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c,*
NDE Centre, Department of Mechanical Engineering, University College London, Torrington Place, London, WC1E 7JE, UK
b
Technical Software Consultants Ltd, 6 Mill Square, Featherstone Road, Wolverton Mill, Milton Keynes, MK12 1RB, UK
Materials Division, Australian Nuclear Science and Technology Organisation, Private Mail Bag 1, Menai, NSW 2234, Australia
Received 10 March 1999; received in revised form 5 July 1999; accepted 5 July 1999
Abstract
This paper describes the generation of parametric equations for weld toe stress intensity factors. The methodology employed
used a two-dimensional finite element analysis to evaluate the crack opening stress distribution in the uncracked plane of T-butt
geometries. This was then used as input into a dedicated weight function solution for the determination of stress intensity factors.
The final parametric equations describe the stress intensity factor distributions for tension and bending as a function of plate
thickness, weld attachment width, weld angle, weld root radius, crack length and crack shape. The equations are compared and
validated against a wide spectrum of published values and appear by comparison accurate and wide ranging. The validation exercise
uncovered situations where present design guidance is unconservative. 1999 Elsevier Science Ltd. All rights reserved.
Keywords: T-butt; Weld toe; Crack; Stress intensity factor; Weight function; Parametric equation; Fatigue life; Engineering design
1. Introduction
A set of parametric equations for the calculation of
stress intensity factors (SIFs) known as Yw parametric
equations for cracks at weld toes have been produced,
based on the NiuGlinka weight function method [1].
These new equations are available for both membrane
and bending loadings and include the influence of crack
size and shape, weld toe radius, weld attachment width
and weld angle. A previous study [2] showed that the
NiuGlinka weight function [1] could be successfully
used to produce accurate stress intensity factors for surface cracks emanating from weldments. That study,
however, did not take into account the attachment size,
and the equations are valid for limited ranges of geometric parameters. Another set of equations for the weld
correction factor, known as the MK factors [3] are also
available for the calculation of SIF for cracks at weld
toes. The equations for MK factors, however, do not consider the effect of weld angle or weld toe radius but do
include the effect of attachment size. MK factors are
2. Parametric equations
The general expression for the stress intensity factor,
K, is as follows:
KYs pa
* Corresponding author. Tel: +61-(0)2-9717-3482; fax: +61-(0)29543-7179.
E-mail address: akh@ansto.gov.au (A.K. Hellier)
(1)
0142-1123/99/$ - see front matter. 1999 Elsevier Science Ltd. All rights reserved.
PII: S 0 1 4 2 - 1 1 2 3 ( 9 9 ) 0 0 0 9 0 - 0
1052
Nomenclature
a
a/c
c
FE
K
L
MK
SCF
SIF
t
T
W
Y
Yb
Yt
Yw
a
r
s
snom
sx
Crack depth
Crack aspect ratio
Half surface crack length
Finite element
Stress intensity factor
Overall width of the welded attachment
Weld correction factor
Stress concentration factor
Stress intensity factor
Attachment thickness
Plate thickness
Plate width
Stress intensity calibration factor
Stress intensity calibration factor in bending
Stress intensity calibration factor in tension
Stress intensity calibration factor based on weight function method
Weld angle (degrees or radians)
Weld toe radius
Nominal stress
Nominal stress
Stress at depth x in plate
Fig. 1. (a) Local weld geometry studied (b) Geometry and loading
used to derive stress intensity factors (c) Crack geometry (semi-elliptical crack).
4. Stress analysis
The stress distribution in the uncracked plane for a
range of T-butt geometries was determined using twodimensional finite element analysis. The entire analysis
was carried out using the ideas [5] package. A twodimensional idealisation was considered adequate as the
NiuGlinka weight function solution is primarily for an
edge crack and corrected for a plane stress three-dimensional weldment. Eighty-six geometries varying weld
angle, weld toe radius, weld attachment size and plate
thickness were considered. Eight-noded shell elements
were used in the mesh definition, an example of which
is shown in Figs. 2 and 3. Fig. 2 shows the weldment
Fig. 2.
Fig. 3.
1053
1054
Fig. 4.
1055
5.2. Bending
The procedure used to derive the parametric equation
for Yb was very similar to that already described for the
tension case. The existing parametric equation for bending due to Hall, Topp and Dover was again found to be
a reasonable starting point for producing new equations.
The Yb values from Ref. [2] tend to be low, frequently
less than 1, and go negative just before a/T reaches 1.
This leads to a considerable number of very large positive and negative percentage errors, although the FE
results and predicted values may actually lie quite close
together in absolute terms. For this reason, and because
Yb values are most likely to be used for a/T0.5, the
histogram of percentage errors used to develop the equation was compiled from this region only. It was apparent that the existing equation systematically overpredicted over most of this region, with the largest
overpredictions occurring for very low a/T (although
even in this region there were also some large
underpredictions).
The same approach used for the tension case, of
adding functional forms involving products of the input
parameters to various powers, was applied to the bending equation. In this case, all of the input parameters
were utilised in each corrective function, in order to gain
the maximum possible improvement in accuracy. A
negative corrective function C3 was first added for
a/T0.25, and its parameters optimised. Secondly, a
function C4 was superimposed upon this where
a/T0.05, which was negative for L/T0.455 and positive for L/T0.455. Thirdly, another negative function
C5 was incorporated where a/T exceeded 0.35. Lastly, a
multiplicative factor of just less than unity was applied
to the natural logarithm component of the original equation, in order to remove the systematic overprediction
which was still apparent from the histogram of percentage errors. All of the coefficients obtained by regression
were then tweaked to optimise the overall accuracy of
the final parametric equation, which is given in the following section. The largest underprediction was by
19.3% and the largest overprediction by +55.8%. A
histogram plot of percentage errors is shown in Fig. 5
(for a/T0.5), from which it is apparent that the equation
fits the data well.
6. Parametric equations for stress intensity factors
Fig. 5.
0.5
a
c
P0.3650.207
a
c
C00.9631.102
a
Mp
c
0.144
0.5
1.430
a
M0
c
C13.0846.542
a
c
0.5
a
a
M1 0.156
c
c
C12.9133.245
a
c
0.5
a
a
M1 0.156
c
c
C122.62710.767
9.023
a
c
C120.06250.557
1.761
0.5
a
c
9.553
a
c
0.5
0.156
a
0.2
c
a
c
a
0.2
c
6.1. Tension
The parametric equation for tension is:
Yt1.03
a P
a
a
exp C0C1
C2
T
T
T
C3C4
(2)
C30.45 0.2
a
T
0.409
1.1
a
c
0.3
L
T
0.549
1.0
1056
a
T
0.15
0.2
exp
a
0.2
T
a
0.2
T
C30
a
C42.5 0.03
T
1.1
a
c
0.7
r
T
a1.5
0.03
a
T
0.285
L
T
29.768
0.5
a
c
C21.6480.926
0.5
a
a
M1 0.1
c
c
a
a
M1 0.1
c
c
2.876
a
c
C28.75841.156
1.28
22.264
0.5
a
c
a
a
M0 0.1
c
c
0.648
0.5
a
c
C12.66422.408
C13.8606.128
0.5
a
c
C00.6451.111
a
a
M2 0.1
c
c
0.00393
a
a
M2 0.1
c
c
0.394
1.0 exp
MA=0.5970.649 a0.0028 (T/r)
M0=1.2821.325 a0.0077 (T/r)
M1=2.222+2.154 a+0.0170 (T/r)
M2=0.7890.621 a0.0097 (T/r)
a
0.03
T
S4
0.5
a
T
C30.25 0.25
1.1
where S4=0.006
r
L
but S4=0.018 if a0.6109 and 0.035 and 0.35
T
T
C40
a
0.03
T
a
c
0.16
r
T
a2.0
0.16
0.37
L
T
1.0 exp
NOTE: a is in radians.
6.2. Bending
a
T
0.15
0.25
a
a
a 2
Yb0.96A ln
C0C1
C2
C3C4
T
T
T
C5
a
0.25
T
C30
A0.3880.958
a
c
0.5
a
c
0.5
A0.6860.310
C00.5444.125
(3)
a
c
0.5
a
MA
c
1.111
0.0622
4.018
C44.0 0.05
a
0.1
c
a
a
MA 0.1
c
c
a
a
M0 0.1
c
c
a
0.25
T
a
T
0.565
1.1
a
c
0.3
a1.35
r
T
0.3
0.455
L
T
0.204
1.0 exp
0.05
a
T
1057
L
a
0.05 and 0.455
T
T
S4
where S4=0.05
L
r
but S4=0.06 if a0.6109 and 0.04 and 0.35
T
T
C40.5 0.05
0.455
1.1
a
T
1.1
0.0384
a
c
0.486
a2.66
r
T
0.11
L
T
a
T
0.015
0.05
1.0 exp
a
L
0.05 and 0.455
T
T
a
0.05
T
C40
C50.14
a
c
a
0.35
T
a0.675
C50
a
0.35
T
0.2
1.1
0.862
0.098
r
T
0.077
L
T
0.148
1.0 exp
published data for validation purposes. Although relevant available data are sparse, sufficient cases were
compared with the SIF parametric equations to establish
confidence in their behaviour.
The equations were firstly compared with the NewmanRaju flat plate SIF solutions [4] for surface cracks.
These are shown in Figs. 6 and 7 for tension and bending
cases respectively. These show the decaying effect of
the weldment as a/T increases from zero. As expected
there is some influence of the weldment through to the
end; however, behaviour of the SIF parametric equations
is consistent with an anticipated variation based on NewmanRaju.
a
0.35
T
a
0.35
T
NOTE: a is in radians.
1058
values are low for a/T values below 0.1, whereas for the
parametric equations the predictions are low above a/T
values equal to 0.1.
In tension, PD6493 [3] is conservative; Bells data
correlates well with the SIF parametric equation. In
bending (Fig. 11), PD6493 again shows unconservatism
relative to both Bells data and the SIF parametric equation in the critical near surface region for a/T values
0.05. Bells data is for r/T=0 and is compared with
the parameter r/T=0.01 limit when calculating the SIF
parametric equation curves.
Figs. 12 and 13 show the parametric equation and
another set of Bells data [7] in tension and bending
respectively. Again Bells data shows Y marginally
higher than the SIF parametric equations, reflecting the
different values of r/T. The only significant mismatch
1059
1060
8. Limits of validity
The derived equations have been produced using the
NiuGlinka weight function equations. This solution
requires input of the through-thickness stress distribution
on the uncracked body and these values have been calculated using 2-D finite element methods. The NiuGlinka
routine from FACTS [9] which was used has been extensively verified and validated. The geometries investigated were T-butt welded joints with the attachment
unloaded, as shown in Fig. 1. The data has been pro-
1061
0.01a/T1.0
0a/c1.0
30a60
0.01r/T0.066
0.3L/T4.0
Full details concerning the development of these equations are contained in Ref. [10].
9. Conclusions
SIF parametric equations have been developed for surface cracks emanating from the weld toe of T-butt
welded joints. These are more comprehensive than any
other similar study to date as parameters included are
weld angle, weld root radius, weld attachment length,
parent plate thickness and crack aspect ratio. Validity
ranges cover realistic engineering values.
The equations, predictions of which were compared
to published data, are consistent, stable and accurate over
the validity ranges.
1062
Acknowledgements
The authors are grateful to the Marine Technology
Support Unit of the Health and Safety Executive, UK
for sponsoring this work.
References
[1] Niu X, Glinka G. Theoretical and experimental analyses of surface fatigue cracks in weldments. In: Proceedings The Symposium on Surface Crack Growth: Model, Experiments and
Structures, ASTM, Reno (Nevada, USA), 25 April 1988.
[2] Hall MS, Topp DA, Dover WD. Parametric equations for stress
intensity factors. Technical Software Consultants Report No.
TSC/MSH/0244 for Dept. of Energy, UK, March 1990.
[3] BS PD6493 Guidance on methods for assessing the acceptability
of flaws in fusion welded structures, appendix E: stress intensity
factor solutions for cracks in welded joints. British Standards
Institution, 1991.