Lyndon Edwards

Greater tolerance for nuclear materials

As interest in new generations of nuclear reactors is increasing worldwide, renewed research effort into new materials more tolerant to extreme conditions is crucial.

Optimisation of Mixed Hardening Material Constitutive Models for Weld Residual Stress Simulation Using the NeT Task Group 1 Single Bead on Plate Benchmark Problem

A single weld bead deposited on a flat plate is a deceptively simple problem that is in practice a challenge for both measurement and prediction of weld residual stresses. Task Group 1 of the NeT collaborative network has examined this problem in an exten

Analysis of Residual Stresses in Three-Pass Slot Weld (NeT-TG4): Finite Element Modelling and Neutron Diffraction

In this paper finite element simulation and neutron diffraction measurements are employed to assess the residual stresses in an AISI 316LN austenitic stainless steel plate containing a three-pass finite length weld in a machined slot. This work forms a part of the Task Group 4 (TG4) measurement and simulation round robin being undertaken by the NeT European network. Finite element (FE) simulations were carried out using the FEAT-WMT and ABAQUS commercial finite element packages. The welding process was modelled both using a 3D moving-heat source (MHS) which is spatially correct but computationally expensive and using a simplified “block-dumped” methodology (BD) in which an entire weld bead is deposited simultaneously. This does not reproduce the effects of welding torch movement, but is computationally less expensive. The mechanical analyses used combined isotropic-kinematic material constitutive models with a two-stage annealing functionality to remove plastic strain accumulated at high temperatures. The finite element predictions of weld residual stress are compared with neutron diffraction measurements obtained on the KOWARI diffractometer at the OPAL reactor at ANSTO.Copyright

From solid solution to cluster formation of Fe and Cr in α-Zr

To understand the mechanisms by which the re-solution of Fe and Cr additions increase the corrosion rate of irradiated Zr alloys, the solubility and clustering of Fe and Cr in model binary Zr alloys was investigated using a combination of experimental and modelling techniques — atom probe tomography (APT), x-ray diffraction (XRD), thermoelectric power (TEP) and density functional theory (DFT). Cr occupies both interstitial and substitutional sites in the α-Zr lattice; Fe favours interstitial sites, and a low-symmetry site that was not previously modelled is found to be the most favourable for Fe. Lattice expansion as a function of Fe and Cr content in the α-Zr matrix deviates from Vegards law and is strongly anisotropic for Fe additions, expanding the c-axis while contracting the a-axis. Matrix content of solutes cannot be reliably estimated from lattice parameter measurements, instead a combination of TEP and APT was employed. Defect clusters form at higher solution concentrations, which induce a smaller lattice strain compared to the dilute defects. In the presence of a Zr vacancy, all two-atom clusters are more soluble than individual point defects and as many as four Fe or three Cr atoms could be accommodated in a single Zr vacancy. The Zr vacancy is critical for the increased apparent solubility of defect clusters; the implications for irradiation induced microstructure changes in Zr alloys are discussed.

The Role of Plasticity Theory on the Predicted Residual Stress Field of Weld Structures

Constitutive plasticity theory is commonly applied to the numerical analysis of welds in one of three ways: using an isotropic hardening model, a kinematic hardening model, or a mixed isotropic-kinematic hardening model. The choice of model is not entirely dependent on its numerical accuracy, however, as a lack of empirical data will often necessitate the use of a specific approach. The present paper seeks to identify the accuracy of each formalism through direct comparison of the predicted and actual post-weld residual stress field developed in a three-pass 316LN stainless steel slot weldment. From these comparisons, it is clear that while the isotropic hardening model tends to noticeably over-predict and the kinematic hardening model slightly under-predict the residual post-weld stress field, the results using a mixed hardening model are quantitatively accurate. Even though the kinematic hardening model generally provides more accurate results when compared to an isotropic hardening formalism, the latter might be a more appealing choice to engineers requiring a conservative design regarding weld residual stress.

Optimised modelling of weld metal constitutive behaviour in the NeT TG4 international weld simulation and measurement benchmark

The NeT TG4 benchmark specimen consists of a three pass type 316L TIG slot weld in a AISI type 316L plate. Phase one of the finite element simulation round robin performed on TG4 by the NeT network made the assumption that the weld metal exhibits the same mechanical behaviour as parent material. A comprehensive series of material characterisation tests on weld metal has now been completed, and these have allowed the derivation of a number of mixed isotropic-kinematic material models specifically for weld metal. The derived models have been used to improve the predicted stresses in the TG4 benchmark specimen. This paper first reviews the weld metal materials testing programme, and then discusses the optimum material hardening model fitting strategy to use for austenitic weld metal. The derived material models are tested by using them to predict residual stresses in the TG4 benchmark, and validating the predictions against the extensive database of measured residual stresses, and distortions.Copyright

The Impact of Key Simulation Variables on Predicted Residual Stresses in Pressuriser Nozzle Dissimilar Metal Weld Mock-Ups: Part 1—Simulation

British Energy (BE) has funded a large work programme to assess the possible impact of primary water stress corrosion cracking on dissimilar metal welds in the primary circuit of the Sizewell ‘B’ pressurised water reactor. This effort has included the design and manufacture of representative pressuriser safety/relief valve nozzle welds both with and without a full structural weld overlay, multiple residual stress measurements on both mock-ups using the deep hole and incremental deep hole methods, and a number of finite element weld residual stress simulations of both the mock-ups and equivalent plant welds. Three organisations have performed simulations of the safety/relief valve nozzle configuration: Westinghouse, Engineering Mechanics Corporation of Columbus (EMC2 ) and the Australian Nuclear Science and Technology Organisation (ANSTO). The simulations employ different welding heat input idealisations, make different assumptions about manufacturing history, and use a variety of different material constitutive models, ranging from simple bilinear kinematic hardening to a full mixed isotropic-kinematic formulation. The availability of both high quality measurements from well characterised mock-ups, and a large matrix of simulations, offers the opportunity for a “mini-round-robin” examining both the accuracy and key solution variables of dissimilar metal weld finite element simulations. This paper is one of a series at this conference that examine various aspects of the BE work programme. It describes the detailed finite element simulation of the mock-ups performed by BE and ANSTO. This makes use of the extensive mock-up manufacturing records to perform a detailed pass-bypass simulation of the entire manufacturing process from initial nozzle buttering through to completion of the safe end to pipe weld. The thermal simulation makes use of a dedicated welding heat source modelling tool to derive Gaussian volumetric heat source parameters from the welding records, and the mechanical simulation employs isotropic, kinematic and mixed isotropic-kinematic material constitutive models. Additional sensitivity studies examine sensitivity to manufacturing history and physical properties such as expansion coefficient mismatch.Copyright

Sensitivity of predicted weld residual stresses in the NeT Task Group 1 single bead on plate benchmark problem to finite element mesh design and heat source characteristics

A single weld bead deposited on a flat plate is a deceptively simple problem that is, in practice, a significant challenge for both measurement and prediction of weld residual stresses. Task Group 1 of the NeT collaborative network has examined this probl

The European network on Neutron Techniques Standardization for Structural Integrity - NeT

This paper provides an overview over the work of the European Network on Neutron Techniques Standardization for Structural Integrity (NeT). The network involves some 35 organisations from industry and academia and these partners undertake the application of modern experimental and numerical techniques to problems related to the structural integrity of components, mainly relevant to nuclear applications. While being built around neutron scattering techniques, which are predominantly applied for analyses of welding residual stresses, one of the major strengths of the consortium is the diversity in available experimental and numerical techniques. In the residual stress area, for example, many types of materials characterizations testing, several methods for residual stress analysis, including neutron and X-ray diffraction, deep hole drilling, the contour method and others, and many different ways of numerical analysis employing several commercially available FEM codes can be covered by the partners. Currently the network has embarked on five different Task Groups. Four of these are dealing with welding residual stress assessment, and one applies Small Angle Neutron Scattering for studying thermal ageing processes in duplex stainless steels used for reactor core internals. The work already performed in the context of NeT and the envisaged investigations for the ongoing Task Groups are briefly outlined in this paper. The aim is to give the reader a comprehensive overview of the work of NeT and to shed some light on the potential present in this kind of collaborative effort.Copyright

Development of Oxide Dispersion Strengthened Steels for High Temperature Nuclear Structural Applications

Oxide dispersion strengthened (ODS) steels are the most promising candidate materials for high temperature nuclear applications. Mechanical alloying and subsequent thermomechanical treatments are applied to manufacture the ODS steels. Recently improved chemical composition and manufacturing processes have been developed to produce ultrafine grain size with high number-density of nanoscale oxide particles and high dislocation density in the microstructure. Usually, fine grains degrade creep resistance at elevated temperatures. However, the fine-grained ODS steels exhibit not only good radiation resistance, but also superior creep properties. The present paper reviews the chemical compositions, manufacturing processing, microstructural features, thermal creep properties and radiation resistance of recently developed ODS steels. Special attention is paid to the effects of the fine-scale microstructural features on thermal creep and radiation resistance.