E-mail: steuwer@ill.fr; James, M.N. [NMMU, Gardham Avenue, PO Box 77000, 6031 Port Elizabeth (South Africa); University of Plymouth, Drake Circus, Plymouth PL4 8AA (United Kingdom)

2009-02-15

This paper investigates the effect of varying welding parameters on the residual stress profiles in friction stir welds of aluminium alloy AA5083-H321, which were created on a fully instrumented friction welding machine. The residual stresses were determined non-destructively using synchrotron X-ray diffraction. The width and maximum of the residual stress profile show clear correlation with the heat input, and in particular feed rate, which was found to be the dominant parameter.

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.

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

X-Ray diffraction technique applied to study of residual stresses after welding of duplex stainless steel plates

International Nuclear Information System (INIS)

Monin, Vladimir Ivanovitch; Assis, Joaquim Teixeira de; Lopes, Ricardo Tadeu; Turibus, Sergio Noleto; Payao Filho, Joao C.

2014-01-01

Duplex stainless steel is an example of composite material with approximately equal amounts of austenite and ferrite phases. Difference of physical and mechanical properties of component is additional factor that contributes appearance of residual stresses after welding of duplex steel plates. Measurements of stress distributions in weld region were made by X-ray diffraction method both in ferrite and austenite phases. Duplex Steel plates were joined by GTAW (Gas Tungsten Arc Welding) technology. There were studied longitudinal and transverse stress components in welded butt joint, in heat affected zone (HAZ) and in points of base metal 10 mm from the weld. Residual stresses measured in duplex steel plates jointed by welding are caused by temperature gradients between weld zone and base metal and by difference of thermal expansion coefficients of ferrite and austenite phases. Proposed analytical model allows evaluating of residual stress distribution over the cross section in the weld region. (author)

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.

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)

Welding residual stress improvement in internal components by water jet peening

International Nuclear Information System (INIS)

Enomoto, K.; Hirano, K.; Hayashi, M.; Hayashi, E.

1996-01-01

Cavitations are generated when highly pressurized water is jetted in water. Surface residual stress is improved remarkably due to the peening effect of extremely high pressure caused by the collapse of cavitation bubbles. This technique is called water jet peening (WJP). WJP is expected to be an effective maintenance technique for the prevention of stress corrosion cracking caused by residual stress in various components of power generating plants. Various kinds of specimens were water jet peened to evaluate the fundamental characteristics of WJP and to select the most appropriate conditions for the residual stress improvement. Test results showed that WJP markedly improved the tensile residual stress caused by welding and grinding to the high compressive residual stress and seems to prevent the stress corrosion cracking

Measurement and modeling of residual stress in a welded Haynes[reg] 25 cylinder

International Nuclear Information System (INIS)

Larsson, C.; Holden, T.M.; Bourke, M.A.M.; Stout, M.; Teague, J.; Lindgren, L.-E.

2005-01-01

An experimental and simulation study of residual stresses was made in the vicinity of a gas tungsten arc weld, used to join a hemispherical end cap to a cylinder. The capped cylinder is used in a satellite application and was fabricated from a Co-based Haynes[reg] 25 alloy. The cylinder was 34.7 mm in outer diameter and 3.3 mm in thickness. The experimental measurements were made by neutron diffraction and the simulation used the implicit Marc finite element code. The experimental resolution was limited to approximately 3 mm parallel to the axis of the cylinder (the weld was 6 mm in the same direction) and comparison over the same volume of the finite element prediction showed general agreement. Subject to the limited spatial resolution, the largest experimentally measured tensile residual stress was 180 MPa, located at the middle of the weld. However, the predictions suggest that there are regions in the weld where average tensile residual stresses as much as 400 MPa exist. One qualitative disparity between the model and the experiments was that the measurement included a larger degree of asymmetry on either side of the weld than predicted by the model

Measurement and modeling of residual stress in a welded Haynes[reg] 25 cylinder

Energy Technology Data Exchange (ETDEWEB)

Larsson, C. [Div. of Eng. Mat., Department of Mech. Eng., Linkoeping University, 58183 Linkoeping (Sweden)]. E-mail: clarsson@cfl.rr.com; Holden, T.M. [Los Alamos National Laboratory, Los Alamos, NM 87545 (United States); Bourke, M.A.M. [Los Alamos National Laboratory, Los Alamos, NM 87545 (United States); Stout, M. [Los Alamos National Laboratory, Los Alamos, NM 87545 (United States); Teague, J. [Los Alamos National Laboratory, Los Alamos, NM 87545 (United States); Lindgren, L.-E. [Div. Comp. Aided Design, Lulea University of Technology and Dalarna University, 97187 Lulea (Sweden)

2005-06-15

An experimental and simulation study of residual stresses was made in the vicinity of a gas tungsten arc weld, used to join a hemispherical end cap to a cylinder. The capped cylinder is used in a satellite application and was fabricated from a Co-based Haynes[reg] 25 alloy. The cylinder was 34.7 mm in outer diameter and 3.3 mm in thickness. The experimental measurements were made by neutron diffraction and the simulation used the implicit Marc finite element code. The experimental resolution was limited to approximately 3 mm parallel to the axis of the cylinder (the weld was 6 mm in the same direction) and comparison over the same volume of the finite element prediction showed general agreement. Subject to the limited spatial resolution, the largest experimentally measured tensile residual stress was 180 MPa, located at the middle of the weld. However, the predictions suggest that there are regions in the weld where average tensile residual stresses as much as 400 MPa exist. One qualitative disparity between the model and the experiments was that the measurement included a larger degree of asymmetry on either side of the weld than predicted by the model.

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

International Nuclear Information System (INIS)

Campos, Wagner R.C.; Rabello, Emerson G.; Silva, Luiz L.; Mansur, Tanius R.; Martins, Ketsia S.

2015-01-01

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)

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)

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.

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

Influence of treatment by vibration in residual stress generated in the laser welding of HSLA and IF steels

International Nuclear Information System (INIS)

Chuvas, T.C.; Fonseca, M.P. Cindra; Castello, D.A.

2010-01-01

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 2 Ψ 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)

Effect of the weld joint configuration on stressed components, residual stresses and mechanical properties

Energy Technology Data Exchange (ETDEWEB)

Cevik, Bekir; Oezer, Alpay; Oezcatalbas, Yusuf [Gazi Univ., Ankara (Turkey)

2014-03-01

The effect of the weld joint configuration on components has been studied, which are under service loads, under repair or construction and the residual stresses as well as the mechanical properties of the joint have been determined. For this purpose, a horizontal positioned tensile testing device and a semi-automatic MIG welding machine have been used and then the weld joints of the plates were subjected to different elastic stresses. When the temperature of the joined elements decreased to room temperature, applied elastic stresses were released. By this means, the effects of the existing tensile stresses in the joined parts and the tensile stresses created by the welding processes were investigated. The tensile stresses occurring in the joined elements were determined by using the photo-elasticity analysis method and the hole-drilling method. Also, tensile-shear tests were applied in order to determine the effect of permanent tensile loads on the mechanical properties of the joint. Experimental results showed that the application of corner welded lap joints for components under tensile loading significantly decrease the shear strength and yielding capacities of the joint. (orig.)

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.

Fatigue behaviour of 304L steel welded structures: influence of residual stresses and surface mechanical finishing

International Nuclear Information System (INIS)

Magnier-Monin, L.

2007-12-01

This study focuses on the influence of residual stresses and surface mechanical finishing on lifetime of stainless steel 304L welded structures. Residual stresses are determined on specific specimens of three types: base-metal, as-welded and ground-welded specimens. Each type is submitted to fatigue tests in order to assess the influence of these parameters on the lifetime, and to determine their evolution. The experiments show that an important surface stress concentration is located in the weld root of as-welded structures, which has a negative effect on the fatigue life. The grinding operation generates high-level surface residual stresses but the lifetime is higher thanks to the reduction of the notch effect. The fatigue test results are compared to the nuclear industry best-fit S-N curves. This enables the determination of correction factors related to fatigue test results of polished specimens, and to assess the lifetime of structures. (author)

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)

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

Indian Academy of Sciences (India)

Unknown

The distribution of the residual stress in the weld joint of HQ130 grade high strength steel was in- vestigated by ... was adopted in this work to find out the instantaneous distribution of .... welding zone of high strength steel are related to the for-.

Analytical description of fatigue crack propagation regularities taking into account residual welding stresses

International Nuclear Information System (INIS)

Trufyakov, V.I.; Knysh, V.V.; Mikheev, P.P.; Kuz'menko, A.Z.

1983-01-01

The procedure, accounting the effect of residual stresses on crack resistance of welded constructions under cyclic loads, is described. The procedure is based on the Paris equation modified by the introduction of the coefficient of residual stress intensity through the functional dependence. The dependence is determined for cases of residual stresses of tension and compression. The experimental data for the 15KhSND steel are presented

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.)

An investigation of the residual stress characterization and relaxation in peened friction stir welded aluminum-lithium alloy joints

International Nuclear Information System (INIS)

Hatamleh, Omar; Rivero, Iris V.; Swain, Shayla E.

2009-01-01

In this investigation the residual stresses generated from friction stir welded (FSW) 2195 aluminum-lithium alloy joints were characterized. The results derived from this research revealed significant levels of tensile residual stresses at the surface and throughout the thickness of the FSW samples. Furthermore, residual stress relaxation at the surface and throughout the thickness of the samples was assessed for laser peened friction stir welded aluminum-lithium joints. To do so the samples were cycled several times at a constant amplitude load. The results indicated that most of the relaxation for the surface residual stresses took place during the first cycle of loading. Also, residual stresses relaxation throughout the thickness of the welded region of unpeened samples significantly exceeded the relaxation exhibited by the laser peened samples.

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)

Simulation of residual stresses and deformations in electron beam-welded copper canisters

International Nuclear Information System (INIS)

Aronen, A.; Leikko, J.; Taskinen, P.; Karvinen, R.

2013-07-01

This report presents the modelling of residual stresses and deformations of an EB-welded copper canister. Two different mock-up lengths are modelled with the Abaqus FEA program, and the similarity of those results is studied. Canister mock-ups of 450 mm and 915 mm were chosen for the test cases. The heat treatment results presented in Taskinen 2009 are used as input data for the mechanical model. For the mechanical analysis some simplifications were made to the model. The contact surface between pipe and lid is assumed to be tied and support from the bottom surface is provided with four support points. Results show that, due to the similarity of 450 mm and 915 mm canisters, the short mock-up can be used to predict the stresses and deformation on a full-length canister (5000 mm). The similarity of the temperature fields has already been shown in the previous reports (Taskinen 2009). The main result in the deformation is the shape of the canister in the residual state. The top of the canister tries to shrink, resulting in the lid buckling inwards. The deformation of the lid of the canister is about 2.2 mm at the centre of the lid. The main results in the stresses are the stress level on the surface, the deviation of stresses over the circle and the stresses near the welding. On the surface there are areas where the circumferential stress is at tension. However, radial and axial stresses are usually in compression on the surface. The deviation of the stress level over the circle is quite small, except in the overlap area and near it. The residual stresses from 0 deg C to 45 deg C change remarkably, but over the rest of the area the stresses are more constant. Near the welding the stresses on the top surface are in compression, but in the centre of the welding the stresses are in tension. In the modelling, the possibility of calculating a mechanical model with the contact surface between pipe and lid, so that they could be separated during the welding, was also tested

Simulation of residual stresses and deformations in electron beam-welded copper canisters

Energy Technology Data Exchange (ETDEWEB)

Aronen, A.; Leikko, J.; Taskinen, P.; Karvinen, R. [Tampere Univ. of Technology (Finland)

2013-07-15

This report presents the modelling of residual stresses and deformations of an EB-welded copper canister. Two different mock-up lengths are modelled with the Abaqus FEA program, and the similarity of those results is studied. Canister mock-ups of 450 mm and 915 mm were chosen for the test cases. The heat treatment results presented in Taskinen 2009 are used as input data for the mechanical model. For the mechanical analysis some simplifications were made to the model. The contact surface between pipe and lid is assumed to be tied and support from the bottom surface is provided with four support points. Results show that, due to the similarity of 450 mm and 915 mm canisters, the short mock-up can be used to predict the stresses and deformation on a full-length canister (5000 mm). The similarity of the temperature fields has already been shown in the previous reports (Taskinen 2009). The main result in the deformation is the shape of the canister in the residual state. The top of the canister tries to shrink, resulting in the lid buckling inwards. The deformation of the lid of the canister is about 2.2 mm at the centre of the lid. The main results in the stresses are the stress level on the surface, the deviation of stresses over the circle and the stresses near the welding. On the surface there are areas where the circumferential stress is at tension. However, radial and axial stresses are usually in compression on the surface. The deviation of the stress level over the circle is quite small, except in the overlap area and near it. The residual stresses from 0 deg C to 45 deg C change remarkably, but over the rest of the area the stresses are more constant. Near the welding the stresses on the top surface are in compression, but in the centre of the welding the stresses are in tension. In the modelling, the possibility of calculating a mechanical model with the contact surface between pipe and lid, so that they could be separated during the welding, was also tested

3-D characteristics of the residual stress in the plate weld between SA508 and stainless steel 316L

Energy Technology Data Exchange (ETDEWEB)

Lee, Kyoung Soo; Kim, Tae Ryong [Korea Electric Power Research Institute, Daejeon (Korea, Republic of); Park, Jai Hak [Chungbuk National Univ., Cheongju (Korea, Republic of); Kim, Man Won [Global New-clear Engineering and Consulting, Daejeon (Korea, Republic of); Cho, Seon Yeong [Korea Laboratory Engineering System Company, Cheonan (Korea, Republic of)

2008-07-01

This study is performed to check the three dimensional characteristics of residual stress in the dissimilar metal weld. Although two dimensional analysis has been widely used for the assessment of weld residual stress, it has limitations to understand the stress distribution of the third direction. 3-D analysis was done to understand residual stress distribution of the welded plate. A simple butt-welded plate was considered to show the stress variation on all direction. A mock-up plate weldment was fabricated with SA-508 and F316L, which are widely used in nuclear power plants. The analysis results were validated with the measured values in the mock-up.

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

Residual stress analysis in linear friction welded in-service Inconel 718 superalloy via neutron diffraction and contour method approaches

Energy Technology Data Exchange (ETDEWEB)

Smith, M. [University of British Columbia – Okanagan, School of Engineering, 3333 University Way, Kelowna, Canada V1V 1V7 (Canada); Levesque, J.-B. [Institut de recherche d' Hydro-Québec (IREQ), 1800 Lionel-Boulet Blvd., Varennes, Canada J3X 1S1 (Canada); Bichler, L., E-mail: lukas.bichler@ubc.ca [University of British Columbia – Okanagan, School of Engineering, 3333 University Way, Kelowna, Canada V1V 1V7 (Canada); Sediako, D. [Canadian Nuclear Laboratories, Building 459, Station 18, Chalk River, Canada K0J 1J0 (Canada); Gholipour, J.; Wanjara, P. [National Research Council of Canada, Aerospace 5145 Decelles Ave., Montreal, Canada H3T 2B2 (Canada)

2017-04-13

In this study, an analysis of elastic residual stress in Inconel{sup ®} 718 (IN 718) linear friction welds (LFWs) was carried out. In particular, the suitability of LFW for manufacturing and repair of aero engine components was emulated by joining virgin and in-service (extracted from a turbine disk) materials. The evolution in the residual strains and stresses in the heat-affected zone (HAZ), thermomechanically affected zone (TMAZ) and dynamically recrystallized zone (DRX) of the weld was characterized using the neutron diffraction and contour methods. The results provided insight into diverse challenges in quantitative analysis of residual stresses in welded IN 718 using diffraction techniques. Specifically, judicious selection of the beam width, height and stress-free lattice spacing were seen to be crucial to minimize measurement error and increase accuracy. Further, the contour method – a destructive technique relying on capturing the stress relaxation after electrical discharge machining – was used to characterize the residual stress distribution on two-dimensional plane sections of the welds. Both techniques suggested an increasing magnitude of residual stress originating from the base metal that reached a peak at the weld interface. Both methods indicated that the peak magnitude of residual stresses were below the yield stress of IN 718.

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.)

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...

Finite element analysis and measurement for residual stress of dissimilar metal weld in pressurizer safety nozzle mockup

International Nuclear Information System (INIS)

Lee, Kyoung Soo; Kim, W.; Lee, Jeong Geun; Park, Chi Yong; Yang, Jun Seok; Kim, Tae Ryong; Park, Jai Hak

2009-01-01

Finite element (FE) analysis and experiment for weld residual stress (WRS) in the pressurizer safety nozzle mockup is described in various processes and results. Foremost of which is the dissimilar simulation metal welding (DMW) between carbon steel and austenitic stainless steel. Thermal and structural analyses were compared with actual residual stress, and actual measurements of. Magnitude and distribution of WRS in the nozzle mockup were assessed. Two measurement methods were used: hole-drilling method (HDM) with strain gauge for residual stress on the surface of the mockup, and block removal and splitting layer (BRSL) method for through-thickness. FE analysis and measurement data showed good agreement. In conclusion, the characteristics of weld residual stress of DMW could be well understood and the simplified FE analysis was verified as acceptable for estimating WRS

Finite element analysis and measurement for residual stress of dissimilar metal weld in pressurizer safety nozzle mockup

Energy Technology Data Exchange (ETDEWEB)

Lee, Kyoung Soo; Kim, W.; Lee, Jeong Geun; Park, Chi Yong; Yang, Jun Seok; Kim, Tae Ryong [Korea Electric Power Research Institute, Daejeon (Korea, Republic of); Park, Jai Hak [Chungbuk University, Cheongju (Korea, Republic of)

2009-11-15

Finite element (FE) analysis and experiment for weld residual stress (WRS) in the pressurizer safety nozzle mockup is described in various processes and results. Foremost of which is the dissimilar simulation metal welding (DMW) between carbon steel and austenitic stainless steel. Thermal and structural analyses were compared with actual residual stress, and actual measurements of. Magnitude and distribution of WRS in the nozzle mockup were assessed. Two measurement methods were used: hole-drilling method (HDM) with strain gauge for residual stress on the surface of the mockup, and block removal and splitting layer (BRSL) method for through-thickness. FE analysis and measurement data showed good agreement. In conclusion, the characteristics of weld residual stress of DMW could be well understood and the simplified FE analysis was verified as acceptable for estimating WRS

Mitigation of inside surface residual stress of type 304 stainless steel pipe welds by inside water cooling method

International Nuclear Information System (INIS)

Sasaki, R.

1980-01-01

The weld residual stress distributions, macro- and microstructures of heat affected zone and IGSCC susceptibility of Type 304 stainless steel pipe welds by natural and inside water cooling methods have been investigated. The residual stresses of pipe welds by the natural cooling method are high tensile on both the inside and the outside surface. While the residual stresses on the inside surface of pipe welds by the inside water cooling method are compressive in both axial and circumferential directions for each pipe size from 2 to 24 inch diameter. The sensitized zones of welds by the inside water cooling method are closer to the fusion line, much narrower and milder than those by the natural cooling method. According to the constant extension rate test results for specimens taken from the inside surface of pipe welds, the inside water cooled welds are more resistant to IGSCC than naturally cooled ones

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.

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

Residual and working stresses in pipe joints in heterogeneous metals, due to common action of welding and service loads

International Nuclear Information System (INIS)

Kiselev, S.N.; Voronin, N.N.; Roshchin, V.V.

1978-01-01

The stresses in the welded joints of cylindrical shells are studied, which are caused by the total effect of the thermal deformation welding cycles, by the preheats connected with the thermal treatment or operation, and by power loads. Studied were the shell joints made of the steels Kh18N10T and St.3, as well as the joints of three shells made of different metals, St.3+18N1aT steel+copper. The schematic diagram showing the residual stresses set up under effect of different factors are presented. The following has been shown by the study: the preheating of the welded joints of the shells made of diverse metals up to the operational temperatures does not result in obviating the residual stresses. If the welded shells are loaded by the internal pressure up to the stresses of (0.8-O.9) sigmasub(T), in certain cases an essential (up to 60-70%) reduction in the residual welding stresses may be obtained. The effectiveness of a variation in the residual stresses is reduced in the joints that have been thermally treated after welding. The working stresses set up in the welded joints of the shells made of different metals under the operational loading may be essentially reduced through initial preheating with the application of a pressure or without it. The preheating temperature and the pressures applied may be chosen so that to create the residual strains and the stresses of inverse sign as compared with the working stresses

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.

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.

3-D Characteristics of the Residual Stress in the Plate Butt Weld Between SA508 and F316L SS

Energy Technology Data Exchange (ETDEWEB)

Lee, Kyoung Soo; Kim, Tae Ryong [Korea Electric Power Research Institute, Daejeon (Korea, Republic of); Park, Jai Hak [Chungbuk National University, Cheongju (Korea, Republic of); Kim, Man Won [GNEC, Daejeon (Korea, Republic of); Cho, Seon Yeong [KLES, Daejeon (Korea, Republic of)

2009-04-15

This study is performed to check the three dimensional characteristics of residual stress in the dissimilar metal weld. Although two dimensional analysis has been widely used for the assessment of weld residual stress, it has limitations to understand the stress distribution of the third direction. 3-D analysis was done to understand residual stress distribution of the welded plate. A simple butt-welded plate was considered to show the stress variation on all direction. A mock-up plate weldment was fabricated with SA-508 and F316L, which are widely used in nuclear power plants. The analysis results were validated with the measured values in the mock-up.

Project of integrity assessment of flawed components with structural discontinuity (IAF). Data book for residual stress analysis in weld joint. Analysis model of dissimilar metal weld joint applied post weld heat treatment (PWHT)

International Nuclear Information System (INIS)

2012-12-01

The project of Integrity Assessment of Flawed Components with Structural Discontinuity (IAF) was entrusted to Japan Power Engineering and Inspection Corporation (JAPEIC) from Nuclear and Industrial Safety Agency (NISA) and started from FY 2001. And then, it was taken over to Japan Nuclear Energy Safety Organization (JNES) which was established in October 2003 and carried out until FY 2007. In the IAF project, weld joints between nickel based alloys and low alloy steels around penetrations in reactor vessel, safe-end of nozzles and shroud supports were selected from among components and pipe arrangements in nuclear power plants, where high residual stresses were generated due to welding and complex structure. Residual stresses around of the weld joints were estimated by finite element analysis method (FEM) with a general modeling method, then the reasonability and the conservativeness was evaluated. In addition, for postulated surface crack of stress corrosion cracking (SCC), a simple calculation method of stress intensity factor (K) required to estimate the crack growth was proposed and the effectiveness was confirmed. JNES compiled results of the IAF project into Data Books of Residual Stress Analysis of Weld Joint, and Data Book of Simplified Stress Intensity Factor Calculation for Penetration of Reactor as typical Structure Discontinuity, respectively. Data Books of Residual Stress Analysis in Weld Joint. 1. Butt Weld Joint of Small Diameter Cylinder (4B Sch40) (JNES-RE-2012-0005), 2. Dissimilar Metal Weld Joint in Safe End (One-Side Groove Joint (JNES-RE-2012-0006), 3. Dissimilar Metal Weld Joint in Safe End (Large Diameter Both-Side Groove Joint) (JNES-RE-2012-0007), 4. Weld Joint around Penetrations in Reactor Vessel (Insert Joint) (JNES-RE-2012-0008), 5. Weld Joint in Shroud Support (H8, H9, H10 and H11 Welds) (JNES-RE-2012-0009), 6. Analysis Model of Dissimilar Metal Weld Joint Applied Post Weld Heat Treatment (PWHT) (JNES-RE-2012-0010). Data Book of

Investigation of effect of post weld heat treatment conditions on residual stress for ITER blanket shield blocks

Energy Technology Data Exchange (ETDEWEB)

Jung, Hun-Chea, E-mail: hcjung@nfri.re.kr [ITER Korea, National Fusion Research Institute, Daejeon (Korea, Republic of); Kim, Sa-Woong [ITER Korea, National Fusion Research Institute, Daejeon (Korea, Republic of); Lee, Yun-Hee [Division of Convergence Technology, Korea Research Institute of Standard and Science (KRISS), Daejeon (Korea, Republic of); Baek, Seung-Wook [Division of Industrial Metrology, Korea Research Institute of Standard and Science (KRISS), Daejeon (Korea, Republic of); Ha, Min-Su; Shim, Hee-Jin [ITER Korea, National Fusion Research Institute, Daejeon (Korea, Republic of)

2016-11-01

Highlights: • PWHT for ITER blanket shield block should be performed for dimensional stability. • Investigation of the effect of PWHT conditions on properties was performed. • Instrumented indentation method for evaluation of properties was used. • Residual stress and hardness decreased with increasing PWHT temperature. • Optimization of PWHT conditions would be needed for satisfaction of requirement. - Abstract: The blanket shield block (SB) shall be required the tight tolerance because SB interfaces with many components, such as flexible support keypads, First Wall (FW) support contact surfaces, FW central bolt, electrical strap contact surfaces and attachment inserts for both FW and Vacuum Vessel (VV). In order to fulfil the tight tolerance requirement, stress relieving shall be performed for dimensional stability after cover welding operation. In this paper, effect of Post Weld Heat Treatment (PWHT) conditions, temperature and holding time, was investigated on the residual stress and hardness. The 316L Stainless Steel (SS) was prepared and welded by manual TIG welding by using filler material with 2.4 mm of diameter. Welded 316L SS plate was machined to prepare the specimen for PWHT. PWHT was implemented at 250, 300, 400 °C for 2 and 3 h (400 °C only) and residual stress after relaxation were determined. The evaluation of residual stress and hardness for each specimen was carried out by instrumented indentation technique. The residual stress and hardness were decreased with increasing the heat treatment temperature and holding time.

Welding-induced local maximum residual stress in heat affected zone of low-carbon austenitic stainless steel with machined surface layer and its influential factors

International Nuclear Information System (INIS)

Okano, Shigetaka; Ihara, Ryohei; Kanamaru, Daisuke; Mochizuki, Masahito

2015-01-01

In this study, the effects of work-hardening and pre-existing stress in the machined surface layer of low-carbon austenitic stainless steel on the welding-induced residual stress were experimentally investigated through the use of weld specimens with three different surface layers; as-cutout, mechanically-polished and electrolytically-polished. The high tensile and compressive stresses exist in the work-hardened surface layer of the as-cutout and mechanically-polished specimens, respectively. Meanwhile, no stress and work-hardened surface layer exist in the electrolytically-polished specimen. TIG bead-on-plate welding under the same welding heat input conditions was performed to introduce the residual stress into these specimens. Using these welded specimens, the distributions of welding-induced residual stress were measured by the X-ray diffraction method. Similarly, the distributions of hardness in welds were estimated by the Vickers hardness test. And then, these distributions were compared with one another. Based on the results, the residual stress in the weld metal (WM) is completely unaffected by the machined surface layer because the work-hardened surface layer disappears through the processes of melting and solidification during welding. The local maximum longitudinal tensile residual stress in the heat affected zone (HAZ) depends on the work-hardening but not on the existing stress, regardless of whether tensile or compressive, in the machined surface layer before welding. At the base metal far from WM and HAZ, the residual stress is formed by the addition of the welding-induced residual stress to the pre-existing stress in the machined surface layer before welding. The features of the welding-induced residual stress in low-carbon austenitic stainless steel with the machined surface layer and their influential factors were thus clarified. (author)

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

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

Residual stress evaluation and fatigue life prediction in the welded joint by X-ray diffraction

International Nuclear Information System (INIS)

Yoo, Keun Bong; Kim, Jae Hoon

2009-01-01

In the fossil power plant, the reliability of the components which consist of the many welded parts depends on the quality of welding. The residual stress is occurred by the heat flux of high temperature during weld process. This decreases the mechanical properties as the strength of fatigue and fracture or occurs the stress corrosion cracking and fatigue fracture. The residual stress of the welded part in the recently constructed power plants has been the cause of a variety of accidents. The objective of this study is measurement of the residual stress by X-ray diffraction method and to estimate the feasibility of this application for fatigue life assessment of the high-temperature pipeline. The materials used for the study is P92 steel for the use of high temperature pipe on super critical condition. The test results were analyzed by the distributed characteristics of residual stresses and the Full Width at Half Maximum intensity (FWHM) in x-ray diffraction intensity curve. Also, X-ray diffraction tests using specimens simulated low cycle fatigue damage were performed in order to analyze fatigue properties when fatigue damage conditions become various stages. As a result of X-ray diffraction tests for specimens simulated fatigue damages, we conformed that the ratio of the FWHM due to fatigue damage has linear relationship with fatigue life ratio algebraically. From this relationships, it was suggested that direct expectation of the life consumption rate was feasible.

Residual-stresses in austenitic stainless-steel primary coolant pipes and welds of pressurized-water reactors

International Nuclear Information System (INIS)

Faure, F.; Leggatt, R.H.

1996-01-01

Surface and through thickness residual stress measurements were performed on an aged cast austenitic-ferritic stainless steel pipe and on an orbital TIG weld representative of those of primary coolant pipes in pressurized water reactors. An abrasive-jet hole drilling method and a block removal and layering method were used. Surface stresses and through thickness stress profiles are strongly dependent upon heat treatments, machining and welding operations. In the aged cast stainless steel pipe, stresses ranged between -250 and +175 MPa. On and near the orbital TIG weld, the outside surface of the weld was in tension both in the axial and hoop directions, with maximum values reaching 420 MPa in the weld. On the inside surface, the hoop stresses were compressive, reaching -300 MPa. However, the stresses in the axial direction at the root of the weld were tensile within 4 mm depth from the inside surface, locally reaching 280 MPa. (author)

Residual stresses

International Nuclear Information System (INIS)

Sahotra, I.M.

2006-01-01

The principal effect of unloading a material strained into the plastic range is to create a permanent set (plastic deformation), which if restricted somehow, gives rise to a system of self-balancing within the same member or reaction balanced by other members of the structure., known as residual stresses. These stresses stay there as locked-in stresses, in the body or a part of it in the absence of any external loading. Residual stresses are induced during hot-rolling and welding differential cooling, cold-forming and extruding: cold straightening and spot heating, fabrication and forced fitting of components constraining the structure to a particular geometry. The areas which cool more quickly develop residual compressive stresses, while the slower cooling areas develop residual tensile stresses, and a self-balancing or reaction balanced system of residual stresses is formed. The phenomenon of residual stresses is the most challenging in its application in surface modification techniques determining endurance mechanism against fracture and fatigue failures. This paper discusses the mechanism of residual stresses, that how the residual stresses are fanned and what their behavior is under the action of external forces. Such as in the case of a circular bar under limit torque, rectangular beam under limt moment, reclaiming of shafts welds and peening etc. (author)

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)

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

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)

Basic numerical study on gap influence of residual stress and distortion during high-brightness laser butt welding

International Nuclear Information System (INIS)

Serizawa, Hisashi; Mori, Daiki; Murakawa, Hidekazu

2013-01-01

High-brightness laser such as fiber laser or disk laser is expected to minimize the total heat input energy in welding due to its high beam quality, and the welding residual stress and distortion also seem to be reduced as a result. However, the diameter of high-brightness laser beam is less than 0.6 mm and it is difficult to set the beam position to contact face between two parts because in general there would be a gap due to quality of parts. In this study, in order to reveal the effect of gap on the residual stress and the welding distortion during fiber laser welding, the butt welding of two plates were examined through the thermal elastic-plastic analysis with a new gap element. From the result of thermal analyses, it was found that the homogeneous ellipsoid body could be applicable to model the shape of heat source for the fiber laser and the gap width would not influence the penetration shape when the gap width was changed from 0.1 to 0.25 mm. In addition, the elastic-plastic analyses indicated that the transverse shrinkage slightly increased with increasing the gap width, while this shrinkage without gap was much smaller than that with gap. Also, it was revealed that the welding speed largely affects both the welding residual stress and distortion. Moreover, it was found that the residual stress was almost independent of the jig position, while the position of fixtures slightly affected the transverse shrinkage. (author)

Rate of fatigue crack growth in residual stress fields of welded titanium joints with different contents of embrittling impurities

International Nuclear Information System (INIS)

Troshchenko, V.T.; Pokrovskij, V.V.; Yarusevich, V.L.; Mikhajlov, V.I.; Sher, V.A.

1990-01-01

Resistance to fatigue crack growth (FCG) has been studied in welded joints of structural titanium alloys contaminated by embrittling impurities. Besides, effect of crack closing has been taken into account what makes it possible to determine the effective coefficient of the stress intensity. The rate of fatigue crack growth is proved to considerably depend on the value and direction of residual stresses. The rate dependence of FCG in welded joints of structural titanium alloys on the swing of effective coefficient of stress intensity is invariant to the value and direction of weld residual stresses

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.

A Simplified Model for the Effect of Weld-Induced Residual Stresses on the Axial Ultimate Strength of Stiffened Plates

Science.gov (United States)

Chen, Bai-Qiao; Guedes Soares, C.

2018-03-01

The present work investigates the compressive axial ultimate strength of fillet-welded steel-plated ship structures subjected to uniaxial compression, in which the residual stresses in the welded plates are calculated by a thermo-elasto-plastic finite element analysis that is used to fit an idealized model of residual stress distribution. The numerical results of ultimate strength based on the simplified model of residual stress show good agreement with those of various methods including the International Association of Classification Societies (IACS) Common Structural Rules (CSR), leading to the conclusion that the simplified model can be effectively used to represent the distribution of residual stresses in steel-plated structures in a wide range of engineering applications. It is concluded that the widths of the tension zones in the welded plates have a quasi-linear behavior with respect to the plate slenderness. The effect of residual stress on the axial strength of the stiffened plate is analyzed and discussed.

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

2007-01-01

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 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 accelerated by residual stress of multi pass welding and surface hardening. (author)

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)

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

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)

Residual Stress Testing of Outer 3013 Containers

International Nuclear Information System (INIS)

Dunn, K.

2004-01-01

A Gas Tungsten Arc Welded (GTAW) outer 3013 container and a laser welded outer 3013 container have been tested for residual stresses according to the American Society for Testing Materials (ASTM) Standard G-36-94 [1]. This ASTM standard describes a procedure for conducting stress-corrosion cracking tests in boiling magnesium chloride (MgCl2) solution. Container sections in both the as-fabricated condition as well as the closure welded condition were evaluated. Significantly large residual stresses were observed in the bottom half of the as-fabricated container, a result of the base to can fabrication weld because through wall cracks were observed perpendicular to the weld. This observation indicates that regardless of the closure weld technique, sufficient residual stresses exist in the as-fabricated container to provide the stress necessary for stress corrosion cracking of the container, at the base fabrication weld. Additionally, sufficiently high residual stresses were observed in both the lid and the body of the GTAW as well as the laser closure welded containers. The stresses are oriented perpendicular to the closure weld in both the container lid and the container body. Although the boiling MgCl2 test is not a quantitative test, a comparison of the test results from the closure welds shows that there are noticeably more through wall cracks in the laser closure welded container than in the GTAW closure welded container

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

International Nuclear Information System (INIS)

Vourna, P

2016-01-01

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. (paper)

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.

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)

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-state ......, numerical framework and application as well as putting them into proper context with respect to some of the new trends in the field, e.g. coupling with subsequent load analyses of the in-service situation or applying residual stress models of FSWin numerical optimization.......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......-state joining process characterized by a pronounced multiphysical behaviour involving phenomena such as change of temperature, material flow, change of microstructures and formation of residual stresses. Thus, models of FSWare typically divided into thermal models, flow models, residual stress models...

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

Science.gov (United States)

2013-06-01

dispersion strengthened - Eurofer steel ,” J. Nucl. Mater., vol. 416 , pp. 2229, Sep 1, 2011. [10] H. J. K. Lemmen and K. J. Sudmeijer, I, “Laser beam...Reynolds and W. Tang, “Structure, properties, and residual stress of 304L stainless steel friction stir welds,” Scr. Mater., vol. 48, pp. 12891294...OF RESIDUAL STRESS AS A FUNCTION OF FRICTION STIR WELDING PARAMETERS IN ODS STEEL MA956 by Martin S. Bennett June 2013 Thesis Advisor

Experimental Analysis of Residual Stresses in Samples of Austenitic Stainless Steel Welded on Martensitic Stainless Steel Used for Kaplan Blades Repairs

Directory of Open Access Journals (Sweden)

Vasile Cojocaru

2011-01-01

Full Text Available Residual stresses occur in materials as a result of mechanical processes: welding, machining, grinding etc. If residual stresses reach high values they can accelerate the occurrence of cracks and erosion of material. An experimental research was made in order to study the occurrence of residual stresses in the repaired areas of hydraulic turbine components damaged by cavitation erosion. An austenitic stainless steel was welded in various layer thicknesses on a martensitic stainless steel base. The residual stresses were determined using the hole drilling strain gage method.

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

Energy Technology Data Exchange (ETDEWEB)

Ham, Junhyuk; Choi, Kyoung Joon; Kim, Ji Hyun [UNIST, Ulsan (Korea, Republic of)

2016-10-15

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{sub Y}15 material is weakest state for PWSCC. The

The residual stress distribution in welded pipe inner surface of stainless steel from the nuclear power plant in Ringhals

International Nuclear Information System (INIS)

Larsson, L.E.

1984-06-01

The axial residual stress distribution on the inner surface of welded pipes of stainless steel SS 2333 (AISI 304) have been measured using the X-ray diffraction technique. Four halves of two pipes with the outer diameter of 114 mm and wall thickness of 10 mm were investigated. The result on the pipe inner surface shows compressive stresses in the weld metal and tensile stresses within a region between 8-23 mm with a maximum of 180MPa at a distance of 17 mm from the weld centerline. The maximum axial and circumferential residual stresses on the pipe outer surface are of the magnitude of 100 MPa. By cutting the pipes into two halves these stresses are relaxed by about 35 MPa. (author)

Measurement and prediction of residual stress in a bead-on-plate weld benchmark specimen

International Nuclear Information System (INIS)

Ficquet, X.; Smith, D.J.; Truman, C.E.; Kingston, E.J.; Dennis, R.J.

2009-01-01

This paper presents measurements and predictions of the residual stresses generated by laying a single weld bead on a flat, austenitic stainless steel plate. The residual stress field that is created is strongly three-dimensional and is considered representative of that found in a repair weld. Through-thickness measurements are made using the deep hole drilling technique, and near-surface measurements are made using incremental centre hole drilling. Measurements are compared to predictions at the same locations made using finite element analysis incorporating an advanced, non-linear kinematic hardening model. The work was conducted as part of an European round robin exercise, coordinated as part of the NeT network. Overall, there was broad agreement between measurements and predictions, but there were notable differences

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.

Systematic Review of Uit Parameters on Residual Stresses of Sensitized AA5456 and Field Based Residual Stress Measurements for Predicting and Mitigating Stress Corrosion Cracking

Science.gov (United States)

2014-03-01

University Press, 2009, pp. 820–824. [30] S. Kou, Welding Metallurgy , 2nd ed. Hoboken, NJ: John Wiley and Sons, Inc., 2003. [31] M. N.James et al...around welds in aluminum ship structures both in the laboratory and in the field. Tensile residual stresses are often generated during welding and, in...mitigate and even reverse these tensile residual stresses. This research uses x-ray diffraction to measure residual stresses around welds in AA5456 before

Optimising residual stresses at a repair in a steam header to tubeplate weld

International Nuclear Information System (INIS)

Soanes, T.P.T.; Bell, W.; Vibert, A.J.

2005-01-01

Following the discovery of incorrect weld metal in the steam side shell to tubeplate weld in a type 316H stainless steel superheater steam header, a repair strategy had to be determined. The strategy adopted was to remove the incorrect weld material, which extended around the full circumference, by machining from the inside of the header, followed by rewelding from the inside using an automatic welding process and localised post-weld heat treatment. Due to concern over potential reheat cracking of the repair after return to service, a considerable amount of residual stress modelling was carried out to support the development and optimisation of a successful repair and heat treatment strategy and thus underwrite the safety case for return to service

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)

Parametric study for welding residual stresses in nozzle of nuclear power plants using finite element method

Energy Technology Data Exchange (ETDEWEB)

Kim, Wan Jae; Lee, Kyoung Soo; Kim, Tae Ryong [Korea Electric Power Research Institute, Daejeon (Korea, Republic of); Song, Tae Kwang [Korea Univ., Seoul (Korea, Republic of)

2008-07-01

Distribution of welding residual stresses are mainly characterized by degrees and frequencies of thermal loads applied to materials. However, other effects as component size and clamping condition can also affect stress distributions to a certain extent thus careful manipulation of these parameters based on clear understanding of how they affect residual stresses distributions and why can be additional measure to mitigate residual stresses. This paper discusses aforementioned issues for the case of safety and relief nozzle in nuclear power plant through finite element analysis.

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.

Residual stress concerns in containment analysis

International Nuclear Information System (INIS)

Costantini, F.; Kulak, R. F.; Pfeiffer, P. A.

1997-01-01

The manufacturing of steel containment vessels starts with the forming of flat plates into curved plates. A steel containment structure is made by welding individual plates together to form the sections that make up the complex shaped vessels. The metal forming and welding process leaves residual stresses in the vessel walls. Generally, the effect of metal forming residual stresses can be reduced or virtually eliminated by thermally stress relieving the vesseL In large containment vessels this may not be practical and thus the residual stresses due to manufacturing may become important. The residual stresses could possibly tiect the response of the vessel to internal pressurization. When the level of residual stresses is significant it will affect the vessel's response, for instance the yielding pressure and possibly the failure pressure. The paper will address the effect of metal forming residual stresses on the response of a generic pressure vessel to internal pressurization. A scoping analysis investigated the effect of residual forming stresses on the response of an internally pressurized vessel. A simple model was developed to gain understanding of the mechanics of the problem. Residual stresses due to the welding process were not considered in this investigation

X-ray diffraction based residual stress analysis of repair welds of CrMo steels

International Nuclear Information System (INIS)

Rai, Sanjay; Sujith, S.; Jayakumar, T.

1996-01-01

Premature failure of weldments is often reported in the industry. Once failure occurs, the common practice now a days is either to replace the whole component or repair the failed region by welding. Since repairing rather than replacing is more economical, the process of repair welding assumes technological significance. However, it is necessary to realise the problems associated with repair-welding. During most of the repair welding cases, after repair weldments are hard and brittle. In many cases it is not possible to give post weld heat treatment (PWHT). This demands better welding techniques for repair without affecting the microstructure. Repair welding requires adoption of special procedure and parameters to obtain acceptable properties of the repair welded regions. In this paper different repair welding methods have been compared from residual stress and hardness point of view. (author)

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

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

Energy Technology Data Exchange (ETDEWEB)

Oh, Seung Hyuk; Ryu, Tae Young; Park, Seung Hyun; Won, Min Gu; Kang, Seok Jun; Kim, Moon Ki; Choi, Jae Boong [Sungkyunkwan University, Suwon (Korea, Republic of); Lee, Kyoung Soo; Lee, Sung Ho [Korea Hydro and Nuclear Power, Daejeon (Korea, Republic of)

2015-03-15

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.

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.

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.

Residual stress characterization of a fabrication weld from the VICTORIA-Class submarine pressure hull: revealing the unseen

International Nuclear Information System (INIS)

McGregor, R.J.; Rogge, R.B.

2010-01-01

Explicit understanding of the residual-stress character of primary submarine pressure hull weldments will improve the fidelity of numerical analysis and experimentation supporting operational envelope and design life. A length of circumferential-seam closure weld was contained within a section of hull plate removed from the HMCS VICTORIA during the extended docking work period (EDWP) refit operations. This has provided a rare opportunity for detailed characterization of the as-received condition of this common weld-type from original vessel assembly. In collaboration with the Canadian Neutron Beam Centre of the National Research Council (NRC), a program was conducted to study this weld using neutron diffraction. Neutron diffraction is able to survey nondestructively through the section thickness, providing a three-dimensional characterization, while leaving the specimen intact for complementary study by other methods. Results indicate tensile stress peaks of up to 80% of the base-material yield stress. Understanding the three-dimensional behaviour of residual stress in this type of weld provides a valuable resource to the numerical modelling community. The results can also support fatigue and fracture experimental work and serve to confirm and improve the interpretation of the existing body of 'surface-only' work conducted on similar welds. (author)

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.

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

2018-07-01

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.

Determination of type, magnitude and direction of residual stresses generated in the welding of AISI H-13 steel with the hole drilling method

International Nuclear Information System (INIS)

Mejia; I; Maldonado, C; Bedolla, A; Velez, M; Medina, A; Bejar, L

2006-01-01

AISI H-13 steel is considered to be a highly ultra resistant steel because its resistance to stress surpasses 1380 MPa. This steel is widely used in tools that heavily used, especially under high temperatures, such as: awls, molds for pressing, extrusion dies, extrusion tools from heat impact, tools for producing screws, bolts, rivets and taps, molds for centrifugal smelting, tools for presses with shaped pieces, knives for hot cutting, among others. The weldability of AISI H-13 steel is generally poor, but it is possible if the proper precautions are taken. Cracking is perhaps the factor that most limits the weldability of AISI H-13 steel. The tendency to crack during welding for this type of steel occurs in the base metal and the zone close to the supporting material (cold cracking). The interlayer covering technique is used in the repair, welding and recovery of pieces of high alloy steels in order to avoid cracking and to lower the residual stresses generated by obstructed contraction and martensitic transformation. This work defined the type, magnitude and direction of residual stresses at different distances starting from the center of the welded union on the 25.4 mm thick AISI H-13 steel sheet. The welding was carried out in a test piece with Y-Groove geometry following JIS Z 3158 standard, using the SMAW process and an AISI 312 stainless steel interlayer between the base metal and the supporting metal. The hole-drilling method was used to measure the type, magnitude and direction of residual stresses using extensometric gauge rosette CEA-06-062UM-120 and CEA-06-062RE-120 following the guidelines established by ASTM E 837 standard. Based on the relaxed deformations that were measured, the type, magnitude and direction of residual stresses were determined with the H-DRILL residual stress program for biaxial condition. The results indicate that under these welding conditions the residual strains at different distances from the welded union are from stress and

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

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)

Effect of using the double layer technique on the microstructure, microhardness and residual stress of welded ASTM A516 GR70 structural steel

International Nuclear Information System (INIS)

Oliveira, George Luiz Gomes de; Miranda, Helio Cordeiro de

2010-01-01

The aim of this work is to evaluate the effect of using the double layer technique on the microstructure, microhardness and residual stresses of welded ASTM A516 Gr70 structural steel. Samples were welded with the same welding parameters and two types of chamfers, while the samples welded using the double layer technique underwent a buttering process on their chamfer face. Residual stress measurement was accomplished through x-ray diffraction, using a mini diffractometer for measurement in field. Metallographic analysis was accomplished in the transverse section of the welded joint, using optic microscopy and scanning electron microscopy. The double layer technique showed that can be used in the welding of ASTM A516 Gr70 steel, because, besides promote a refinement and a drawing back of the CG-HAZ, it increased compressive residual stress in the whole surface of the analyzed samples.(author)

Residual stress measurement of electron beam welded copper plates using prism hole drilling method

International Nuclear Information System (INIS)

Laakkonen, M.

2013-12-01

Eleven electron beam (EB) welded copper plates were measured in this investigation with Prism hole drilling equipment made by Stresstech Oy. All samples contained a linear weld in their center. Two different sets of plates were measured in this investigation. The first set included five samples (X436, X437, X438, X439 and X440) which were welded using four different welding speeds. Samples X439 and X440 were welded with the same speed but X440 is the only sample of the set that received a cosmetic pass. The second set received heat treatments at four different temperatures. Samples X456 and X458 were annealed at the same temperature but sample X456 received a cosmetic pass while X458 did not. Samples X455 and X457 were both annealed at a different temperature, with (X455) or without (X457) the cosmetic pass. Two areas were machined from the samples. About five millimeters was machined from the surfaces on the both of areas. Machined surfaces located on the top surfaces. The measurement points on the top surface are located on the weld and 20 mm and 120 mm from the weld on machined areas. Lower surface measurements are located -20 mm, 20 mm and 120 mm from the weld. All measurements were about 122 mm from the edges perpendicular to the weld. The top surfaces of all samples were machined in two areas across the weld. About 5 mm were removed. Stress measurements on the top surfaces were performed in these two areas, on the weld and 20 mm and 120 mm away from the weld. Stresses were also measured on the back sides, at -20 mm, 20 mm and 120 mm distance from the weld. All measurement locations were about 122mm from the sample edges. Most of the measurements give tensile strengths from 0 MPa to 30 MPa. Stresses parallel to the weld were slightly higher than weld stresses in transverse direction. The machined surfaces have residual stress values above 30 MPa near the surface. (orig.)

Residual stress measurement of electron beam welded copper plates using prism hole drilling method

Energy Technology Data Exchange (ETDEWEB)

Laakkonen, M. [Stresstech Oy, Jyvaeskylae (Finland)

2013-12-15

Eleven electron beam (EB) welded copper plates were measured in this investigation with Prism hole drilling equipment made by Stresstech Oy. All samples contained a linear weld in their center. Two different sets of plates were measured in this investigation. The first set included five samples (X436, X437, X438, X439 and X440) which were welded using four different welding speeds. Samples X439 and X440 were welded with the same speed but X440 is the only sample of the set that received a cosmetic pass. The second set received heat treatments at four different temperatures. Samples X456 and X458 were annealed at the same temperature but sample X456 received a cosmetic pass while X458 did not. Samples X455 and X457 were both annealed at a different temperature, with (X455) or without (X457) the cosmetic pass. Two areas were machined from the samples. About five millimeters was machined from the surfaces on the both of areas. Machined surfaces located on the top surfaces. The measurement points on the top surface are located on the weld and 20 mm and 120 mm from the weld on machined areas. Lower surface measurements are located -20 mm, 20 mm and 120 mm from the weld. All measurements were about 122 mm from the edges perpendicular to the weld. The top surfaces of all samples were machined in two areas across the weld. About 5 mm were removed. Stress measurements on the top surfaces were performed in these two areas, on the weld and 20 mm and 120 mm away from the weld. Stresses were also measured on the back sides, at -20 mm, 20 mm and 120 mm distance from the weld. All measurement locations were about 122mm from the sample edges. Most of the measurements give tensile strengths from 0 MPa to 30 MPa. Stresses parallel to the weld were slightly higher than weld stresses in transverse direction. The machined surfaces have residual stress values above 30 MPa near the surface. (orig.)

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.

Effect of Activated Flux on the Microstructure, Mechanical Properties, and Residual Stresses of Modified 9Cr-1Mo Steel Weld Joints

Science.gov (United States)

Maduraimuthu, V.; Vasudevan, M.; Muthupandi, V.; Bhaduri, A. K.; Jayakumar, T.

2012-02-01

A novel variant of tungsten inert gas (TIG) welding called activated-TIG (A-TIG) welding, which uses a thin layer of activated flux coating applied on the joint area prior to welding, is known to enhance the depth of penetration during autogenous TIG welding and overcomes the limitation associated with TIG welding of modified 9Cr-1Mo steels. Therefore, it is necessary to develop a specific activated flux for enhancing the depth of penetration during autogeneous TIG welding of modified 9Cr-1Mo steel. In the current work, activated flux composition is optimized to achieve 6 mm depth of penetration in single-pass TIG welding at minimum heat input possible. Then square butt weld joints are made for 6-mm-thick and 10-mm-thick plates using the optimized flux. The effect of flux on the microstructure, mechanical properties, and residual stresses of the A-TIG weld joint is studied by comparing it with that of the weld joints made by conventional multipass TIG welding process using matching filler wire. Welded microstructure in the A-TIG weld joint is coarser because of the higher peak temperature in A-TIG welding process compared with that of multipass TIG weld joint made by a conventional TIG welding process. Transverse strength properties of the modified 9Cr-1Mo steel weld produced by A-TIG welding exceeded the minimum specified strength values of the base materials. The average toughness values of A-TIG weld joints are lower compared with that of the base metal and multipass weld joints due to the presence of δ-ferrite and inclusions in the weld metal caused by the flux. Compressive residual stresses are observed in the fusion zone of A-TIG weld joint, whereas tensile residual stresses are observed in the multipass TIG weld joint.

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)

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

Stress Distribution around Laser-Welded Cutting Wheels Using a Spherical Indentation

Energy Technology Data Exchange (ETDEWEB)

Lee, Yun Hee; Lee, Wan Kyu; Jeong, In Hyeon; Nahm, Seung Hoon [KRISS, Daejeon (Korea, Republic of)

2008-04-15

A spherical indentation has been proposed as a nondestructive method of measuring local residual stress field in laser-voided joints. The apparent yield strengths interpreted from the spherical indentation data of as-welded cutting wheel were compared with the intrinsic yield strengths measured at nearly equivalent locations in annealed wheel. Their difference along the distance from the welding line is welding stress distribution because the intrinsic yield strength is invariant regardless of the elastic residual stress. The spherical indentations show that the laser-welded diamond cutting wheel displays a 10 min-wide distribution of the welding residual stress and has peak compressive and tensile stresses in the shank and tip regions, respectively.

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

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...

Measurements of the residual stresses in the welded steel columns based on the x-ray diffraction method, 2

International Nuclear Information System (INIS)

Kaneta, Kiyoshi; Nishizawa, Hidekazu; Arashiyama, Masaki.

1982-01-01

In order to evaluate the applicability of two kinds of techniques of the X-ray stress analysis, namely, the standard sin 2 psi method and the newly developed phi-sin 2 psi method, bending tests have been performed. The test results have proved that the values of the stresses measured by means of the mechanical devices and of those measured by the two kinds of the X-ray techniques coincide each other. Then, these two methods have been applied to measure the surface residual stresses of the box-typed, welded steel columns and the following conclusions have been drawn. 1. The principal stress of the surface residural stresses is, in most cases, oriented to the rolled directions at the center of the steel plates, and it tends to rotate in the neighborhood of the heat affected zones. 2. Tensile residual stresses of a large magnitude have been observed in the direction parallel to the beads of the weld, and the moderate compressive residual stresses can be detected in the direction normal to the beads. (author)

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)

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.

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)

Residual stress analysis in BWR pressure vessel attachments

International Nuclear Information System (INIS)

Dexter, R.J.; Leung, C.P.; Pont, D.

1992-06-01

Residual stresses from welding processes can be the primary driving force for stress corrosion cracking (SCC) in BWR components. Thus, a better understanding of the causes and nature of these residual stresses can help assess and remedy SCC. Numerical welding simulation software, such as SYSWELD, and material property data have been used to quantify residual stresses for application to SCC assessments in BWR components. Furthermore, parametric studies using SYSWELD have revealed which variables significantly affect predicted residual stress. Overall, numerical modeling techniques can be used to evaluate residual stress for SCC assessments of BWR components and to identify and plan future SCC research

Fatique crack propagation in bimetallic welds influence of residual stresses and metallurgical look

International Nuclear Information System (INIS)

Zahouane, A.I.

1988-06-01

Generally, in nuclear power plants, many components made of austenitic stainless steels are very often replaced by low alloyed steels cladded with stainless steels, mainly for economical reasons. Due to cracks existing at the limit of the two kinds of steel, it is interesting to try to understand how they appear. Residual stresses are generally identified as one of the factors which act to produce these cracks. Measurements of such residual stresses have been performed, using the hole drilling method (drilling of a hole at the center of a gauge roset stuck at the surface of the material). Owing to the obtained results, it is possible to explain the decrease in the crack propagation rate observed, on fatigue crack growth test performed on specimens taken in the transition ferritic/austenitic zone. The stress intensity factor due to the residual stresses is valued by weight function method. It is possible to explain qualitatively the phenomena observed under cyclic loading when using the obtained value of this stress intensity factor. A more quantitative approach based on the use of an efficient stress intensity factor, allow to better describe the effect of residual stresses on the fatigue crack propagation in bimetallic welds [fr

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)

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.

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.

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)

Stress-free reference for neutron diffraction measurement of residual stress in butt-welded joints of austenitic stainless steel pipes

International Nuclear Information System (INIS)

Maekawa, Akira; Takahashi, Tsuneo; Tsuji, Takashi; Suzuki, Hiroshi; Moriai, Atsushi

2012-01-01

Stress-free lattice spacing d_0 has the most influence on reliability of neutron stress measurements made using an angle dispersive method. However, it is hard to evaluate the lattice spacing of welded structures and ductile materials such as stainless steel accurately. In this study, suitable measurement conditions for d_0 of welded pipe joints of austenitic stainless steel were discussed. The d_0 values derived from {311} and {111} reflections, which are often used in austenitic stainless steel for residual stress measurement, were examined. Comparison of the residual strains and stresses evaluated using the obtained d_0 and the finite element analysis showed that the way the d_0 values were chosen affected the measurement accuracy significantly. The stress measurement accuracy was remarkably improved when the {311} reflection was used and the proper d_0 value was chosen in the respective neutron diffraction measurements. For instance, for the axial diffraction measurements using the {311} reflection, it was recommended that only the axial d_0 value of the {311} reflection be used; the measurements using the {111} reflection were less accurate due to the large Young's modulus. Additionally, a lower diffraction angle was judged to be one of the factors leading to a decrease of the strain measurement accuracy. (author)

Stress Distribution in the Dissimilar Metal Butt Weld of Nuclear Reactor Piping due to the Simulation Technique for the Repair Welding

International Nuclear Information System (INIS)

Lee, Hweeseung; Huh, Namsu; Kim, Jinsu; Lee, Jinho

2013-01-01

During welding, the dissimilar metal butt welds of nuclear piping are typically subjected to repair welding in order to eliminate defects that are found during post-weld inspection. It has been found that the repair weld can significantly increase the tensile residual stress in the weldment, and therefore, accurate estimation of the weld residual stress due to repair weld, especially for dissimilar metal welds using Ni-based alloy 82/182 in nuclear components, is of great importance in order to assess susceptibility to primary water stress corrosion cracking. In the present study, the stress distributions of dissimilar metal butt welds in nuclear reactor piping subjected to repair weld were investigated based on detailed nonlinear finite element analyses. Particular emphasis was placed on the variation of the stress distribution in the dissimilar metal butt weld according to the finite element welding analysis sequence for the repair welding process

Study on the stress and strain during welding of plate-to-pipe joint

Energy Technology Data Exchange (ETDEWEB)

Na, S.J.; Kim, H.W.

1986-09-01

In manufacturing of pipe walls for boiler units, distortion can result in pipe-to-pipe joints from the nonuniform expansion and contraction of the weld metal and the adjacent base metal during heating and cooling cycle of the welding process. In this study, the stresses and strains during longitudinal welding of the plate-to-pipe joint were investigated. Using the method of sucessive elastic solution, longitudinal stresses and strains during and after welding were calculated from the information of temperature distributions obtained by Rosenthal's equations. In order to confirm the validity of the numerical results, the temperature and residual stress distributions were measured and compared with the calculated results. In spite of some assumptions, the one-dimensional analytical results of residual stresses were in fairly good agreement with the experimental ones. The residual stresses due to welding of plate-to-pipe joints are tensile near the weld line and compressive in the base metal as in the welding of plates. The amount and distribution of residual stresses were deeply dependent on the heat input ratio of the plate and pipe.

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

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...

Investigation of surface residual stress profile on martensitic stainless steel weldment with X-ray diffraction

Directory of Open Access Journals (Sweden)

I.I. Ahmed

2018-04-01

Full Text Available The development of residual stresses during fabrication is inevitable and often neglected with dire consequences during the service life of the fabricated components. In this work, the surface residual stress profile following the martensitic stainless steel (MSS pipe welding was investigated with X-ray diffraction technique. The results revealed the presence of residual stresses equilibrated across the weldment zones. Tensile residual stress observed in weld metal was balanced by compressive residual stresses in the parent material on the opposing sides of weld metal. Keywords: Residual stress, Weld, Stainless steel, X-ray, HAZ

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

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.

Sustainability of compressive residual stress by stress improvement processes

International Nuclear Information System (INIS)

Nishikawa, Satoru; Okita, Shigeru; Yamaguchi, Atsunori

2013-01-01

Stress improvement processes are countermeasures against stress corrosion cracking in nuclear power plant components. It is necessary to confirm whether compressive residual stress induced by stress improvement processes can be sustained under operation environment. In order to evaluate stability of the compressive residual stress in 60-year operating conditions, the 0.07% cyclic strains of 200 times at 593 K were applied to the welded specimens, then a thermal aging treatment for 1.66x10 6 s at 673 K was carried out. As the result, it was confirmed that the compressive residual stresses were sustained on both surfaces of the dissimilar welds of austenitic stainless steel (SUS316L) and nickel base alloy (NCF600 and alloy 182) processed by laser peening (LP), water jet peening (WJP), ultrasonic shot peening (USP), shot peening (SP) and polishing under 60-year operating conditions. (author)

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.

In-situ X-ray residual stress measurement on a peened alloy 600 weld metal at elevated temperature under tensile load

International Nuclear Information System (INIS)

Yunomura, Tomoaki; Maeguchi, Takaharu; Kurimura, Takayuki

2014-01-01

In order to verify stability of residual stress improvement effect of peeing for mitigation of stress corrosion cracking in components of PWR plant, relaxation behavior of residual stress induced by water jet peening (WJP) on surface of alloy 600 weld metal (alloy 132) was investigated by in-situ X-ray residual stress measurement under thermal aging and stress condition considered for actual plant operation. Surface residual stress change was observed at the early stage of thermal aging at 360°C, but no significant further stress relaxation was observed after that. Applied stress below yield stress does not significantly affect stress relaxation behavior of surface residual stress. For the X-ray residual stress measurement, X-ray stress constant at room temperature for alloy 600 was determined experimentally with several surface treatment and existence of applied strain. The X-ray stress constant at elevated temperatures were extrapolated theoretically based on the X-ray stress constant at room temperature for alloy 600. (author)

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.

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.

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

Internal Stress Distribution Measurement of TIG Welded SUS304 Samples Using Neutron Diffraction Technique

Science.gov (United States)

Muslih, M. Refai; Sumirat, I.; Sairun; Purwanta

2008-03-01

The distribution of residual stress of SUS304 samples that were undergone TIG welding process with four different electric currents has been measured. The welding has been done in the middle part of the samples that was previously grooved by milling machine. Before they were welded the samples were annealed at 650 degree Celsius for one hour. The annealing process was done to eliminate residual stress generated by grooving process so that the residual stress within the samples was merely produced from welding process. The calculation of distribution of residual stress was carried out by measuring the strains within crystal planes of Fe(220) SUS304. Strain, Young modulus, and Poisson ratio of Fe(220) SUS304 were measured using DN1-M neutron diffractometer. Young modulus and Poisson ratio of Fe(220) SUS304 sample were measured in-situ. The result of calculations showed that distribution of residual stress of SUS304 in the vicinity of welded area is influenced both by treatments given at the samples-making process and by the electric current used during welding process.

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.

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.

The effect of Residual Stress on the Stress Intensity Factor of Nuclear Material

International Nuclear Information System (INIS)

Song, Taek Ho

2008-01-01

As NPP (Nuclear Power Plant) gets aged, the importance of the pressure boundary integrity increases very much to those who are trying to operate their plant beyond its design life. Not long ago, Boric acid crystal was found at the RPV outlet nozzle of V.C. Summer plant during the visual examination in 2000. After this finding, non-destructive examination was taken to find out what's taken place. As a result of this examination, circumferential and axial cracks were found. With Metallurgical structure examination, it was shown that crack had been developed at the mid-point between Inco-alloy buttering and weld metal. It was turned out that high welding residual stress was the main cause of the cracking. Because of the through wall crack, nozzle and welding parts were replaced. Many other nuclear power plants experienced similar pressure boundary stress corrosion cracks (SCCs). KEPRI (Korea Electric Power Research Institute) has carried out research projects for managing and preventing these kinds of cracks in nuclear power plants (NPPs). The titles of these research projects are 'Development of Stress Corrosion Cracking Management Technology and Aging Monitor for NPP Main Components' and 'Development of Analysis Technology for Crack Management of Dissimilar Metal Weld'. Through these projects, residual stress measurement techniques have been exercised at various points in mock-up test specimens to simulate nuclear power plant dissimilar base metal and weldment residual stress. X-ray test and hole drilling method have been reviewed to measure residual stresses of the dissimilar metal welds. This paper shows some point of view in residual stress measurement. Fracture mechanics analysis has been performed to explain the importance of residual stress measurement in association with nuclear power plant safety

Mechanical behavior of multipass welded joint during stress relief annealing

International Nuclear Information System (INIS)

Ueda, Yukio; Fukuda, Keiji; Nakacho, Keiji; Takahashi, Eiji; Sakamoto, Koichi.

1978-01-01

An investigation into mechanical behavior of a multipass welded joint of a pressure vessel during stress relief annealing was conducted. The study was performed theoretically and experimentally on idealized research models. In the theoretical analysis, the thermal elastic-plastic creep theory developed by the authors was applied. The behavior of multipass welded joints during the entire thermal cycle, from welding to stress relief annealing, was consistently analyzed by this theory. The results of the analysis show a good, fundamentally coincidence with the experimental findings. The outline of the results and conclusions is as follows. (1) In the case of the material (2 1/4Cr-1Mo steel) furnished in this study, the creep strain rate during stress relief annealing below 575 0 C obeys the strain-hardening creep law using the transient creep and the one above 575 0 C obeys the power creep law using the stational creep. (2) In the transverse residual stress (σsub(x)) distribution after annealing, the location of the largest tensile stress on the top surface is about 15 mm away from the toe of weld, and the largest at the cross section is just below the finishing bead. These features are similar to those of welding residual stresses. But the stress distribution after annealing is smoother than one from welding. (3) The effectiveness of stress relief annealing depends greatly on the annealing temperature. For example, most of residual stresses are relieved at the heating stage with a heating rate of 30 0 C/hr. to 100 0 C/hr. if the annealing temperature is 650 0 C, but if the annealing temperature is 550 0 C, the annealing is not effective even with a longer holding time. (4) In the case of multipass welding residual stresses studied in this paper, the behaviors of high stresses during annealing are approximated by ones during anisothermal relaxation. (auth.)

X-ray and neutron diffraction determination of residual stresses in a pressed and welded component

International Nuclear Information System (INIS)

Albertini, G.; Broda, M.; Fiori, F.; Girardin, E.; Giuliani, A.; Quadrini, E.

1999-01-01

Complete text of publication follows. Problems connected with welding and pressing are very important in mechanical design, as these processed create microstructural alterations and internal stresses in the material that cannot be neglected. A pressing steel (FEP13) machine element is considered, designed to support a scooter engine. Two kinds of fatigue are to be supported by the component during operation: high loads at low frequency, due to the interaction of the scooter with the soil and low loads at high frequency due to the engine. The knowledge of the residual stress field occurring before operation is fundamental in order to perform theoretical predictions of the stress state during operation, and also to determine the loads to be used in fatigue tests which the component will be submitted to. The results of X-ray and neutron experiments are presented, carried out across a 'critical' weld in the component. (author)

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)

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

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.)

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).

Prediction of residual stresses and distortions due to laser beam welding of butt joints in pressure vessels

International Nuclear Information System (INIS)

Moraitis, G.A.; Labeas, G.N.

2009-01-01

A two-level three-dimensional Finite Element (FE) model has been developed to predict keyhole formation and thermo-mechanical response during Laser Beam Welding (LBW) of steel and aluminium pressure vessel or pipe butt-joints. A very detailed and localized (level-1) non-linear three-dimensional transient thermal model is initially developed, which simulates the mechanisms of keyhole formation, calculates the temperature distribution in the local weld area and predicts the keyhole size and shape. Subsequently, using a laser beam heat source model based on keyhole assumptions, a global (level-2) thermo-mechanical analysis of the LBW butt-joint is performed, from which the joint residual stresses and distortions are calculated. All the major physical phenomena associated to LBW, such as laser heat input via radiation, heat losses through convection and radiation, as well as latent heat are accounted for in the numerical model. Material properties and particularly enthalpy, which is very important due to significant material phase changes, are introduced as temperature-dependent functions. The main advantages of the developed model are its efficiency, flexibility and applicability to a wide range of LBW problems (e.g. welding for pressure vessel or pipework construction, welding of automotive, marine or aircraft components, etc). The model efficiency arises from the two-scale approach applied. Minimal or no experimental data are required for the keyhole size and shape computation by the level-1 model, while the thermo-mechanical response calculation by the level-2 model requires only process and material data. Therefore, it becomes possible to efficiently apply the developed simulation model to different material types and varying welding parameters (i.e. welding speed, heat source power, joint geometry, etc.) in order to control residual stresses and distortions within the welded structure

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

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.

Experimental investigation and finite element simulation of laser beam welding induced residual stresses and distortions in thin sheets of AA 6056-T4

International Nuclear Information System (INIS)

Zain-ul-abdein, Muhammad; Nelias, Daniel; Jullien, Jean-Francois; Deloison, Dominique

2010-01-01

Laser beam welding has recently found its application in the fabrication of aircraft structures where fuselage panels, made of thin sheets of AA 6056-T4 (an aluminium alloy), are welded with stiffeners of the same material in a T-joint configuration. The present work simulates laser beam welding induced residual stresses and distortions using industrially employed thermal and mechanical boundary conditions. Various measurements performed on small-scale welded test specimens provide a database of experimental results that serves as a benchmark for qualification of the simulation results. The welding simulation is performed with the commercial finite element software Abaqus and a Fortran programme encoding a conical heat source with Gaussian volumetric distribution of flux. A sequentially coupled temperature-displacement analysis is undertaken to simulate the weld pool geometry, transient temperature and displacement fields. The material is assumed to follow an elasto-plastic law with isotropic hardening behaviour (von Mises plasticity model). A comparison between the experimental and simulation results shows a good agreement. Finally, the residual stress and strain states in a T-joint are predicted.

Investigations in thermal fields and stress fields induced by electron beam welding

International Nuclear Information System (INIS)

Basile, G.

1979-12-01

This document presents the thermal study of electron beam welding and identifies stresses and strains from welding: description of the operating principles of the electron gun and characterization of various welding parameters, examination of the temperature fields during electron beam welding development of various mathematic models and comparison with experimental results, measurement and calculation of stresses and strains in the medium plane of the welding assembly, residual stresses analysis [fr

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)

Residual stress analysis in reactor pressure vessel attachments

International Nuclear Information System (INIS)

Dexter, R.J.; Pont, D.

1991-08-01

Residual stresses in cladding and welded attachments could contribute to the problem of stress-corrosion cracking in boiling-water reactors (BWR). As part of a larger program aimed at quantifying residual stress in BWR components, models that would be applicable for predicting residual stress in BWR components are reviewed and documented. The review includes simple methods of estimating residual stresses as well as advanced finite-element software. In general, simple methods are capable of predicting peak magnitudes of residual stresses but are incapable of adequately characterizing the distribution of residual stresses. Ten groups of researchers using finite-element software are reviewed in detail. For each group, the assumptions of the model, possible simplifications, material property data, and specific applications are discussed. The most accurate results are obtained when a metallurgical simulation is performed, transformation plasticity effects are included, and the heating and cooling parts of the welding thermal cycle are simulated. Two models are identified which can provide these features. The present state of these models and the material property data available in the literature are adequate to quantify residual stress in BWR components

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

Study on mechanism of intergranular stress corrosion cracking and analysis of residual stress and work hardening in welds of low-carbon austenitic stainless steel with hard surface machining

International Nuclear Information System (INIS)

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

2007-01-01

In order to make clear the effects of residual stress and hardening on intergranular stress corrosion cracking (IGSCC) behavior in the welds of Type 316L low-carbon austenitic stainless steel with surface hardening, the residual stress and hardness in the butt-joint of pipes as a typical example of the actual structure were estimated and the grain boundary sliding was analyzed from the viewpoint of micro-deformation. On the basis of these results, the mechanism of IGSCC was discussed by the integrated knowledge between metallurgy and mechanics. The relationship between plastic strain and hardness in hard-machined surface near welds was clarified from the experimented relationship and the analysis method by the thermal elastic-plastic analysis. The distributions of hardness and residual stress with the actual surface machining could be simulated. It was made clear that grain boundary sliding occurred in the steel at 561K by a constant strain rate tensile test. From the comparison of grain boundary sliding behavior between solution treated specimen and cold-rolled one, it was found that the grain boundary sliding in cold-rolled one occurs in smaller strain conditions than that in as received one, and the amount of grain boundary sliding in cold-rolled one increases remarkably with increases in rolling reduction. 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 Type 316L 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)

Residual stress effects in LMFBR fracture assessment procedures

International Nuclear Information System (INIS)

Hooton, D.G.

1984-01-01

Two post-yield fracture mechanics methods, which have been developed into fully detailed failure assessment procedures for ferritic structures, have been reviewed from the point of view of the manner in which as-welded residual stress effects are incorporated, and comparisons then made with finite element and theoretical models of centre-cracked plates containing residual/thermal stresses in the form of crack-driving force curves. Applying the procedures to austenitic structures, comparisons are made in terms of failure assessment curves and it is recommended that the preferred method for the prediction of critical crack sizes in LMFBR austenitic structures containing as-welded residual stresses is the CEGB-R6 procedure based on a flow stress defined at 3% strain in the parent plate. When the prediction of failure loads in such structures is required, it is suggested that the CEGB-R6 procedure be used with residual/thermal stresses factored to give a maximum total stress of flow stress magnitude

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)

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)

Influence of heat input and radius to pipe thickness ratio on the residual stresses in circumferential arc welded pipes of API X46 steels

International Nuclear Information System (INIS)

Hemmatzadeh, Majid; Moshayedi, Hessamoddin; Sattari-Far, Iradj

2017-01-01

The present work aims to study residual stresses caused by circumferentially welding of two similar API X46 steel pipes by means of finite element modeling. Considering the metallurgical phase transformations and through thermal-mechanical uncoupled analysis, the 3D modeling was carried out by SYSWELD software. Materialistic thermal and mechanical properties of all phases were defined in terms of temperature as well as phase transformation properties. Residual stress was measured through hole-drilling method. The obtained results were used to verify the finite element model. By means of full factorial experiment designing method, effects of heat input and radius to pipe thickness ratio on maximum values of hoop and axial residual stresses were investigated. The effect of each factor was studied in 3 levels and by 9 experiments. Results of statistical analysis revealed that increase in heat input and radius-thickness ratio would lead to higher values of maximum hoop and axial residual stresses. However, interactions of high level of heat input and a low level of radius-thickness ratio increased inter-pass temperature and consequently caused a sudden raise in maximum values of residual stresses. - Highlights: • A FEM model was developed to simulate welding considering phase transformations. • The obtained residual stresses were validated by experiments. • Effect of heat input and radius-to-thickness ratio on residual stress were investigated. • Increasing heat input for 100% caused increasing hoop and axial residual stress until 200%. • Interaction of high heat input and low R/t causes a sudden increase in axial residual stresses.

Impacts of weld residual stresses and fatigue crack growth threshold on crack arrest under high-cycle thermal fluctuations

Energy Technology Data Exchange (ETDEWEB)

Taheri, Said, E-mail: Said.taheri@edf.fr [EDF-LAB, IMSIA, 7 Boulevard Gaspard Monge, 91120 Palaiseau Cedex (France); Julan, Emricka [EDF-LAB, AMA, 7 Boulevard Gaspard Monge, 91120 Palaiseau Cedex (France); Tran, Xuan-Van [EDF Energy R& D UK Centre/School of Mechanical, Aerospace and Civil Engineering, The University of Manchester, Manchester M13 9PL (United Kingdom); Robert, Nicolas [EDF-DPN, UNIE, Strategic Center, Saint Denis (France)