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Fatigue of Welded Pressure Vessels

CCOPPS Webinar Wednesday 21st May 2008 15:00 16:00 BST

Steve Maddox g (TWI) ) The Welding Institute (

Jim Wood y y University of Strathclyde

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Agenda
Introduction and Relevant CCOPPS Activity
Jim Wood

Fatigue of Welded Pressure Vessels

Steve Maddox

Q&A Session
Steve Maddox & Jim Wood

Closing Remarks
Jim Wood

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Industry Needs Survey

Findings relevant to this webinar:
FEA use is increasing as is complexity of models Interfacing with codes of practice seen as issue Happy with facilities in commercial codes in general (exception is weld modelling and assessment + automation of the analysis process) Non-European Codes are used often by most respondents.

P li i Preliminary report available for download from t il bl f d l df http://www.ccopps.eu/

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

Agenda
Introduction and Relevant CCOPPS Activity
Jim Wood

Fatigue of Welded Pressure Vessels

Steve Maddox

Q&A Session
Steve Maddox & Jim Wood

Closing Remarks
Jim Wood

World Centre for Materials Joining Technology

Fatigue design of welded pressure vessels

BS PD 5500 Annex C, EN 13445-3 and ASME VIII, Division 2 (new structural stress approach) Fatigue failure in pressure vessels Fatigue design data Stresses used in fatigue design Detailed fatigue assessment - use of design curves - classification of weld details - stress concentrations - fatigue life improvement Simplified assessment methods Fatigue assessment of welding imperfections Future needs

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Effect of welding on fatigue resistance

400

Stress range, MPa

300 200 100 50

R=0 Grade 50 structural steel

10 105 106 107 108

Cycles

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Fatigue cracking in a welded joint

Fatigue cracking F ti ki from weld root

X
Fatigue failure in plate at toe ( (from p pre-existing sharp flaw at X) g p )

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Key features of welds and welded joints

Sharp section changes p g - High SCF g Local discontinuities - Crack initiation sites High tensile residual stresses - Maximum mean stress effect, compressive stresses damaging Consequences: Relatively low fatigue strength, strength dominated by fatigue crack growth and controlled by full applied stress range range. Fatigue life not increased by use of higher strength material

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Fatigue failure in pressure vessels

Fatigue loading
Pressure fluctuations Temperature changes Temperature differentials External mechanical loading Vibration

Sources of stress concentration and hence fatigue cracking

Joints (welds, bolts) Geometric discontinuities (openings, nozzles, ends, ( i l d supports) Temporary attachments

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Fatigue failure from weld details

Fatigue cracking from inside of butt weld between a cylindrical shell and a flat end

Fatigue cracking from nozzle weld toe

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Fatigue design process

Compare number of repetitions (ni ) of stress range Sri which vessel or part of vessel must withstand in its service life with the number (Ni ) withstood by representative specimens at same stress in f fatigue tests, such that:

n1 n2 n3 ni + + + etc = t 1 .0 N1 N2 N3 Ni
N values obtained from relevant design S-N curves

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Basis of fatigue design data and assessment method for welded joints
BS PD 5500 and EN 13445 adapted from nominal stress-based fatigue rules for welded structures (bridges, offshore structures, etc) Thus, grid of S-N curves each applicable to one or more particular weld detail, chosen on the basis of a classification system In general, curves related to structural stress range g , g For potential fatigue failure from weld toe, structural stress range at toe (hot-spot structural stress range) may be used New ASME VIII uses only hot-spot structural stress calculated in a specific way and converted to a fracture mechanicsbased parameter called the Equivalent structural stress range parameter

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Fatigue design curves for weld details in BS PD 5500 and other UK Standards
E = 2.09 x 10 N/mm
5 2

Stress range Sr N/mm

2

Class
D E F F2 G W

Sr N = constant 7 for N > 10 cycles

Sr N = constant 7 for N < 10 cycles

10 Endurance N, cycles y

to any of metals covered by b PD 5500 on 5500, basis of relative E values For thickness e > eref, where eref =22mm, =22mm allowable stress 0.25 eref = Sr . e

Applicable

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Weld detail classification in BS PD 5500

Classification depends on: welded joint geometry direction of loading crack initiation site methods of manufacture and inspection

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Stresses used in BS PD 5500 for fatigue design

Structural (primary + secondary) stress range Principal stress (not stress intensity) used directly Nominal stress for simple details (e.g. attachments, seam welds) Nominal stress x SCF for structural details, or Hot spot Hot-spot structural stress at any weld toe (Higher design curve than those used with nominal stress) Net section of load-carrying fillet welds load carrying

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Fatigue design S-N curves for weld details in EN 13445

Class
Stress range Sr N/mm
2

Class = fatigue 2 strength in N/mm 6 at 2 x 10 cycles Sr N = constant 6 for N > 5x10 cycles
5

100 90 80 71 63 56 50 45 40 32
3

Currently applicable only to steel For thickness e > 25mm 25mm, allowable stress
25 mm = Sr . e
0.25

Sr N = constant 6 for N < 5 x 10 cycles

2x10 Endurance N cycles N,
6

5x10

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Stresses used in EN 13445 for fatigue design

Structural (primary + secondary) stress range O Option to use principal or equivalent stress range Nominal stress for simple details (e.g. attachments, seam welds) ld ) Structural stress at any weld toe (Hot-spot stress) Net section of load-carrying fillet welds

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Weld detail classification in EN 13445

Ring stiffener

0 s8 as Cl
Vessel shell Hoop stress Longitudinal stress

Class 71

EN 13445 offers choice of using equivalent stress or principal stress. Since equivalent stress has no direction, a consequence is that the lowest detail Class must be assumed. , j Thus, the joint shown would be designed as Class 71.

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Fatigue design curves from ASME VIII

1500 1000

Applicable to any of pp y
ASME 'Master' fatigue design curves

Sess MPa/mm

-0.222

500 400 300 200

Mean - 2 SD

Mean - 3SD M (normal design curve)

100

50 10
3

10

10

10

10

10

metals covered by ASME on basis of relative E values Stress parameter depends on plate thickness, membrane/bending stress ratio and applied stress ratio (Not units of stress) No other thickness correction required

Endurance, cycles

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Basis of fatigue design curves

Regression analysis of S N data obtained from tests S-N on actual welded joints 2 5% probability of failure (mean 2 standard 2.5% deviations of log N [SD]):BS PD 5500 design curves; included in ASME ASME. 0.1% probability curves (mean - 3SD):BS PD 5500 simplified design methods; all EN 13445 design curves for weld details; generally required for ASME S

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Application of design curves for weld details

No effect of applied mean stress in PD 5500 and EN 13445; mean stress correction in ASME No effect of material tensile strength No effect of welding process May need to be reduced to allow for corrosive environment; no specific guidance in BS PD 5500 or EN 13445 but penalty factors specified in ASME

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Stresses used in ASME VIII Div. 2 for fatigue design of welded joints
Structural (primary + secondary) stress range based on through-thickness stress distribution obtained by numerical analysis y Structural equivalent stress range parameter (a function of materials fatigue crack propagation properties (m=3.6), applied structural stress range () material thickness (t) (), (t), membrane to bending stress ratio and applied stress ratio):

Sess =

t ess .I .fM
2 m 2m 1 m

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Generalized stress parameter (Maddox, 1974)

da / dN = C( K ) m , K = Y a , Y = f ( a / t & crack front shape a / 2 c )
af

ai

d ( at ) (Y
a ) m
t

= I = C
1

m ( m 1 ) 2

( m 1 ) t 2 i .e I or where or

( )

. N = 1 = cons tan t C
1 m

* m

.N = a cons tan t ,
m

t ' Generalize d stress p parameter ' = I

*

2 1

* =

t
2 m 2m

.I

1 m

( cf M ASME Sess )

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ASME Equivalent structural g p stress range parameter Sess

Based on: Structural stress (presumably assumed to allow for SCF factor Mk normally applied to stress intensity factor) ) Fatigue life mainly growth of a pre-existing crack p p Implicit assumptions made about initial flaw size and shape p g growth rate relationship p Specific fatigue crack g

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Hot-spot structural stress approach

Fatigue Hot spot Hot-spot crack k Hot-spot stress = structural stress at weld toe. It includes all stress concentrating effects except the local notch effect of the weld toe toe.

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Hot-spot structural stress from through-thickness stress distribution

Actual stress Structural stress

hot-spot

(y)

x(y)

m m b

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Methods for calculating the hot-spot structural stress

Using surface stresses (e.g. measured): Surface stress extrapolation (SSE) Using through-thickness stress distribution (e.g. from numerical analysis): - Through-thickness integration (TTI) - Nodal forces (NF) method

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Hot-spot stress developments in British Standards

Current TWI joint-industry project aims to produce guidance on hot-spot structural str ct ral stress approach for incl sion in British Standard fatig e inclusion fatigue design rules (initially BS 7608) Comparison of the three methods of calculating hot-spot stress (SSE, TTI and NF) from FEA Solid and shell elements, examination of sensitivity to mesh size Case studies on range of structural components All methods mesh sensitive but mesh sensitivity least for simple welded joints in plates under unidirectional loading Findings so far indicate that nodal force method most mesh sensitive of the three when applied to structural component Mesh insensitivity of the ASME method may be for a restricted set of possible mesh types and weld meshing options.

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Fatigue data expressed in terms of hotspot stress range (SSE method)

500 400 300

Hot-spot stress range at weld toe

200

N/mm

Class E Cl
100 90

Pressure vessels - nozzles Plate welded components 95% confidence i t fid intervals l enclosing data

60

10

10

10

10

3x10

Endurance, cycles

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Comparison with mean 2SD S-N curves derived from ASME VIII
500

Hot-spot stress range at weld toe N/mm

2

400 300

Pressure vessel data Structural specimen or component data Mean 2SD

200

BS PD 5500 Class E Cl
100 90

ASME VIII, Div.2 R 0, t 16mm lower: all membrane upper: all bending

60 10
4

10

10

10

3x10

Endurance, Endurance cycles

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Comparison with mean 3SD S-N curves derived from ASME VIII
500 400 300

Hot-spot stress range at weld toe N/mm

2

Pressure vessel data Structural specimen or component data Mean 3SD

200

EN 13445 Class 71 Class 63

100 90

ASME VIII, Div.2 R 0, t 16mm lower: all membrane upper: all bending
10
4

60 10
5

10

10

3x10

Endurance, Endurance cycles

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Misalignment as a source of stress concentration

Bending stresses due to misalignment Same guidance on calculation of SCF is given in PD5500 and EN 13445

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Treatment of weld details subject to g combined or multi-axial loading

L = Maximum change in L
L H 45

H = Maximum change in H 45 = Maximum change in H45 Principal stresses then calculated from L, H, and 45

Same approach in PD5500 and EN 13445. Current research should provide better method for out-of-phase loading.

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ASME t t treatment of weld details subject t f ld d t il bj t to multi-axial loading

Sess
1 = 2 m 1 F ( ) t 2 m .I m .f M ess + 3 m 1 22m m t ess .I
2

0 .5

Where: For in-phase l di ( i i l stress di ti F i h loading (principal t directions remain constant i t t throughout loading cycle), F() = 1 while For out-of-phase loading (principal stress directions change during loading cycle), F() = function of applied normal and shear stresses and out-of-phase angle, or conservative value of 1/2

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Elastic-plastic (E-P) conditions

BS PD 5500 & EN 13445:
Stress range

For stress ranges > twice yield: E-P strain obtained directly from analysis and converted to stress or Stresses from design S-N curves reduced by factor that depends on load source (mechanical or thermal) and stress range / yield. ASME VIII, Div. 2: For every case:

Corrected for plasticity

Design S-N curve

10

10

10

10

10

10

Endurance N, cycles

E-P strain obtained directly from analysis (Neubers rule & materials cyclic stress-strain properties) and converted to stress range stress strain

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Fatigue life improvement methods

BS PD 5500 and EN 13445 allow weld toe grinding and corresponding i i di d di increase i d i in design classification ASME VIII accepts weld toe grinding, TIG dressing or hammer peening. Equivalent structural stress parameter design curves increased accordingly with greatest benefit in accordingly, high-cycle regime

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Assessment of welding flaws

Guidance given in BS PD 5500 and EN 13445 on flaw assessment based on fitness-for-purpose: Reference to BS 7910 Specific recommendations on: 1. Planar flaws not acceptable 2. Buried flaws - inclusions, porosity; ,p y; 3. Deviations from design shape misalignment, peaking, ovality. ASME seems to accept planar flaws since equivalent structural stress parameter can be calculated for cracks up to 10% of section thickness

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Fatigue design of pressure vessels future needs

Parametric hot-spot SCFs for pressure vessel details Elastic-plastic fatigue Effect of environment (corrosive, elevated temperature, hydrogen) Closer link between design and fabrication quality Experimental methods for design (draft for EN 13445 now available)

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Thank you for your attention

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Agenda
Introduction and Relevant CCOPPS Activity
Jim Wood

Fatigue of Welded Pressure Vessels

Steve Maddox

Q&A Session
Steve Maddox & Jim Wood

Closing Remarks
Jim Wood

World Centre for Materials Joining Technology

Agenda
Introduction and Relevant CCOPPS Activity
Jim Wood

Fatigue of Welded Pressure Vessels

Steve Maddox

Q&A Session
Steve Maddox & Jim Wood

Closing Remarks
Jim Wood