NDLI: Study of Crack Extension Effects on a Weld-Induced Residual Stress Field

Content Provider	The American Society of Mechanical Engineers (ASME) Digital Collection
Author	Jeong, K. Hong Thomas, P. Forte
Copyright Year	2013
Abstract	For many applications, welding is the best manufacturing process for joining two separate components. However, the welding process with its highly localized heating and cooling results in the residual stresses both along the surface and through the thickness of the joint. These residual stresses will affect the rate of growth of a fatigue crack as it propagates through the joint and therefore will affect the service life. Therefore, service life predictions must consider the residual stresses as well as their redistribution that occurs as the crack grows. Analytical approaches to assess fitness-for-service such as API 579 are available to evaluate the effect of weld-induced residual stresses. However, current industry practices calculate stress intensity factors (SIFs) for fracture and fatigue crack growth life estimates without considering the redistribution of the residual stresses as the crack propagates, and thus tend to be very conservative. In this paper, Battelle’s weld residual stress modeling methods are combined with a procedure for calculating the SIF using local crack tip displacements that accounts for the redistribution of the residual stresses due to crack extension. In addition, the finite element model used to determine the weld residual stresses is also used to determine the SIF. Therefore, the complete mechanical response to the welding, including residual stress, deformed geometry, elastic and plastic strains, etc. are available for the crack growth analysis. This new unified procedure is demonstrated for simple joints and is compared to a “simplified” crack growth analysis that uses stress mapping. The unified procedure clearly characterizes mixed mode crack behavior at the crack tip. In this paper the procedure is presented in terms of how the crack affects the weld-induced residual stress field; it is equally well suited for practical design use to assess structural integrity in the presence of a weld-induced residual stress field with or without external service loading.
Sponsorship	Pressure Vessels and Piping Division Nondestructive Evaluation Engineering Division
File Format	PDF
ISBN	9780791855713
DOI	10.1115/PVP2013-98017
Volume Number	Volume 6B: Materials and Fabrication
Conference Proceedings	ASME 2013 Pressure Vessels and Piping Conference
Language	English
Publisher Date	2013-07-14
Publisher Place	Paris, France
Access Restriction	Subscribed
Subject Keyword	American petroleum institute Analytical methods Welding Service life (equipment) Fitness-for-service Joining Fracture (materials) Residual stresses Modeling Stress Design Geometry Finite element model Manufacturing Heating and cooling Fatigue cracks
Content Type	Text
Resource Type	Article

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