Bostjan Bezensek

The re-characterisation of complex defects: Part I: Fatigue and ductile tearing

Abstract Defect assessment codes idealise complex defects as simple shapes which are amenable to analysis in a process known as re-characterisation. The present work examines the re-characterisation of complex defects which extend by fatigue, ductile tearing or cleavage. A family of representative defects were analysed numerically, while a related experimental programme investigated defect interaction and failure. Part I of the paper focuses on fatigue and ductile tearing. Part II examines cleavage. The numerical and experimental results are discussed within the context of the re-characterisation procedures described in BS 7910 (Guidance on methods for assessing the acceptability of flaws in metallic structures. London, UK: British Standard Institution; 1999 [Chapter 7]) and R6/4 (Assessment of the integrity of structures containing defects. Gloucester: British Energy Generation Ltd.; 2001 [Revision 4, Chapters I and II.3]). The level of conservatism of the re-characterisation procedures for fatigue and ductile tearing are discussed. A possible non-conservatism of the re-characterisation for cleavage is discussed in Part II, within the framework of constraint based statistical fracture mechanics.

Experimental Study of Ductile Fracture for Non-Aligned Multiple Flaws in a Plate

The fitness-for-service code requires the characterization of non-aligned multiple flaws for the flaw evaluation, which is performed using a flaw proximity rule. Worldwide almost all codes provide own proximity rule, often with unclear technical bases of the application of proximity rule to ductile fracture. To clarify the appropriate proximity rule for non-aligned multiple flaws in fully plastic fracture, fracture tests on flat plate specimen with non-aligned multiple through wall flaws were conducted at ambient temperature. The emphasis of this study was put on the flaw alignment rule, which determines whether non-aligned flaws are treated as independent or aligned onto the same plane for the purpose of flaw evaluations. The effects of the flaw separation and flaw size on the maximum load were investigated. The experimental results were compared with the estimations of the collapse load using the alignment rules in the ASME Section XI, BS7910 and API 579-1 codes. A new estimation procedure specific to the fully plastic fracture was proposed and compared with the comparison with the experimental results.Copyright

The re-characterisation of complex defects: Part II: cleavage

Abstract The re-characterisation of complex defects with re-entrant sectors has been addressed for cracks extending by fatigue, ductile tearing and cleavage. In Part I crack extension by fatigue and ductile tearing was discussed. In Part II cleavage data are presented for a family of complex defects with re-entrant sectors. Experimental tests on complex and re-characterised profiles are analysed using deterministic and probabilistic approaches. The work addresses the conservatism of re-characterisation procedures when applied to cleavage failure on the lower shelf and in the ductile–brittle transition.

Evaluation of Alignment Rules Using Stainless Steel Pipes With Non-Aligned Flaws

Multiple flaws such as stress corrosion cracks are frequently detected in the same welded lines in pipes. If multiple discrete flaws are in close proximity to one another, alignment rules are used to determine whether the flaws should be treated as non-aligned or as coplanar. Alignment rules are provided in fitness-for-service codes, such as ASME, JSME, API 579, BS 7910, etc. However, the criteria of the alignment rules are different among these codes. This paper briefly introduces these flaw alignment rules, and four-point bending tests performed on stainless steel pipes with two non-aligned flaws. The experimental plastic collapse stresses are determined from the collapse loads and compared with collapse stresses calculated from the limit load criteria. The limit loads are obtained for single non-aligned or aligned coplanar flaws in accordance with the alignment rules. On this basis, the conservatism of the alignment rules in the above codes is assessed.© 2009 ASME

The non-coplanar coalescence of interacting defects in fatigue

Defects in real structures frequently have complex shapes. The present work examines complex defects which result from the interaction of adjacent coplanar semi-elliptical cracks. Attention is focused on fatigue growth leading to coalescence and the formation of a coplanar single defect with a re-entrant sector. An experimental study investigated the fatigue crack path on the free surface. The study found that the deviations from the straight crack path determine the size of the re-entrant sector and whether coalescence occurs on the surface or sub-surface. Surface coalescence occurs by a shear mechanism resulting in a step in the coalesced crack front. A numerical line spring analysis based on the concept introduced by Rice and Levy [1] and extended by Parks and White [2] to include Mode II and III component, has been used to investigate the effect of coalescence in re-entrant sector on the crack tip parameters. The presence of a step in the re-entrant sector introduces a Mode III component and reduces amplified values of Mode I stress intensity factor, which is a feature of coplanar coalescence. The study concludes with discussion of the significance of non-coplanar coalescence on catastrophic brittle failure.

Prediction Method for Plastic Collapse of Circumferentially Cracked Pipes Subjected to Combined Bending and Torsion Moments

When a crack is detected in a pipe during in-service inspection, the failure estimation method given in the Codes such as the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code Section XI or the Japan Society of Mechanical Engineers (JSME) S NA-1-2008 can be applied to assess the integrity of the pipe. In the current edition of the ASME Code Section XI, the failure estimation method is provided for combined bending moment and pressure loads. The provision of evaluating torsion load is not made in the ASME Code Section XI. In this paper, finite element analyses are conducted for stainless steel pipes with a circumferential surface crack subjected to the combined bending and torsion moments, focusing on the entire range of torsion moments, including pure torsion. The effect of the internal pressure on failure behavior is also investigated. Based on the analysis results, a prediction method for plastic collapse under the combined loading conditions of bending and torsion is proposed for the general magnitude of torsion moments.

Effects of Torsion on Equivalent Bending Moment for Limit Load and EPFM Circumferential Pipe Flaw Evaluations

The circumferential flaw evaluation procedures in ASME Boiler and Pressure Vessel Code Section XI nonmandatory Appendix C are currently limited to straight pipes under pressure and bending loads without consideration of torsion loading. The Working Group on Pipe Flaw Evaluation of the ASME Boiler and Pressure Vessel Code is developing guidance for considering the effects of torsion by a mean of an equivalent bending moment, which is a square root of sum square combination of bending moment and torsion load with a weighted factor for torsion moment. A torsion weighted factor, Ce, is established in this paper using large strain finite element limit load analysis with elastic perfectly plastic materials. Planar flaws and nonplanar flaws in a 10.75 in. (273 mm) OD pipe are investigated. Additionally, a finite element J-integral calculation is performed for a planar through wall circumferential flaw with elastic plastic materials subjected to bending and torsion load combinations. The proposed Ce factor for planar flaws is intended for use with the ASME B&PV Code Section XI, Appendix C for limit load and Elastic Plastic Fracture Mechanics (EPFM) circumferential planar flaw evaluations.

Prediction Method for Plastic Collapse of Pipes Subjected to Combined Bending and Torsion Moments

When a crack is detected in a pipe during in-service inspection, the failure estimation method given in the codes such as ASME Boiler and Pressure Vessel Code Section XI non-mandatory Appendix C or JSME S NA-1-2008 Appendix E-8 can be applied to assess the integrity of the pipe. In the current editions of these codes, the failure estimation method is provided for bending moment and pressure. Torsion load is assumed to be relatively small and is not considered in the method. In this paper, finite element analyses are conducted for 24-inch stainless steel pipe with a circumferential surface crack subjected to the combined bending and torsion moments, focusing on large and pure torsion moments. Based on the analysis results, a prediction method for plastic collapse under the combined loading conditions of bending and torsion is proposed for the entire range of torsion moments.Copyright

Inclusion of Torsion Loads in Section XI Flaw Evaluation Procedures for Pipes Containing Circumferential Planar Surface Crack-Like Flaws on the Basis of Limit Load Analysis

Piping systems in power plant may experience combined bending-torsion loads in the presence of planar crack-like flaws. ASME Boiler and Pressure Vessel Code Section XI nonmandatory Appendix C provides flaw evaluation procedures for pipes with flaws. These are currently limited to straight pipes under pressure and bending loads and no provision is made for torsion loading. The working group on pipe flaw evaluation is developing guidance for including the torsion load within the existing solutions provided in the Appendix C for bending loading on a straight pipe under fully plastic fracture regime. This paper reports on the finite element limit load analyses performed on the straight pipe containing a circumferential planar crack-like flaw. Pipe diameters were ranging from 4 in. (100 mm) to 24 in. (600 mm) nominal diameter (OD) and R/t ranging from 6 to 40. For the purpose of nonmandatory Appendix C flaw evaluation, it is concluded that the torsion loads can be combined with bending loads using the root of the sum of the squares (RSS) method of Section III of the ASME Boiler Code, without any additional weighting on torsion.

Increased Temperature Margins Due to Constraint Loss

Enhanced levels of toughness due to loss of crack tip constraint have been related to temperature shifts in the ductile–brittle transition curve. An argument to quantify the temperature shift is developed using the self-similarity of near-tip stress fields under contained yielding combined with scaling techniques developed by Dodds and co-workers (1-2) for cleavage. This allows the temperature changes which give the same stress field at failure in constrained and unconstrained fields to be determined. The procedure is illustrated using the data of Sherry (3) for an A533B pressure vessel steel. The results are consistent with empirical expressions proposed by Wallin (4), and enable a discussion of the micromechanics of cleavage.