Residual Stress Shakedown in Typical Weld Joints and Its Effect on Fatigue of FPSOs

2007 ◽  
Author(s):  
Liangbi Li ◽  
Torgeir Moan ◽  
Bin Zhang
Keyword(s):  
Residual Stress ◽  
Cyclic Loading ◽  
Residual Stresses ◽  
Welded Joints ◽  
Hot Spot ◽  
Fatigue Behaviour ◽  
Combined Effect ◽  
Element Analysis ◽  
Variable Amplitude ◽  
Initial Residual Stress

Structural members of FPSO hulls often undergo fairly large static loading before they enter service or variable amplitude cyclic loading when they are in service. The combined effect of both applied stress and high initial residual stress is expected to cause shakedown of the residual stresses. Only a few papers seem to deal with appropriate procedures for fatigue analysis by considering the combined effect of variable amplitude cyclic loading with shakedown of residual stresses. Hence, the fatigue behaviour of welded joints in some experiments could not be explained reasonably well. In this paper, some typical welded connections in ship-shaped structures are investigated with 3-D elastic-plastic finite element analysis. The effect of residual stress relaxation, initial residual stress and the applied load after variable amplitude cyclic loading is revealed, and a formula for predicting the residual stress at hot spot quantitatively is proposed. Based on the formula, an improved fatigue procedure is introduced. The proposed fatigue procedure was validated against the experimental results. Therefore, the modified fatigue procedure could be applied to welded joints under arbitrary cyclic loading while accounting for shakedown of residual stresses.

Fatigue Assessment of Welded Joints Taking Into Account Effects of Residual Stress

2010 ◽  
Author(s):  
Nur Syahroni ◽  
Stig Berge
Keyword(s):  
Residual Stress ◽  
Fatigue Strength ◽  
Welded Joints ◽  
Fatigue Testing ◽  
International Association ◽  
Hot Spot ◽  
Mean Stress ◽  
Element Analysis ◽  
Structural Rules ◽  
Fatigue Design

Residual stress may have a significant effect on the fatigue strength of welded joints. As a non-fluctuating stress, it has an effect similar to that of the mean stress. Recently the International Association of Ship Classification Societies (IACS) has issued Common Structural Rules (CSR) for respectively tankers (IACS 2006a) and bulk carriers (IACS 2006b). The effect of mean stress in fatigue design is taken into account in both sets of rules. However, the treatment is quite different, in particular with regard to residual stress and shakedown effects. In the present paper a comparative study of fatigue design procedures of the IACS rules is reported, with emphasis on residual stress effects. Testing was carried out with longitudinal attachment welds in the as-welded condition. The initial residual stress was measured by a sectioning method using strain gages. Hot spot stress was determined experimentally by strain gauges and numerically by finite element analysis using different types of elements. Fatigue testing was carried out and SN-curves were plotted according to the relevant stress as specified by the rules. In order to investigate the shake-down effect of residual stress, testing was performed for several pre-load conditions which could be taken to represent maximum load levels in a load history. The aim of the study is to contribute towards better understanding of the effect of residual stress and shakedown on fatigue strength of welded joints.

Estimation of Residual Stresses in Steel Welded Joints Using Three Dimensional Finite Element Analysis

2018 ◽  
Author(s):  
Shivdayal Patel ◽  
B. P. Patel ◽  
Suhail Ahmad
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Boundary Conditions ◽  
Welding Speed ◽  
Welded Joints ◽  
Plate Thickness ◽  
Welding Process ◽  
Element Analysis

Welding is one of the most used joining methods in the ship industry. However, residual stresses are induced in the welded joints due to the rapid heating and cooling leading to inhomogenously distributed dimensional changes and non-uniform plastic and thermal strains. A number of factors, such as welding speed, boundary conditions, weld geometry, weld thickness, welding current/voltage, number of weld passes, pre-/post-heating etc, influence the residual stress distribution. The main aim of this work is to estimate the residual stresses in welded joints through finite element analysis and to investigate the effects of boundary conditions, welding speed and plate thickness on through the thickness/surface distributions of residual stresses. The welding process is simulated using 3D Finite element model in ABAQUS FE software in two steps: 1. Transient thermal analysis and 2. Quasi-static thermo-elasto-plastic analysis. The normal residual stresses along and across the weld in the weld tow region are found to be significant with nonlinear distribution. The residual stresses increase with the increase in the thickness of the plates being welded. The nature of the normal residual stress along the weld is found to be tensile-compressive-tensile and the nature of normal residual stress across the weld is found to be tensile along the thickness direction.

Fatigue Assessment of Welded Joints Taking Into Account Effects of Residual Stress

2011 ◽  
Vol 134 (2) ◽  
Author(s):  
Nur Syahroni ◽  
Stig Berge
Keyword(s):  
Residual Stress ◽  
Fatigue Strength ◽  
Welded Joints ◽  
Fatigue Testing ◽  
International Association ◽  
Hot Spot ◽  
Strain Gauges ◽  
Mean Stress ◽  
Element Analysis ◽  
Fatigue Design

Residual stress may have a significant effect on the fatigue strength of welded joints. As a nonfluctuating stress, it has an effect similar to that of the mean stress. Recently the International Association of Ship Classification Societies (IACS) has issued Common Structural Rules (CSR) for respectively tankers and bulk carriers. The effect of mean stress in fatigue design is taken into account in both sets of rules. However, the treatment is quite different, in particular with regard to residual stress and shakedown effects. In the present paper a comparative study of fatigue design procedures of the IACS rules is reported, with emphasis on residual stress effects. Testing was carried out with longitudinal attachment welds in the as-welded condition. The initial residual stress was measured by a sectioning method using strain gauges. Hot spot stress was determined experimentally by strain gauges and numerically by finite element analysis using different types of elements. Fatigue testing was carried out and SN-curves were plotted according to the relevant stress as specified by the rules. In order to investigate the shakedown effect of residual stress, testing was performed for several preload conditions, which could be taken to represent maximum load levels in a load history. The aim of the study is to contribute towards a better understanding of the effect of residual stress and shakedown on fatigue strength of welded joints.

Relaxation of Peening Residual Stresses Due to Cyclic Thermo-Mechanical Overload

2005 ◽  
Vol 127 (2) ◽  
pp. 170-178 ◽  
Author(s):  
S. A. Meguid ◽  
G. Shagal ◽  
J. C. Stranart ◽  
K. M. Liew ◽  
L. S. Ong
Keyword(s):  
Residual Stress ◽  
Cyclic Loading ◽  
Residual Stresses ◽  
Three Dimensional ◽  
Target Material ◽  
High Strength ◽  
Residual Stress Field ◽  
Element Analysis ◽  
Strain Rate Effects ◽  
Multiple Impact

Shot-peening induced residual stresses can be relaxed due to cyclic loading. This relaxation plays an important role in determining the fatigue life of the peened components. It is therefore the purpose of this study to conduct comprehensive three-dimensional dynamic elasto-plastic finite element analysis of the joint peening treatment and relaxation process. In this regard, a novel symmetry cell is developed and used to model the multiple impact indentations resulting from multiple impingements of a cluster of shots. The model was further extended to integrate the relaxation resulting from cyclic loading at stresses above the yield strength of the material. This integrated model accounts for the main features of both stages by considering strain-rate effects, shot and target inertia and the dependence of the mechanical properties of the target material on temperature. A wide spectra of cyclic mechanical and thermal loads as well as their combinations is considered and the resulting relaxed residual stress field is determined. As an application, the model was used to predict the residual stress relaxation in a high-strength steel target made from AISI 4340 under different peening and thermomechanical cyclic overload.

scholarly journals Numerical simulation of laser welded joints: modern fatigue analysis methodology

2020 ◽  
Vol 53 (4) ◽  
pp. 342-355
Author(s):  
Rami Markus Kokko ◽  
Joona Vaara ◽  
Teemu Kuivaniemi ◽  
Tero Frondelius
Keyword(s):  
Numerical Simulation ◽  
Cyclic Loading ◽  
Residual Stresses ◽  
Welded Joints ◽  
Fatigue Cracks ◽  
Fatigue Behaviour ◽  
Noticeable Effect ◽  
Microstructural Changes ◽  
Analysis Methodology ◽  
Simulation Results

Welding always induces discontinuities and imperfections in the structure that allows for potential fatigue cracks. Welding effects thermal strains, which yield to residual stresses of the structure that have a noticeable effect on the fatigue behaviour of the structure. Welding inexorably leads to microstructure and geometry changes in the welding region. Material internal changes, residual stresses and microstructural changes can be simulated numerically, and the simulation results can be used in cyclic loading analysis in FEA.

Effect of Residual Stress or Plastic Deformation History on Fatigue Life Simulation of Pipeline Dents

2018 ◽  
Author(s):  
Xian-Kui Zhu ◽  
Rick Wang
Keyword(s):  
Residual Stress ◽  
Plastic Deformation ◽  
Fatigue Life ◽  
Residual Stresses ◽  
Three Dimensional ◽  
Strain History ◽  
Deformation History ◽  
Stress Strain ◽  
Element Analysis ◽  
Fea Model

Mechanical dents often occur in transmission pipelines, and are recognized as one of major threats to pipeline integrity because of the potential fatigue failure due to cyclic pressures. With matured in-line-inspection (ILI) technology, mechanical dents can be identified from the ILI runs. Based on ILI measured dent profiles, finite element analysis (FEA) is commonly used to simulate stresses and strains in a dent, and to predict fatigue life of the dented pipeline. However, the dent profile defined by ILI data is a purely geometric shape without residual stresses nor plastic deformation history, and is different from its actual dent that contains residual stresses/strains due to dent creation and re-rounding. As a result, the FEA results of an ILI dent may not represent those of the actual dent, and may lead to inaccurate or incorrect results. To investigate the effect of residual stress or plastic deformation history on mechanics responses and fatigue life of an actual dent, three dent models are considered in this paper: (a) a true dent with residual stresses and dent formation history, (b) a purely geometric dent having the true dent profile with all stress/strain history removed from it, and (c) a purely geometric dent having an ILI defined dent profile with all stress/strain history removed from it. Using a three-dimensional FEA model, those three dents are simulated in the elastic-plastic conditions. The FEA results showed that the two geometric dents determine significantly different stresses and strains in comparison to those in the true dent, and overpredict the fatigue life or burst pressure of the true dent. On this basis, suggestions are made on how to use the ILI data to predict the dent fatigue life.

Finite Element Analyses of Residual Stresses in Typical Welded Joints Used in Nuclear Power Plants and Comparisons With Experiments

2010 ◽  
Author(s):  
Dean Deng ◽  
Kazuo Ogawa ◽  
Nobuyoshi Yanagida ◽  
Koichi Saito
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Residual Stresses ◽  
Welded Joints ◽  
Nuclear Power ◽  
Power Plants ◽  
Butt Joint ◽  
Welding Residual Stress ◽  
Dissimilar Metal ◽  
Water Reactors

Recent discoveries of stress corrosion cracking (SCC) at nickel-based metals in pressurized water reactors (PWRs) and boiling water reactors (BWRs) have raised concerns about safety and integrity of plant components. It has been recognized that welding residual stress is an important factor causing the issue of SCC in a weldment. In this study, both numerical simulation technology and experimental method were employed to investigate the characteristics of welding residual stress distribution in several typical welded joints, which are used in nuclear power plants. These joints include a thick plate butt-welded Alloy 600 joint, a dissimilar metal J-groove set-in joint and a dissimilar metal girth-butt joint. First of all, numerical simulation technology was used to predict welding residual stresses in these three joints, and the influence of heat source model on welding residual stress was examined. Meanwhile, the influence of other thermal processes such as cladding, buttering and heat treatment on the final residual stresses in the dissimilar metal girth-butt joint was also clarified. Secondly, we also measured the residual stresses in three corresponding mock-ups. Finally, the comparisons of the simulation results and the measured data have shed light on how to effectively simulate welding residual stress in these typical joints.

Stress and Fatigue Life Modeling of Cannon Breech Closures Including Effects of Material Strength and Residual Stress

2000 ◽  
Vol 123 (1) ◽  
pp. 150-154
Author(s):  
John H. Underwood ◽  
Michael J. Glennon
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Fatigue Life ◽  
Yield Strength ◽  
Residual Stresses ◽  
Solid Mechanics ◽  
Element Model ◽  
Pressure Vessels ◽  
Material Strength ◽  
Element Analysis

Laboratory fatigue life results are summarized from several test series of high-strength steel cannon breech closure assemblies pressurized by rapid application of hydraulic oil. The tests were performed to determine safe fatigue lives of high-pressure components at the breech end of the cannon and breech assembly. Careful reanalysis of the fatigue life tests provides data for stress and fatigue life models for breech components, over the following ranges of key parameters: 380–745 MPa cyclic internal pressure; 100–160 mm bore diameter cannon pressure vessels; 1040–1170 MPa yield strength A723 steel; no residual stress, shot peen residual stress, overload residual stress. Modeling of applied and residual stresses at the location of the fatigue failure site is performed by elastic-plastic finite element analysis using ABAQUS and by solid mechanics analysis. Shot peen and overload residual stresses are modeled by superposing typical or calculated residual stress distributions on the applied stresses. Overload residual stresses are obtained directly from the finite element model of the breech, with the breech overload applied to the model in the same way as with actual components. Modeling of the fatigue life of the components is based on the fatigue intensity factor concept of Underwood and Parker, a fracture mechanics description of life that accounts for residual stresses, material yield strength and initial defect size. The fatigue life model describes six test conditions in a stress versus life plot with an R2 correlation of 0.94, and shows significantly lower correlation when known variations in yield strength, stress concentration factor, or residual stress are not included in the model input, thus demonstrating the model sensitivity to these variables.

Simplified FEA Models in the Analysis of the Redistribution of Beneficial Compressive Stresses in Welds During Cyclic Loading

2018 ◽  
Author(s):  
B. L. Josefson ◽  
J. Alm ◽  
J. M. J. McDill
Keyword(s):  
Cyclic Loading ◽  
Residual Stresses ◽  
Compressive Stress ◽  
Welding Process ◽  
Plastic Behavior ◽  
Element Analysis ◽  
Compressive Stresses ◽  
Static Contact ◽  
Weld Toe ◽  
Compressive Residual Stresses

The fatigue life of welded joints can be improved by modifying the weld toe geometry or by inducing beneficial compressive residual stresses in the weld. However, in the second case, the induced compressive residual stresses may relax when the welded joint is subjected to cyclic loading containing high tensile or compressive stress peaks. The stability of induced compressive stresses is investigated for a longitudinal gusset made of a S355 steel. Two methods are considered; either carrying out a high frequency mechanical impact (HFMI) treatment after welding or alternatively using low transformation temperature (LTT) electrodes during welding. The specimen is then subjected to a cyclic loading case with one cycle with a tensile peak (with magnitude reaching the local yield stress level) followed by cycles with constant amplitude. A sequential finite element analysis (FEA) is performed thereby preserving the history of the elasto-plastic behavior. Both the welding process and the HFMI treatment are simulated using simplified approaches, i.e., the welding process is simulated by applying a simplified thermal cycle while the HFMI treatment is simulated by a quasi-static contact analysis. It is shown that using the simplified approaches to modelling both the welding process and HFMI treatment gives results that correlate qualitatively well with the experimental and FEA data available in the literature. Thus, for comparison purposes, simplified models may be sufficient. Both the use of the HFMI treatment and LTT electrodes give approximately the same compressive stress at the weld toe but the extent of the compressive stress zone is deeper for HFMI case. During cyclic loading it is shown that the beneficial effect of both methods will be substantially reduced if the test specimen is subjected to unexpected peak loads. For the chosen load sequence, with the same maximum local stress at the weld toe, the differences in stress curves of the HFMI-treated specimen and that with LTT electrodes remain. While the LTT electrode gives the lowest (compressive) stress right at the well toe, it is shown that the overall effect of the HFMI treatment is more beneficial.

scholarly journals Use of 3D Scan of Weld Joint in Finite Element Analysis and Stochastic Analysis of Hot-Spot Stresses in Tubular Joint for Fatigue Life Estimation

2019 ◽  
Author(s):  
Mikkel L. Larsen ◽  
Vikas Arora ◽  
Marie Lützen ◽  
Ronnie R. Pedersen ◽  
Eric Putnam
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Welded Joints ◽  
Hot Spot ◽  
Strain Range ◽  
Fe Model ◽  
Design Codes ◽  
Element Analysis ◽  
Hot Spot Stress ◽  
Weld Toe

Abstract Several methods for modelling and finite element analysis of tubular welded joints are described in various design codes. These codes provide specific recommendations for modelling of the welded joints, using simple weld geometries. In this paper, experimental hot-spot strain range results from a full-scale automatically welded K-node test are compared to corresponding finite element models. As part of investigating the automatically welded K-joint, 3D scans of the weld surfaces have been made. These scans are included in the FE models to determine the accuracy of the FE models. The results are compared to an FE model with a simple weld geometry based on common offshore design codes and a model without any modelled weld. The results show that the FE model with 3D scanned welds is more accurate than the two simple FE models. As the weld toe location of the 3D scanned weld is difficult to locate precisely in the FE model and as misplacement of strain gauges are possible, stochastic finite element modelling is performed to analyse the resulting probabilistic hot-spot stresses. The results show large standard deviations, showing the necessity to evaluate the hot-spot stress method when using 3D scanned welds.

Sign in / Sign up

Export Citation Format

Share Document