Finite Element Analysis of Welding Residual Stress of the Ultra-Thick 13MnNiMoR Steel Cylinder of a Large EO Reactor Made in China

2013 ◽  
Author(s):  
Yongbin Wen ◽  
Luyang Geng ◽  
Jianming Gong ◽  
Yangfei Wang ◽  
Shantung Tu
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Fe Analysis ◽  
Welding Residual Stress ◽  
Inside Surface ◽  
Stress Distributions ◽  
Steel Cylinder ◽  
Made In China ◽  
Made In

The finite element (FE) analysis was applied to investigate welding residual stresses generated in the weld region of the ultra-thick 13MnNiMoR steel cylinder of a large Ethylene Oxide (EO) reactor made in China, with an outer diameter of 6760mm and wall thickness of 110mm. The FE Analysis consists of the nonlinear thermal and thermo-mechanical axisymmetric numerical simulations. In the FE analysis, an alternating welding model was created for the double U-type groove welding. The residual stress distributions on the inside surface and the outside surface were obtained. The analyzed results show that the axial and hoop welding residual stresses on the inside surface and the outside surface are tensile in the weld zone and its vicinity. The residual stress distributions on the inside surface and the outside surface are very sensitive to the distance from the weld centerline. The effects of the temperature of PWHT on the welding residual stress were analyzed by taking into account PWHT at 600 °C, 620 °C and 640 °C. The simulated results show the residual stresses decrease with the increase in the temperature of PWHT, and an appropriate temperature of PWHT is 620 °C for the ultra-thick cylinder of the domestic EO reactor.

Engineering J Estimation Equations for Spent Fuel Canisters Under Combined Mechanical and Welding Residual Stresses

2018 ◽  
Author(s):  
Hyun-Jae Lee ◽  
Jae-Yoon Jeong ◽  
Yun-Jae Kim ◽  
Poh-Sang Lam
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Fe Analysis ◽  
Welding Residual Stress ◽  
Spent Fuel ◽  
Basic Form ◽  
Estimation Equations ◽  
Reference Stress ◽  
J Estimation

This paper provides engineering J estimation equations for Spent Fuel Canisters (SFCs) under combined mechanical and welding residual stress (WRS) fields. The basic form of estimation equations is reference stress-based ones as in R6. Interaction between mechanical (primary) and residual (secondary) stresses is treated using the V-factor. Based on systematic finite element (FE) analysis and J results, the V-factors for the combined mechanical and welding residual stresses are reported.

scholarly journals Finite Element Prediction of Residual Stress Distributions in a Multipass Welded Piping Branch Junction

2006 ◽  
Author(s):  
Wei Jiang ◽  
Kadda Yahiaoui
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Welding Process ◽  
Pressure Vessels ◽  
Welding Residual Stress ◽  
Stress Distributions ◽  
Multipass Welding ◽  
Hexahedral Elements ◽  
Element Removal

Piping branch junctions and nozzle attachments to main pressure vessels are common engineering components used in the power, oil and gas, and shipbuilding industries amongst others. These components are usually fabricated by multipass welding. The latter process is known to induce residual stresses at the fabrication stage which can have severe adverse effects on the in-service behavior of such critical components. It is thus desirable if the distributions of residual stresses can be predicted well in advance of welding execution. This paper presents a comprehensive study of three dimensional residual stress distributions in a stainless steel tee branch junction during a multipass welding process. A full 3D thermo-mechanical finite element model has been developed for this purpose. A newly developed meshing technique has been used to model the complex intersection areas of the welded junction with all hexahedral elements. Element removal/reactivate technique has been employed to simulate the deposition of filler material. Material, geometry and boundary nonlinearities associated with welding were all taken into account. The analysis results are presented in the form of stress distributions circumferentially along the weldline on both run and branch pipes as well as at the run and branch cross sections. In general, this computational model is capable of predicting 3D through thickness welding residual stress, which can be valuable for structural integrity assessments of complex welded geometries.

scholarly journals Finite Element Prediction of Residual Stress Distributions in a Multipass Welded Piping Branch Junction

2006 ◽  
Vol 129 (4) ◽  
pp. 601-608 ◽  
Author(s):  
Wei Jiang ◽  
Kadda Yahiaoui
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Three Dimensional ◽  
Pressure Vessels ◽  
Welding Residual Stress ◽  
Stress Distributions ◽  
Multipass Welding ◽  
Hexahedral Elements ◽  
Element Removal

Piping branch junctions and nozzle attachments to main pressure vessels are common engineering components used in the power, oil and gas, and shipbuilding industries amongst others. These components are usually fabricated by multipass welding. The latter process is known to induce residual stresses at the fabrication stage, which can have severe adverse effects on the in-service behavior of such critical components. It is thus desirable if the distributions of residual stresses can be predicted well in advance of welding execution. This paper presents a comprehensive study of three dimensional residual stress distributions in a stainless steel tee branch junction during a multipass welding process. A full three dimensional thermomechanical finite element model has been developed for this purpose. A newly developed meshing technique has been used to model the complex intersection areas of the welded junction with all hexahedral elements. Element removal/reactivate technique has been employed to simulate the deposition of filler material. Material, geometry, and boundary nonlinearities associated with welding were all taken into account. The analysis results are presented in the form of stress distributions circumferentially along the weld line on both run and branch pipes as well as at the run and branch cross sections. In general, this computational model is capable of predicting three dimensional through-thickness welding residual stress, which can be valuable for structural integrity assessments of complex welded geometries.

Engineering J Estimates for Spent Fuel Canisters Under Combined Mechanical and Welding Residual Stresses

2019 ◽  
Author(s):  
Hyun-Jae Lee ◽  
Yun-Jae Kim ◽  
Poh-Sang Lam ◽  
Robert L. Sindelar
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Fe Analysis ◽  
Welding Residual Stress ◽  
Spent Fuel ◽  
Reference Stress ◽  
Fracture Assessment

Abstract This paper compares engineering J estimates for Spent Fuel Canisters (SFCs) under combined mechanical and welding residual stress (WRS) with finite element (FE) results. Engineering J estimates are based on reference stress method provided in the R6 procedure considering interaction between primary and secondary stresses using the V-factor. It is found that residual stress should be considered in fracture assessment and the R6 estimates are reasonably conservative compared to FE analysis results.

Prediction of Residual Stress Distributions in Welded Sections of P92 Pipes with Small Diameter and Thick Wall based on 3D Finite Element Simulation

2015 ◽  
Vol 34 (3) ◽  
Author(s):  
Xiaowei Wang ◽  
Jianming Gong ◽  
Yanping Zhao ◽  
Yanfei Wang
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Small Diameter ◽  
Fe Analysis ◽  
Thick Wall ◽  
Fe Model ◽  
Stress Distributions ◽  
Residual Stress Field ◽  
Heat Treated

AbstractThis study used ABAQUS finite element (FE) software to investigate the residual stress distributions of P92 welded pipes in both the as-weld and post weld heat treated (PWHT) condition. Sequential coupling quasi-static thermo-mechanical in conjunction with moving double ellipsoidal heat source and an element add/remove technique to simulate deposition of new weld material, are combined in the 3D FE analysis. To validate the simulation results, the residual stresses in axial direction at the surface of pipe were measured by X-ray diffraction technique and compared with the results of FE analysis. Detailed characteristic distributions of the residual stresses are discussed. Results show that the FE model can predict the residual stress distributions satisfactorily. Highest residual stresses on the outer surface are found in the last weld bead to be deposited. And the highest tensile residual stress for the full welded section take place in heat affected zone (HAZ) near the middle thickness. Larger residual sstress can be found around the welding start point along the pipe circumference. Comparison of heat treated specimen and untreated specimen illustrates that PWHT has a strong effect on the residual stress field.

scholarly journals Investigation of Clamping Effect on the Welding Residual Stress and Deformation of Monel Plates by Using the Ultrasonic Stress Measurement and Finite Element Method

2014 ◽  
Vol 137 (1) ◽  
Author(s):  
Yashar Javadi
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Acoustic Waves ◽  
Stress Measurement ◽  
Fe Analysis ◽  
Ultrasonic Waves ◽  
Welding Residual Stress ◽  
Longitudinal Residual Stress ◽  
Ultrasonic Stress Measurement

Welding of nickel-based alloys is increasingly used in the industry to manufacture many important components of the marine industries, chemical processing, etc. In this study, a 3D thermomechanical finite element (FE) analysis is employed to evaluate residual stresses and deformations caused by the tungsten inert gas (TIG) welding of Monel 400 (Nickel-Copper alloy) plates. The FE results related to the residual stresses and deformations have been verified by using the hole-drilling stress measurement and common dimensional measurement tools, respectively. Residual stresses analyzed by the FE simulation are then compared with those obtained from ultrasonic stress measurement. The ultrasonic stress measurement is based on acoustoelasticity law, which presents the relation between the acoustic waves and the stress of material. The ultrasonic stress measurement is carried out by using longitudinal critically refracted (LCR) waves which are longitudinal ultrasonic waves propagated parallel to the surface inside the tested material. Two welded plates are experimentally prepared (with and without using clamp) to investigate the clamping effect on the welding residual stress and deformations. By utilizing the FE analysis along with the LCR method, the distribution of longitudinal residual stress could be achieved. It has been concluded that the applied methodologies are enough accurate to distinguish the clamping effect on the welding residual stresses and deformations of Monel plates.

Finite Element Welding Residual Stress Analysis of CRDM Penetration Nozzles

2021 ◽  
Vol 144 (1) ◽  
Author(s):  
Seung-Jae Kim ◽  
Eui-Kyun Park ◽  
Hong-Yeol Bae ◽  
Ju-Hee Kim ◽  
Nam-Su Huh ◽  
...  
Keyword(s):  
Residual Stress ◽  
Yield Strength ◽  
Residual Stresses ◽  
Nuclear Reactor ◽  
Reactor Vessel ◽  
Welding Residual Stress ◽  
Alloy 600 ◽  
Stress Distributions ◽  
Control Rod ◽  
Residual Stress Analysis

Abstract This article investigates numerically welding residual stress distributions of a tube with J-groove weld in control rod drive mechanisms of a pressurized nuclear reactor vessel. Parametric study is performed for the effect of the tube location, tube dimensions, and material's yield strength. It is found that residual stresses increase with increasing the inclination angle of the tube, and the up-hill side is the most critical. For thicker tube, residual stresses decrease. For material's yield strength, both axial and hoop residual stresses tend to increase with increasing the yield strength of Alloy 600. Furthermore, axial stresses tend to increase with increasing yield strength of Alloys 82/182.

Welding Residual Stress Analysis Using Axisymmetric Modeling for Shroud Support Structure

2008 ◽  
Author(s):  
Kazuo Ogawa ◽  
Yukihiko Okuda ◽  
Toshiyuki Saito ◽  
Takahiro Hayashi ◽  
Rie Sumiya
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Large Scale ◽  
Structural Integrity ◽  
Plastic Material ◽  
Welding Residual Stress ◽  
Stress Distributions ◽  
Surface Residual Stress ◽  
Actual Structure ◽  
Elastic Plastic Material

Recently, several cracks caused by stress corrosion cracking (SCC) have been found on welds of shroud supports in Boiling Water Reactor (BWR) plants. The major cause of SCC in a weld joint is considered due to welding residual stress generated in the fabrication processes of the components. For continuous safety operations, it is necessary to estimate the structural integrity of such shroud supports with cracks based on the distribution of residual stresses induced by welding. In order to know and to validate the numerical method of residual stresses induced by welding of large scale and complex shaped components, a BWR shroud support mock-up with a hemispherical base of reactor pressure vessel (RPV) was fabricated by Japan Nuclear Energy Safety Organization (JNES) as a national project. The mock-up has a 32° section of actual BWR shroud supports with approximately the same configurations, materials and welding conditions of an actual component. During welding in the fabrication process of the mock-up, temperature was measured and after completion of the mock-up fabrication, surface residual stress distributions for each weld were also measured by the sectioning method. In addition, through-thickness residual stress distributions were investigated. Residual stress for each weld was calculated by using axisymmetric models considering temperature dependent elastic-plastic material properties. Though the actual structure of shroud supports is essentially complex, we simplified axisymmetric models in the center of the cross section. The analysis results show a similar profile and good agreement with the measured results on the surface of all the welds and through the welds at the upper and lower joints of the shroud support leg.

Interpretation of residual stress distributions in previously loaded cracked beams

1992 ◽  
Vol 27 (2) ◽  
pp. 77-83 ◽  
Author(s):  
D J Smith ◽  
M A M Bourke ◽  
A P Hodgson ◽  
G A Webster ◽  
P J Webster
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Neutron Diffraction ◽  
Residual Stresses ◽  
Crack Tip ◽  
Stress Distributions ◽  
Element Analysis ◽  
Sampling Volume ◽  
Neutron Diffraction Technique ◽  
Good Agreement

The measurement and prediction of residual stress distributions in a fatigue pre-cracked and a plastically overloaded A533B steel beam are described. The residual stresses were obtained experimentally using the neutron diffraction technique. Finite element analysis was employed to predict the elastic-plastic response and residual stresses introduced after overloading. Comparison of the experimental results have been made with the finite element predictions (for both plane stress and strain conditions) averaged over the same sampling volume used to make the neutron diffraction measurements. It has been found that good agreement is achieved away from the near crack tip region. However, close to the crack tip the measured compressive residual stresses are significantly smaller than predicted. This difference is attributed to the A533B steel exhibiting a Bauschinger effect and yielding at a lower stress after a stress reversal.

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