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21st European Conference on Fracture, ECF21, 20-24 June 2016, Catania, Italy
21st European Conference on Fracture, ECF21, 20-24 June 2016, Catania, Italy

Elastic-plastic behaviour of welded joints during loading and

Elastic-plastic behaviour of welded joints during loading and
XV Portuguese Conference
on Fracture, PCF
2016, 10-12vessels
February 2016, Pao de Arcos, Portugal
unloading
of pressure
unloading of pressure vessels
b
c
a
a
Simon Sedmakaa, Mahdi Algool
Sedmak
Dzindoof
Thermo-mechanical
modeling
of
a
high
pressure
turbine
blade
b, Aleksandar
c, Uros Tatic
a, Emina
Simon Sedmak , Mahdi Algool , Aleksandar Sedmak , Uros Tatic , Emina Dzindoa an
Innovation Centre
of Faculty of Mechanical
Engineering, engine
11000 Belgrade, Serbia
airplane
gas
turbine
Innovation Centre of Faculty
of Mechanical
University
of Sirte,Engineering,
Sirte, Libya 11000 Belgrade, Serbia
a
a

UniversityUniversity
of Sirte, Sirte,
Libya 11000 Belgrade, Serbia
Faculty of Mechanical Engineering,
of Belgrade,
a
b
c
c
Faculty of Mechanical Engineering,
University of Belgrade,
11000 Belgrade,
Serbia
c

P. Brando , V. Infante , A.M. Deus *

Department of Mechanical Engineering, Instituto Superior Tcnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa,
Portugal
IDMEC, Department of Mechanical Engineering, Instituto Superior Tcnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa,
Abstract
Portugal
Abstract
c
CeFEMA, Department of Mechanical Engineering, Instituto Superior Tcnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa,
In this paper elastic-plastic behaviour of welded joints during loading
Portugal and unloading of pressure vessel has been analysed. Two
b

In
thispressuring
paper elastic-plastic
of welded
jointsexperimental
during loading
and unloading
of pressureusing
vessel
beenelement
analysed.
Two
stage
process hasbehaviour
been applied
in previous
investigation
and simulated
thehas
finite
method.
stageeffect
pressuring
process
hasand
been
applied
in previous
experimental investigation and simulated using the finite element method.
The
of residual
stress
strain
has been
analysed.
The
effect of residual stress and strain has been analysed.
Abstract
2016 The Authors. Published by Elsevier B.V.

2016,
(Procedia
StructuralbyIntegrity)
Hosting
by Elsevier Ltd. All rights reserved.

2016 PROSTR
Thetheir
Authors.
Published
Elsevier
B.V.
During
operation,
modern
aircraft
engine
components are subjected to increasingly demanding operating conditions,
Peer-review
under
responsibility
the
Scientific
Committee
Peer-review
under
responsibility
of theof
Scientific
Committee
of ECF21.of ECF21.
Peer-review
responsibility
of the(HPT)
Scientific
Committee
of ECF21.
especially under
the high
pressure turbine
blades.
Such conditions
cause these parts to undergo different types of time-dependent
degradation, one of behaviour;
which is creep.
model
using vessel;
the finite
element
method (FEM)
was integrity
developed, in order to be able to predict
Keywords:elastic-plastic
weldedAjoints;
pressure
static
loading-unloading;
structural
Keywords:elastic-plastic
joints;
pressure
static
loading-unloading;
structural
integrity
the creep behaviourbehaviour;
of HPTwelded
blades.
Flight
data vessel;
records
(FDR)
for a specific
aircraft,
provided by a commercial aviation
company, were used to obtain thermal and mechanical data for three different flight cycles. In order to create the 3D model
for the FEM analysis, a HPT blade scrap was scanned, and its chemical composition and material properties were
1. needed
Introduction
The data that was gathered was fed into the FEM model and different simulations were run, first with a simplified 3D
1. obtained.
Introduction
rectangular block shape, in order to better establish the model, and then with the real 3D mesh obtained from the blade scrap. The
The penstock
during
the late
seventies inwas
theobserved,
scope ofinreversible
power
plant
Bajina
(HPP
overall
expected built
behaviour
in terms
of displacement
particular athydro
the trailing
edge
of the
blade. Basta
Therefore
such a
The
penstock
built
during
the
late
seventies
in
the
scope
of
reversible
hydro
power
plant
Bajina
Basta
(HPP
BB)
required
innovative
design
and
extensive
experimental
research
to
verify
its
structural
integrity,
[Sedmak
et al.
model can be useful in the goal of predicting turbine blade life, given a set of FDR data.

BB)
required innovative design and extensive experimental research to verify its structural integrity, [Sedmak et al.
(2011)].
(2011)].
To
2016
Theimportant
Authors. Published
Elsevierwas
B.V.the decision to produce one penstock instead of two, as would be remost
aspect ofbydesign
To most
important
aspect
ofofdesign
wasused.
the
decision
produce
penstock
instead
two, as steel
wouldofbe
rePeer-review
under
responsibility
the been
Scientific
Committee
PCF
2016. onethe
quired
if a mild
structural
steel
had
For onlyoftoone
penstock
application
of of
structural
yield
quired
if
a
mild
structural
steel
had
been
used.
For
only
one
penstock
the
application
of
structural
steel
of
yield
strength level 700 MPa was inevitable. This requirement was satisfied by HT80, weldable, quenched and tempered,
Keywords: High
Pressure
Blade; Creep;This
Finite Element Method;
Model; Simulation.
strength
MPaTurbine
was
inevitable.
was3Dsatisfied
HT80,
quenched
and tempered,
low alloylevel
high700
strength
(HSLA)
steel, withrequirement
ultimate tensile
strength by
above
800weldable,
MPa. Anyhow,
selection
of this
low
alloy
high
strength
(HSLA)
steel,
with
ultimate
tensile
strength
above
800
MPa.
Anyhow,
selection
of this
HSLA steel opened a new problem. Namely, the plate thickness in the penstock most stressed part was calculated
to
HSLA
steel
opened
a
new
problem.
Namely,
the
plate
thickness
in
the
penstock
most
stressed
part
was
calculated
be slightly above 47 mm, which was the upper limit in plate fabrication, [Sedmak and Sedmak (1995), Sedmak to
et
be
47 mm,
was the
upper limit
in plate
fabrication,
[Sedmak
and to
Sedmak
et
al. slightly
(2011)] above
Therefore,
twowhich
full scale
prototypes
of this
penstock
were made
in order
gather (1995),
the dataSedmak
about its
al.
(2011)]
Therefore,
two
full
scale
prototypes
of
this
penstock
were
made
in
order
to
gather
the
data
about
its
integrity, one tested in the static loading-unloading sequence, and the other one impact loading (explosion). The
integrity, one tested in the static loading-unloading sequence, and the other one impact loading (explosion). The

2452-3216 2016 The Authors. Published by Elsevier B.V.

2452-3216 2016
The
Authors. Published
Elsevier B.V.
Peer-review
under
responsibility
of thebyScientific
Committee of ECF21.
* Corresponding
Tel.: +351of218419991.
Peer-review
underauthor.
responsibility
the Scientific Committee of ECF21.

E-mail address: amd@tecnico.ulisboa.pt

2452-3216 2016 The Authors. Published by Elsevier B.V.

Peer-review under responsibility of the Scientific Committee of PCF 2016.

2452-3216 2016, PROSTR (Procedia Structural Integrity) Hosting by Elsevier Ltd. All rights reserved.
Peer-review under responsibility of the Scientific Committee of ECF21.
10.1016/j.prostr.2016.06.442

Simon Sedmak et al. / Procedia Structural Integrity 2 (2016) 35463553

Author name / StructuralIntegrity Procedia 00 (2016) 000000

3547

overall behavior of a welded penstock under load was analyzed based on this approach, allowing an evaluation of
crack significance and "fitness-for-purpose" assessment.
In this paper elastic-plastic behaviour of welded joints during loading and unloading of pressure vessel has been
analysed by using the Finite Element Method (FEM) to simulate experimental results, briefly presented as well,
whereas more details are given in [Tati et al.].
2. Pressure vessel full-scale model
The most important data for the full-scale model of the penstock are given. The welded joints, longitudinal (L)
and circular (C), as shown in Fig. 1, were produced by shielded metal arc welding (SMAW) and submerged arc
welding (SAW) processes. Typical chemical composition of SM 80P steel plates and its weld metals is given in
Table 1, and mechanical properties in Table 2.

Fig. 1. Instrumentation and specimens sampling in the penstock model static pressure test
Table 1. Chemical composition of SM 80P steel and of MAW and SAW weld metals
Element

Si

Mn

SM 80P
Weld
metal

Cu

Cr

Ni

Mo

Ceq

0.10

0.30

0.90

0.01

0.008

0.24

0.48

1.01

0.47

0.03

0.0016

0.5

MAW

0.06

0.53

1.48

0.011

0.005

0.24

1.80

0.43

SAW

0.07

0.37

1.87

0.01

0.011

0.44

0.13

0.73

Table 2. Mechanical properties of SM 80P steel and of MAW and SAW weld metals
Material

Direction

Tensile
Y.S., MPa

SM 80P
Weld metal

U.T.S., MPa

Charpy impact test

Elongation

vE-40, J

vTrs, C

rolling

794 - 755

804 - 834

24 - 29

156 - 224

-92

cross rolling

794 - 755

795 - 834

22 - 23

60 - 147

-58

MAW

722

810

22

99

-5

SAW

687

804

23

78

-18

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Figure 2 shows the instrumentation on the developed model mantle, with the scheme of specimens cutting [Tati
et al.].
Pressurizing of the model had been performed in two stages. In the first loading (FL) stage the pressure reached
90.2 bar (t = 399 MPa), corresponding to working pressure, then model was held under pressure of 73.5 bar for two
hours. After unloading (UL), model was tested by the pressure of 120.6 bar (t=533 MPa) in the second loading
(SL) stage, close to the total working and water hammer load.

Fig. 2. Typical relationships between pressure and strain

3. Results and discussion

Finite element analysis (ABAQUS) of full-scale model of penstock has been performed and presented in the
following form: Von Misses stresses distribution, (FL-UL, SL-UL), Von Misses stress-strain curves (FL-UL, SLUL), Von misses stress-pressure curves (FL-UL, SL-UL), Pressure-von Misses strain curves (FL-UL, SL-UL) and
Hoop stresses-strain curves (FL-UNL, SL-UL).
3.1. Pressure vessel without RS
Figure 3 shows, the von Misses distribution of finite element model for first load as calculated in ABAQUS
software, the highest stresses was in weld joint (LSI SAW), and the base metal at that same side. This concentration
of stresses is due to the geometry of model.

Fig. 3. von Misses stresses distribution of FE model of first load, (P =14.5MPa)

Simon Sedmak et al. / Procedia Structural Integrity 2 (2016) 35463553

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As indicated in figure 4, the plastic strain initiate just in the weld joint (LS1 SAW), this behavior is due to the
lower yield strength of joint and its location in the stress concentration region.

Fig. 4. plastic deformation of FE model (FL-UNL, P=14.5MPa).

As the internal pressure increased in the second load of FE model the level of von Misses stress will increased,
and the distribution of stress has been not changed compared to the first load except the behavior of weld joint (LS1
SAW), which is has stress lower than base metal at that side of stress concentration region due to the effect of
initiation of plasticity as indicated in figure 5.

Fig. 5. von Misses stresses distribution of FE model of second load, (P=18.5MPa)

As illustrated in figure 6, the level of von Misses stresses have been exceeded yielding of base metal and weld
joints at that side of stress concentration region and the plasticity initiated and spreads in base metal and weld joints
in this area.

Fig. 6. plastic deformation of FE model (SL-UNL, P=18.5MPa).

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Simon Sedmak et al. / Procedia Structural Integrity 2 (2016) 35463553

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3.2. Results without RS (FL-UNL, SL-UNL).

Figure 7 illustrates the behavior of von Misses stress-strain curve of weld joint (LS1) for FL-UN and second
load-unload, this behavior showed the linearity of stress-strain curve of loading and unloading behavior for first and
second load.
Figure 8 shows the behavior of von Misses stresses with loading and unloading, as the pressure increasing the
von Misses stresses increasing until the yield point of the weld joint, then the changing of Von Misses stresses will
be lower, for unloading the behavior will be linear, until the effect of residual stresses then will be non-linear.

Fig. 7. Von Misses stress-strain behaviour LS1 SAW without RS as

calculated in ABAQUS.

Fig. 8, Von Misses-Inner Pressure behaviour of WM LSI SAW as

calculated in ABAQUS.

The behaviour of von Misses strain with inner pressure as calculated in ABAQUS is illustrated in figure 9, this
behaviour showed linearity during loading and unloading with a little bit changing during plasticity.
The behaviour of hoop stress-strain curve as indicated in figure (5-8), the yielding for first load starts at 13.34
MPa of inner pressure (531.5 MPa of hoop stresses), while for second load the plastic deformation initiated at 14.8
MPa of inner pressure (586.1 MPa of hoop stresses).

Fig. 9. Pressure-Von Misses strain of LS1

Fig. 8, Von Misses-Inner Pressure behaviour of WM LSI SAW as

calculated in ABAQUS.

Simon Sedmak et al. / Procedia Structural Integrity 2 (2016) 35463553

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3.3. Results for FL (with RS).

Figure 11 shows von Misses stresses distribution, the highest stresses has been in weld joints at the stress
concentration side, due to the effect of initial residual stresses (40% of yield strength) stresses and the shape of
geometry of model. Figure 12 shows the initiation of plasticity after FL, in LS1, due to the lower yield point and its
location. Figure 13 shows von Misses distribution in SL, with the maximum in weld joints at the concentration
stresses side with a considerable increasing of von Misses stresses in base metal at that side.As the inner pressure
increased for second load the plastic strain initiated in the other weld joints at the shorter side CMAW, LS3 SEW

Fig. 11. Von Misses stresses distribution of FE model for first load with RS (P=11.2MPa)

Fig. 12. plastic strain of WM LS1 SAW after FL (P=11.2MPa).

Fig 13. Von Misses distribution of FE model for SL with RS (P=14.4MPa).

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Fig. 14. Plastic strain of WM LS1 SAW after SL (P=14.4 MPa)

3.4. Results for weld metal LS1 SEW, (FL-UNL, SL-UNL, with RS)
The behavior of von Misses stress-strain curve of weld joint LS1 SAW with residual stresses is similar to the
behaviour without residual stresses, but it yields at lower level of inner pressure due to the effect of residual stresses
as illustrated in figure 15.
The behavior of hoop-stress-strain curve of weld joint LS1 SAW with residual stresses showed that, the plastic
strain for first load was in direction of axial stresses not in circumferential direction (there is no plasticity for first
load in hoop stress-strain curve) as indicated in figure 16, this behaviour is due to the shape of the geometry model
(angle of 5), which is exerted more compression in axial direction.

Fig. 15. von Misses stresses-strain curve of WM LS1 SAW with RS as

calculated in ABAQUS.

Fig. 16. Hoop stresses-strain of WM LS1 SAW with RS as

calculated in ABAQUS

4. Conclusions
Based on the results presented here and in more details in [1], one can conclude the following:

Simon Sedmak et al. / Procedia Structural Integrity 2 (2016) 35463553

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For the higher heat input inicis always higher, while aunis higher in WM, but smaller in HAZ, so the higher heat
input is somewhat better.
The HAZ of microalloyed steel has greater resistance against cracks than the WM, being quite different
comparing e.g. to the behaviour of microalloyed steels welded joints.
High stress levels for initiation of stable crack growth suggest the possibility that the welded structure can operate
safely even in the presence of relatively large surface cracks.
The integrity of heterogeneous welded joints is not affected by the presence of surface cracks because
overmatching plays a protecting role, which consists in a small plastic deformation of weld metal even at high
loads causing fracture of parent metal. The latest conclusion holds at low temperatures, as well.
Acknowledgements
We acknowledge the support for this investigation by Ministry for Education, Science and Technological
Development, Republic of Serbia, project TR 174004.
References
Algool, M., 2015. Initial Plastic Deformations and Residual Stresses Influencing the Welded Joint Behaviour in the Presence of Cracks, Doctoral
Thesis, University of Belgrade, Faculty of Mechanical Engineering.
Sedmak, A., Sedmak, S., Milovi, Lj., 2011. Pressure Equipment Integrity Assessment by Elastic-Plastic Fracture Mechanics Methods, published
by DIVK.
Sedmak, S., Sedmak, A.,1995. Experimental investigation into the operational safety of a welded penstock by a fracture mechanics approach,
Fatigue and Fracture of Engineering Materials and Structures 18(5), 527-538.
Tati, U., Sedmak, S., urevi, A., Sedmak, A., Baki, R., Numerical Modelling of Full'Scale Penstock Model Testing, 3rd International
Conference High Strength Steels for Hydropower Plants.