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INTRODUCTION
In fields such as nuclear power, chemical engineering, boilermaking
and shipbuilding, flaws are often found in pressurized components
during in-service inspection. Thus, a particular question related to the
flaw is whether anything must be done about it immediately or whether
197
Int. J. Pres. Ves. & Piping (26) (1986)-- Elsevier Applied Science Publishers Ltd,
England, 1986. Printed in Great Britain
198
199
Yield Ultimate
strength strength
(MPa) (MPa)
1Crl8Ni9Ti
224.3
658.2
SUS321TP
207.7
618.6
No. of
models
Through-wall
Surface
Through-wall
Surface
5
2
3
2
[~
(deg)
ti
(mm)
Ri
(ram)
S
(mm 2)
exp
Croi
(MPa)
cal
~ro~
(MPa)
cs8-01
cs8~)2
cs8-O3
cs8~)4
cs8~)5
cs8q)6
cs8~)7
cs8~)8
cs8~9 ~
cs8-10 ~
cs8-11 a
cs8-12"
15'00
47-00
0"00
42"00
62.00
42"50
51.00
30"00
30.00
47.50
50"00
41'00
6"35
6" 10
6"60
6"25
6.20
7"60
7.50
8"15
6.50
6"00
7"60
7"85
36"83
36.95
36'70
36.88
36"90
75.70
75.75
75.18
36.75
37.00
75.45
75.33
209.3
233. I
224"4
404.0
342"5
561 "7
676.4
838.0
162.0
126.6
441-7
399.6
312.8
356'4
261 "7
231.4
315'2
273.5
262.5
171.9
443.6
538.2
350.5
320.0
283.3
383"7
261-1
235'3
357" 1
288.6
268.0
188.0
415.7
581.7
389"5
381'0
200
In order to prepare the sharpness of the flaw tips, both for the
through-wall flaw and at the front for the surface flaw, so that they
were more similar to the practical cases produced in components under
operational conditions, models 04, 05, 11 and 12 were not subjected to
low-cycle fatigue cycles until the onset of their initial flaws.
A leak-proof device made of 0"2mm thick stainless steel plate and
3 mm thick rubber was used to cover the internal surface of the model
at the position of the through-wall flaw, so as to prevent leakage of the
liquid pressurization medium from the model with an oblique throughwall flaw under experimental conditions.
The experiments on all the pressure vessel models were carried out
with the High Pressure Cycle-Fatigue Device, shown in Fig. 1. The
device did not pump machine oil into those filled with water until failure.
One of the models after test is shown in Fig. 2.
After the completion of the bursting experiment on all models, the
tested objects were photographed, and the deformations of the models
201
TABLE 3
((mm)
fl(O (ram)
f2(~) (mm)
13.80
14.30
14-80
15-30
15.80
16.34
21.00
26.00
31.00
36.00
41.00
46-00
49.38
50.13
50.33
50.53
50.72
14.34
14.84
15.16
15.45
15.77
15.98
17.41
17.84
18.18
18.48
18.75
18.86
18.68
18.59
18.55
18.45
18.57
14.34
13.27
12.05
10.43
9.73
9.12
10.53
11.07
11-48
! 1.74
11.99
12.09
12.27
12.34
16.87
17.67
18-37
and the sizes of the fractured areas were measured. The fracture area
was machined out from the failure region at which the artificial flaw
was located, and the surface dimensions of the flaw were measured with
a tooling microscope; an example of such measured results is shown in
Table 3. Finally, the flaw was studied under the Scanning Electron
Microscope.
The results o f fractography showed that fracture consisted mainly of
the following three parts (see Fig. 3): (a) fatigue-streak, (b) a dimple
structure, and (c) a quasi-cleavage structure. The fatigue-streak proves
that the fatigue parts of both tips for oblique through-wall flaws and
b
Fig. 3.
Enlargements from fracture surface (original magnification x 4000): (a) fatiguestreak; (b) dimple structure; (c) quasi-cleavage structure.
202
of the flaw fronts for oblique surface flaws were produced before the
bursting of the model. The dimple structure shows that stable crack
growth set in more or less before failure. Lastly, the quasi-cleavage
structure is typical of unstable crack growth.
In order to obtain the engineering strength indices of the materials
in the form of tubes, a standard tension specimen with cross-section in
the form of a circular arc was prepared according to the relevant Chinese
standard, as Fig. 4 shows. Six specimen pieces of 1Crl8Ni9Ti and six
Fig. 4.
203
(1)
[f,(() - f2(()] d(
(2)
The functions fl(~) and f2(~) express respectively the upper and lower
boundary lines of an initially cracked plane, that is, a cracked plane
before the onset of the stable crack growth under bursting conditions.
These are shown in Fig. 5.
Based on differential-integral calculus, the right-hand side of eqn (2)
can be approximated by the trapezium expression. Hence, it can be
converted as follows:
o)-~k
ap, = S/t, = 2nt, {[f,((o) -f2((o)] + 2[f,(,) -f2((,)]
+ " " + [f,((.- ,) - f 2 ( . - ,)] + [1]((.) -f2((.)]}
where S is initial flaw area.
(3)
204
(4)
When fli = 90, eqn (1) takes its simplest form and can be applied to a
circumferentially cracked component under internal pressure in the
range of values of aZojRit~ from 6 to 16.
If internal pressure P~ and external bending m o m e n t Mx~ are applied
to component i with a circumferential flaw, another equation can give
a satisfactory outcome, as follows:
~(1 + l'636aZoJRit~)235ao~
(5)
205
,,
....
experiments
a ~ i I Ri t i : 0.501
0.550
1.161
1'619
,,
....
"
1.473
1,193
',
a~i I R i t i =1.095
3.334
2. 373
3' 579
4.314
~.532
60(
500
m
a.
300
301
'
2.373
3.5:,9
4"314
,
0
30
~i
60
(degree)
Fig. 6.
90
30
l
60
~i (degree)
I
90
u, ~,.~L, v-=,,,= V w e l d i n g
Fig. 8.
Simulated cylinder.
206
Material
Weld seam
Base
Si
0.14
0.21
0.28
0
Mn
Mo
Nb
TABLE 5
Mechanical Properties of 18MnMoNb Vessels Investigated in Ref. 6
a yj
(MPa)
~roj
(MPa)
601.5
719.1
640.7
738.7
642.3
449.5
760.0
598.2
428.3
616.2
207
600
-~ 4 0 0
&
:E
e&
,-:
200
200
Fig. 9.
400
0'exp (MPa)
ei
600
weld seam; Q, Q-T electroslag weld seam; A , normalized base material; /k, Q-T base
material.
800
oo I
b
400,-
0
A,
a
0
A
200
Fig. 10.
~oo
R.W. Derby 7
R.H. Bryan et al. 8
H. L a r s s o n et al. 9
R.J. E i b e r et al. 10
.,oo
o';';"
600
(.Pa)
800
208
TABLE 6
Tested and Predicted Results for 18MnMoNb Vessels
Investigated in Ref. 6
Model
no.
C401 a
C402 a
C403 a
C404
C708 a
CM3 b
T508 c
T509 c
T510 c
T512 c
TI01 c
TM3 d
a Flaw
h Flaw
c Flaw
seam.
d Flaw
fli
(deg)
aai
Ri
ti
aex"
a'al
(ram) (rnrn) (mm) (MPa) (MPa)
90.0
75.0
61.7
45.0
0.0
0.0
75-0
60-5
45.0
30.0
0.0
0.0
40.60
31.00
21.80
14.50
9.50
10.00
33.00
33.00
22.60
17.00
13.75
13.50
41.40
41.30
41.50
41.33
41.44
41-34
41.38
41.41
41.32
41.42
41.45
41.34
3.60
3.50
3.43
3,54
3.53
3.62
3.65
3.55
3.48
3.60
3.50
3.52
501.9
468.7
460.3
467.1
435.1
475.9
578.1
494.2
468.1
445.7
456.4
458.4
522.1
424.1
426.5
427.4
336.6
324.6
561.7
455-3
437-4
408.5
339.6
361.6
TABLE 7
Material Properties a n d External Load for Pipes Investigated in Ref. 21
Tesl
ayj
auj
P
(Nmm -2) (Nmm -2) (Nmm -2)
15
16
310
310
633
633
17'2
7'23
Mxi
(Nmm)
13"8 10 6
9'4 10 6
TABLE 8
Predicted Results for Pipes Investigated in Ref. 21
Test
15
16
Ri
(mm)
li
(ram)
Oi
Pical
MxC~l
(deg)
(Nmm- 2)
(Nmm)
53.4
53.4
8.56
8'56
38"0
67.5
17.20
7-23
15.5 10 6
7-8 10 6
209
(6)
a o = %j + ~ a u j - tTyj)tTuj/ay j
(7)
when
when
when
when
when
fli = 0, O'O06<a~i/Riti<36;
0 < f l i _< 3 0 , 0-06< a~i/Rit i < 26;
30 < fli-< 45, 0-6 < a~i/Rit i < 20;
2
45 < f l i < 9 0 o, 2<a~i/Riti<
16;
fli = 90, 6<-a~i/Riti< 16.
210
CONCLUSIONS
A new general approach has been theoretically derived and its predictions
have been compared with various experiments. The important conclusions emerging from the preceding section are as follows:
(1) The validity of the new general approach has been verified by
the experiments. Its accuracy proved to be very good.
(2) The specific form of this approach, i.e. the use of eqn (4)
for calculating the failure load of a longitudinally cracked
component, has been confirmed by many experiments, including
not only models but also prototypes carried out in China and
other countries.
(3) The application of the approach covers an extensive range of
importance in engineering practice.
(4) Another equation, i.e. eqn (5), has also been supported by some
experiments.
A C K N O W L E D G E M ENTS
The authors wish to thank the Heads of the PWR Research Institute
and its Department of Applied Mechanics for their permission to allow
the publication of the present paper. They also thank Mr Zhang Yong
for typing it.
REFERENCES
1. Ye Gang Da, Assessments of the safety and the life of oxygen or hydrogen
storage vessel with a defect, J. New Metal Material (China), No. 11-12,
1975,
2. Sun Xun Fang, Fracture mechanics analysis of cracked pressure vessel,
Experimental Mechanics (Sichuan, China), 1980.
3. Duffy, A. R., Studies of hydrostatic test levels and defect behavior,
Symposium on Line Pipe Research, American Gas Association, New York.
1965.
4. Hahn, G. T. et al., Criteria for crack extension in cylindrical pressure
vessels, Int. J. Fract. Mech., 5(3) September (1969).
5. Folias, E. S., On the prediction of failure in pressurized vessel, Proc. 1st
Int. Con[i on Pressure Vessel Technology, Delft, The Netherlands, 29
September- 2 October 1969.
211