Finite Element Modelling of a Tube to Vessel Attachment Weld and Local Post-Weld Heat Treatment

2011 ◽  
Author(s):  
Benjamin M. E. Pellereau ◽  
Paul R. Hurrell ◽  
Christopher M. Gill ◽  
Sarah L. Allen
Keyword(s):  
Heat Treatment ◽  
Finite Element ◽  
Pressure Vessel ◽  
Hold Time ◽  
Measurement Data ◽  
Stress Relief ◽  
Post Weld Heat Treatment ◽  
Isotropic Hardening ◽  
Fe Model ◽  
Weld Heat

This paper describes Finite Element (FE) modelling of a weld between a tube and a machined feature on a curved pressure vessel surface. The components were manufactured from a ferritic steel with a matched weld metal deposited by a mechanised TIG process. The weld region then underwent a local Post-Weld Heat Treatment (PWHT) which used heating bands and cooling air flows to control the temperature distribution. The PWHT’s aim was to provide stress relief and HAZ tempering, while minimising the stresses due to thermal gradients in the component. Trial welds on representative test pieces had predicted significant welding-induced distortions. Therefore, during the weld and PWHT, restraints were applied to the tube to prevent excessive deformation. The material behaviour was represented using Abaqus’ built-in material options, with the same properties for both the base metal and the filler. Isotropic hardening was assumed and the stress relaxation during the PWHT was modelled by applying a Norton creep law only during the hold time. Phase transformation effects in the ferritic material were not included. Initial modelling used a 2D axisymmetric model to allow sensitivity studies to inform the development of the PWHT process. These showed that the degree of stress relief was much more sensitive to the soak temperature than the hold time. Subsequent runs analysed a 3D model using a segmented block-dumping technique, with the deposition modelled by introducing the weld elements in 90° segments. The 3D modelling was undertaken in order to more accurately model potentially asymmetric welding distortions and residual stresses. The torch was represented by a body flux into each segment after its introduction. This model was also run without restraint to provide validation by comparing the predicted distortion with measurements from the welding trials; a good match was demonstrated. Further comparisons were made between the predicted stresses and results of Incremental Centre Hole-Drilling (ICHD) stress measurements made on the trial specimens both in the as-welded condition and after PWHT. The measured stresses were close to those predicted by the FE analysis and the key features of the predicted stress field were apparent in the measurement data. Due to the location of the tube’s attachment to the pressure vessel, thermal expansion of the vessel during the PWHT caused the tube to bend. The induced bending stresses were then relaxed during the soak and re-introduced in the opposite sense as the system cooled. This effect was captured by running the analysis as a submodel of a global FE model with displacements read across at nodes in the pressure vessel shell immediately below the weld.

Residual Stress Relaxation in a Tube Attachment Weld Inside a Pressure Vessel Forging During Post Weld Heat Treatment

2007 ◽  
Author(s):  
P. R. Hurrell ◽  
J. Davies ◽  
N. A. Leggatt ◽  
R. J. Dennis ◽  
R. H. Leggatt
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Stress Relaxation ◽  
Pressure Vessel ◽  
Hold Time ◽  
Stress Relief ◽  
Post Weld Heat Treatment ◽  
Secondary Creep ◽  
Axial Tensile ◽  
Weld Heat

This paper presents analyses done to determine residual stress relief achieved by post weld heat treatment (PWHT) of tube attachment welds inside a thick SA508 steel pressure vessel forging. Finite element (FE) analyses were performed modelling the manufacturing operations in detail including welding, machining and PWHT. The analyses demonstrate that PWHT at 600°C for 8 hours is effective in reducing as-welded residual stress levels from tensile yield magnitude (+500MPa approx) to <100MPa. The maximum residual stress was computed to be 90MPa sub-surface in a region of hydrostatic (tri-axial tensile) stress. Secondary creep was modelled using data from creep tests on SA508 steel uni-axial tensile specimens. Practically all of the stress relaxation is due to creep strain with minimal additional plastic strain. Most stress relief occurs during the first hour of soak, with diminishing benefit thereafter. Analysis results also indicate that PWHT effectiveness is more sensitive to soak temperature than hold time. These FE results are considered slightly pessimistic but are reasonably consistent with other analytical predictions. By comparison surface hole drilling stress measurements of <50MPa (10% yield strength) were recorded from a representative welded test block. Analysis pessimism was attributed to ignoring both primary creep and relaxation during the slow warm up phase of the heat treatment cycle.

Establishing Recommended Guidance for Local Post Weld Heat Treatment Configurations Based on Thermal-Mechanical Finite Element Analysis

2016 ◽  
Author(s):  
Phillip E. Prueter ◽  
Brian Macejko
Keyword(s):  
Heat Treatment ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Crack Initiation ◽  
Residual Stresses ◽  
Pressure Vessel ◽  
Post Weld Heat Treatment ◽  
Element Analysis ◽  
Non Linear ◽  
Weld Heat

Post weld heat treatment (PWHT) is an effective way to minimize weld residual stresses in pressure vessels and piping equipment. PWHT is required for carbon steels above a Code-defined thickness threshold and other low-alloy steels to mitigate the propensity for crack initiation and ultimately, brittle fracture. Additionally, PWHT is often employed to mitigate stress corrosion cracking due to environmental conditions. Performing local PWHT following component repairs or alterations is often more practical and cost effective than heat treating an entire vessel or a large portion of the pressure boundary. In particular, spot or bulls eye configurations are often employed in industry to perform PWHT following local weld repairs to regions of the pressure boundary. Both the ASME Boiler and Pressure Vessel (B&PV) Code and the National Board Inspection Code (NBIC) permit the use of local PWHT around nozzles or other pressure boundary repairs or alterations. Additionally, Welding Research Council (WRC) Bulletin 452 [1] offers detailed guidance relating to local PWHT and compares some of the Code-based methodologies for implementing local PWHT on pressure retaining equipment. Specifically, local PWHT methodologies provided in design Codes: ASME Section VIII Division 1 [2] and Division 2 [3], ASME Section III Subsection NB [4], British Standard 5500 [5], Australian Standard 1210 [6], and repair Codes: American Petroleum Institute (API) 510 [7] and NBIC [8] are discussed and compared in this study. While spot PWHT may be appropriate in certain cases, if the soak, heating, and gradient control bands are not properly sized and positioned, it can lead to permanent vessel distortion or detrimental residual stresses that can increase the likelihood of in-service crack initiation and possible catastrophic failure due to unstable flaw propagation. It is essential to properly engineer local or spot PWHT configurations to ensure that distortion, cracking of adjacent welds, and severe residual stresses are avoided. In some cases, this may require advanced thermal-mechanical finite element analysis (FEA) to simulate the local PWHT process and to predict the ensuing residual stress state of the repaired area. This paper investigates several case studies of local PWHT configurations where advanced, three-dimensional FEA is used to simulate the thermal-mechanical response of the repaired region on a pressure vessel and to optimize the most ideal PWHT arrangement. Local plasticity and distortion are quantified using advanced non-linear elastic-plastic analysis. Commentary on the ASME and NBIC Code-specified local PWHT requirements is rendered based on the detailed non-linear FEA results, and recommended good practice for typical local PWHT configurations is provided. Advanced computational simulation techniques such as the ones employed in this investigation offer a means for analysts to ensure that local PWHT configurations implemented following equipment repairs will not lead to costly additional damage, such as distortion or cracking that can ultimately prolong equipment downtime.

Design Optimisation of a Ferritic Ring Weld Specimen Using FE Modelling

2009 ◽  
Author(s):  
Christopher M. Gill ◽  
Paul Hurrell ◽  
John Francis ◽  
Mark Turski
Keyword(s):  
Heat Treatment ◽  
Residual Stress ◽  
Finite Element ◽  
Neutron Diffraction ◽  
Stress Field ◽  
Finite Element Modelling ◽  
Post Weld Heat Treatment ◽  
Stress Fields ◽  
Element Modelling ◽  
Weld Heat

This paper describes the design optimisation of an SA508 ferritic steel ring weld specimen using FE modelling techniques. The aim was to experimentally and analytically study the effect of post weld heat treatment upon a triaxial residual stress field. Welding highly constrained geometries, such as those found in some pressure vessel joints, can lead to the formation of highly triaxial stress fields. It is thought that application of post weld heat treatments will not fully relax hydrostatic stress fields. Therefore a ferritic multi-pass ring weld specimen was designed and optimised, using 2D finite element modelling, to generate a high magnitude triaxial stress field. The specimen thickness and weld-prep geometry was optimised to produce a large hydrostatic stress field and still allow efficient use of neutron diffraction to measure the residual stress. This paper reports the development of the test specimen geometry and compares the results of welding FE analysis and neutron diffraction measurements. Welding residual stresses were experimentally determined using neutron diffraction; both before post weld heat treatment. Three dimensional moving heat source weld finite element modelling has been used to predict the residual stresses generated by the welding process used. Finite element modelling examined the effect of phase transformation upon the residual stress field produced by welding. The relaxation of welding stresses by creep during post weld heat treatment has also been modelled. Comparisons between the modelled and measured as-welded residual stress profiles are presented. This work allows discussion of the effect of post weld heat treatment of triaxial stress fields and determines if finite element modelling is capable of correctly predicting the stress relaxation.

scholarly journals The Influence of the Post-Weld Heat Treatment on the Microstructure of Inconel 625/Carbon Steel Bimetal Joint Obtained by Explosive Welding

Metals ◽  
2019 ◽  
Vol 9 (2) ◽  
pp. 246 ◽  
Author(s):  
Robert Kosturek ◽  
Marcin Wachowski ◽  
Lucjan Śnieżek ◽  
Michał Gloc
Keyword(s):  
Heat Treatment ◽  
Diffusion Zone ◽  
Explosive Welding ◽  
Stress Relief ◽  
Scanning Transmission Electron Microscope ◽  
Post Weld Heat Treatment ◽  
Inconel 625 ◽  
Scanning Transmission ◽  
Inconel 625 Alloy ◽  
Weld Heat

Inconel 625 and steel P355NH were bonded by explosive welding in this study. Explosively welded bimetal clad-plate was subjected to the two separated post-weld heat treatment processes: stress relief annealing (at 620 °C for 90 min) and normalizing (at 910 °C for 30 min). Effect of heat treatments on the microstructure of the joint has been evaluated using light and scanning electron microscopy, EDS analysis techniques, and microhardness tests, respectively. It has been stated that stress relief annealing leads to partial recrystallization of steel P355NH microstructure in the joint zone. At the same time, normalizing caused not only the recrystallization of both materials, but also the formation of a diffusion zone and precipitates in Inconel 625. The precipitates in Inconel 625 have been identified as two types of carbides: chromium-rich M23C6 and molybdenum-rich M6C. It has been reported that diffusion of alloying elements into steel P355NH takes place along grain boundaries with additional formation of voids. Scanning transmission electron microscope observation of the grain microstructure in the diffusion zone shows that this area consists of equiaxed grains (at the side of Inconel 625 alloy) and columnar grains (at the side of steel P355NH).

Effect on Hardness and Microstructures of Rail Joint with Ultra-Narrow Gap Arc Welding by Post Weld Heat Treatment

2017 ◽  
Vol 737 ◽  
pp. 90-94 ◽  
Author(s):  
Lian Gong ◽  
Liang Zhu ◽  
Hong Xiang Zhou
Keyword(s):  
Heat Treatment ◽  
Arc Welding ◽  
Weld Seam ◽  
Stress Relief ◽  
Post Weld Heat Treatment ◽  
Test Results ◽  
Narrow Gap ◽  
Narrow Gap Welding ◽  
Scanning Electron ◽  
Weld Heat

U71Mn rails were welded by ultra-narrow gap welding with constrained arc by flux strips，then normalizing treatment and stress relief annealing were performed for the joints. Another sample with no heat treatment, was studied in comparison. The effect of post weld heat treatment on the hardness and microstructure of rail joint were studied by scanning electron microscope (SEM) and microhardness test. The test results showed that normalizing treatment can improve the hardness of weld seam and base metal, and stress relief annealing couldn’t improve the hardness of joints obviously.

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