Nuclear Engineering and Design 195 (2000) 189 196

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Influence of mis-match of weld and base material creep

properties on elevated temperature design of pressure vessels
and piping
P. Chellapandi *, S.C. Chetal
Design and Technology Group, Indira Gandhi Centre for Atomic Research, Kalpakkam, Tamilnadu 603 102, India

Received 6 November 1997

Abstract

The stress and strain concentrations developed at the weldments during the long time operation of pressure vessels
and piping at high temperature due to the mis-match in the creep properties of weldment constituents (weld, heat
affected zone and base metal) are estimated using detailed finite element analysis. Three materials, viz. 2.25Cr 1Mo,
SS 316 LN and modified 9Cr 1 Mo which are the most commonly used materials in the nuclear and thermal power
plants are considered. A longitudinal seam weld with single and double V (X) configurations are analysed. Parametric
studies have been done on weld angle and stresses. Based on the analysis, critical locations and the maximum stress
concentration factors in the weldments for the above materials are identified. The weld design procedures of the
currently used pressure vessel and piping codes are commented. The importance of ductility based failure criteria is
emphasised. 2000 Elsevier Science S.A. All rights reserved.

1. Introduction The creep properties of metallic materials sub-

The structural integrity of components that op-
erate at high temperatures and pressures is depen-
dent on the design codes and assessment
procedures used. The current pressure vessel/
boiler design codes and procedures do not contain
matured design guidelines for weldments. Most of
the creep design of welded structures are not
carried out thoroughly because of the metallurgi-
cal complexities. Hence the creep damage remains
a depressingly common occurrence in the
weldments.
* Corresponding author. Fax: +91-4114-40368.
jected to a constant stress at a specific tempera-
ture, may be characterised by the minimum creep
strain rate, the creep strength and the creep ductil-
ities. The creep strength or uniaxial rupture stress
and the creep ductility are the damage/design
parameters. In the present context, the minimum
creep strain rate is of interest for the creep defor-
mation analysis of weldments. When a weldment
is subjected to high temperature and stresses, its
constituents, viz. base metal (BM), weld (WM)
and heat affected zone (HAZ) will produce differ-
ent creep strain rates depending upon the materi-
als and welding procedures. The WM may exhibit
a higher strain rate than the BM when subjected

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190 P. Chellapandi, S.C. Chetal / Nuclear Engineering and Design 195 (2000) 189196

than the BM. Thus the welding process produces

Fig. 1. Geometrical details of weldments.
to the same stress. It is called creep-soft weld. A
creep hard weld exhibits a lower creep strain rate
Fig. 2. Finite element mesh.
mis-matched weldment and consequently, a non-
uniform stress and strain field will develop with
time due to creep. These stresses and strains,
developed due to weldment mismatch, may be
enhanced by the weld geometry and the loading
conditions. The current conventional boiler or
pressure vessel codes utilise the parent material
properties for the design of welded component by
incorporating weld joint efficiencies on the allow-
able stresses based on weld joint and inspection.
However, the nuclear pressure vessel design codes
for fast reactors (ASME Code Case N47 and
French code RCC-MR (1993)) accounts for the
weld effects to the greater extent, by introducing
weld strength reduction factor, and reduced al-
lowable strain limits (strain limit of weld is 50% of
base metal). An estimation of stress and strain
concentrations at the weldments due to the mis-
matched creep properties will help to assess real
factor of safety in the design codes. The effective
way to solve this problem is the use of numerical
simulation of creep of weldments by taking into
account all the possible complexities that are asso-
ciated with a weld design.
A number of research papers are available on
the numerical simulation of creep behaviour of
welded components. A few of them which have
direct relevance to the current work are reported
in this paper. Walters and Cockraft (1972) might
have been the first ones who used finite element
method in analysing the creep of weldments.
Coleman et al. (1985) incorporated a three-mate-

Table 1
Material constants used for the analysis

Material Temp Youngs modulus Creep law Rupture Ref

(K) (MPa) stress (MPa)

Base metal Weld

2.25Cr-1 Mo 811 1.42105 1.1016 s 8 51016s 8 45.5 Stevick, 1994

SS 316LN 873 1.45105 2.2681026s 8.2 2.2681024s 8.2 92.0 RCC-MR, 1993
P91 873 1.51105 2.511028s 9.1 2.001028s 8.6 80.0 RCC-MR, 1993
 P. Chellapandi, S.C. Chetal / Nuclear Engineering and Design 195 (2000) 189196 191

Fig. 3. Development of stress concentration along neutral plan (2.25 Cr 1Mo).

Fig. 4. Development of strain concentration along neutral plan (2.25 Cr 1Mo).

rial model and used a parametric approach to

cover a wide range of weld metal/base metal creep
ratios. Ivarsson and Sandstrom (1980) studied the
creep stress redistribution and rupture of welded
AISI 316 steel tubes by finite different method.
Ivarsson (1983) studied the creep deformation of
welded 12% chromium steel tubes. Eggeler et al.
(1994) performed a creep stress analysis of the
welded pressure vessel made of modified 9Cr-1Mo
Fig. 5. Saturated stress contours for 2.25 Cr-1Mo.
material (P91) based on Nortons creep law and
192 P. Chellapandi, S.C. Chetal / Nuclear Engineering and Design 195 (2000) 189196
Fig. 6. Effect of weld angle on stress concentration (2.25Cr
1Mo).
Robinsons model concentrating on the accumu-
lated hoop and axial strains in the welds. In their
work, it is seen that the measured and calculated
axial and hoop strains were found to be in good
agreement. In-service failures of longitudinal X
welds in large diameter pipes in the USA were
analysed by Stevick (1994). The influence of dif-
ferences in creep properties between the weldment
constituents and the size effects of the cross weld
Fig. 7. Development of stress concentration along neutral plan (SS 316LN).
specimen were studied using finite element by
Segle et al. (1996) for the 1Cr-0.5Mo butt welded
pipe. Tu et al. (1996) proposed a concept of
structural creep rupture strength to define the
weld stress reduction factors. Finite element anal-
ysis is used by Tu and Sanstrom (1994) for the
creep analysis of an AISI 316 butt-welded joint in
pressurised tubes with creep soft weld. On the
basis of the predicted structural response, the
rupture life is calculated and subsequently the
weldment creep reduction factors are evaluated
for different lifetimes. These reduction factors are
also compared with those defined by the ASME
Code Case N47-29. Although considerable re-
search efforts have been concentrated on the gen-
eral creep behaviour of welded components, it
seems there is still a lack of link to design aspects.
This paper presents finite element calculations
that have been performed using in-house code
CONE on longitudinal X and V welds in a
large diameter pipe to determine the stress and
strain concentrations due to mismatch of creep
properties of the base and weld metals. Basically
three materials, viz 2.25Cr-1Mo at 811 K, SS 316
LN and P91 at 873 K are considered. For the
material 2.25Cr-1Mo, a parametric study is done
on weld geometry to compare the predictions by
CONE with published values. Additional studies
 P. Chellapandi, S.C. Chetal / Nuclear Engineering and Design 195 (2000) 189196 193

Fig. 8. Development of strain concentration along neutral plan (SS 316LN).

are presented for SS 316 LN to see the effect of
applied nominal stresses on the stress concentra-
tions. These results help to understand the weld
strength reduction factors recommended in the
recent French code RCC-MR 1993 for the struc-
tural design of fast breeder reactors.
and Sanstrom (1994) forAISI 316/304 steels, it is
seen that the weldments have creep soft welds.
The creep strain rate ratio (ow/ob) lies in the range
of 27520 for the stress range of 184250 MPa at
873 K.

3. Creep design procedure of welded structures

The current creep design for conventional

2. Creep behaviour of weldment constituents power plant components is performed by rule-

Based on a literature survey the minimum creep

rates of weld and base metals (ow and ob) are
obtained for the most commonly used structural
materials in the power plants, viz. low alloy steels
(2.25Cr-1Mo and 0.5Cr-0.25-0.25V), modified
9Cr-1Mo (P91) and austenitic stainless steel (AISI
316 and 304), at the temperature of interest. The
creep data (for 30 200 MPa at 838 K) presented
by Parker (1995) for weldments manufactured in
low alloy steel (2.25Cr-1Mo and 0.5Cr-0.25Mo-
0.25V) with nominally matching consumable indi-
cate that the weld metal deforms at (average) five
times the creep rate of the BM and may be as
much as 50. When the stresses increases the ratio
(ow/ob) normally decreases. The data presented by
Eggeler et al. (1994) for the P91 material over the
stress range 80 160 MPa and at temperature
ranges 873 933 K, show that the weld metal
creeps slower than the BM, indicating that it is a Fig. 9. Effect of stress on stress concentration factor (SS 316
creep hard weld. From the data presented by Tu LN).
194 P. Chellapandi, S.C. Chetal / Nuclear Engineering and Design 195 (2000) 189196

Fig. 10. Saturated stress contours for P91.

based concepts using the codes ASME/ANSI strength. A recent study (Tu and Sanstrom, 1994)
B31.1 and ASME-VIII Div 1. The rule-based indicates that the code principles are
design procedures require minimal material non-conservative for the relatively longer life.
information and structural calculation. In this, the A rational approach would be to analyse the
creep strength properties of the base metal are weldments by incorporating the different
used and strength reduction due to weld is constitutive material behaviour law for the WM,
accounted for by incorporating weld joint HAZ and BM in the rigorous inelastic analysis
efficiencies. Whilst in general, service experiences
indicates that those design approaches are
conservative, failure has been encountered at
weldments because of the inadequacy in these
codes.
For the nuclear pressure vessels and piping, the
analysis-based route is followed using the codes
ASME Code Case N47, CEGB-R5 and French
code RCC-MR. The current design procedures of
these codes require the elastic/inelastic analysis of
the structure using the base material properties
without considering the mis-matched properties.
A reduced design allowance is then imposed to
account for the presence of the weld in the form
of the weld strength reduction factor which is
given as a function of temperature and life (and
welding consumables and process). Further these
codes prescribe reduced strain limits for welds as
50% allowables for the parent metal. Accordingly
at any location the local peak strain accumulated
at the end of the life should not exceed 2.5% for
the weld. The weld strength reduction factors
given in the codes do not take into account the
multiaxial effect and they are applicable only to
the weldments of relatively lower weld metal Fig. 11. Time variation of stress concentration effects.
 P. Chellapandi, S.C. Chetal / Nuclear Engineering and Design 195 (2000) 189196
and perform a coupled damage analysis involving
appropriate damage models. However, in this
approach, there is a serious lack of material data
for the constituent parts of a weldment.
4. Finite element simulation of creep deformation of
weldments
In the present paper, a longitudinal weld which
has a single V or double V (X) configuration
is analysed. Longitudinal seam weld is selected
here because it is quite common in the power
industry to use this to reduce the manufacturing
cost. However, severe in-service accidents for this
type of large diameter pipes working in creep
regime have occurred mainly due to mistmatch in
weldment creep behaviour. Idealised weld
geometries considered for the analysis are shown
in Fig. 1. For simplicity, the curvature at the pipe
is neglected and plane strain conditions are
assumed.
Finite element analysis is performed using an
in-house code CONE developed for the inelastic
analysis of plane stress/plane strain/axisymmetric
structures with various constitutive models,
including the Chaboche viscoplastic model. The
formulation used for the present problem
considers only elastic deformation and steady
state creep. The finite element mesh used in the
analysis is shown in Fig. 2. The element size is
kept to a minimum so as to obtain the stress
concentration effects at the fusion line with
satisfactory accuracy.
Three materials, viz. 2.25Cr-1Mo at 811 K, P91
and SS 316LN at 873 K are considered. The
material constants used in the analysis are given
in Table 1.
While X weld configuration is assumed for
2.25Cr-1Mo and SS 316LN (weld soft materials),
single and double V configurations are assumed
for P91 (weld hard material). The applied stresses
for each of these materials are nothing but the
minimum creep rupture strength at the
appropriate temperature for the life of 1 105 h
which are included in Table 1. The idea here is to
see whether the stress/strain concentrations
accumulated at the weldments during the design
195
life of the component are significant enough to
cause premature failure.
5. Results of analysis
5.1. For the material 2.25Cr-1Mo
The stress concentration develops at the weld
fusion line on the neutral plane of the pipe wall.
Figs. 3 and 4 show the development of stress and
strain concentrations respectively along the
neutral plane. Fig. 5 shows the shaded stress
contours after reaching the saturation above 104
h. It can be seen that the stress concentrations are
highly localised and hence may not produce a
significant increase in the membrane stress
intensity across the wall thickness. Some
additional bending stress intensity might have
developed which will not exceed the code limits.
The main concern is the strain concentrations
which may exceed the creep ductility limit. Fig. 6
shows the effect of weld angle from 0 to 45 on
the saturated stress concentration factors. The
higher weld angle produces higher stress
concentrations, yielding a factor 1.5 for 45 weld
angle. In this figure, the similar results obtained
by Stevick (1994) are included to demonstrate the
validation of the predictions by CONE.
5.2. For the material SS 316 LN
Figs. 7 and 8 show the development of stress
and strain concentrations, respectively. Compared
to 2.25Cr-1Mo, the situations for SS 316 LN are
less critical even though the minimum creep strain
ratio (ow/ob) is 100, compared to 5 for
2.25Cr-1Mo. The results of a parametric study
done on the applied nominal stress on the stress
concentration factor (SCF) are given in Fig. 9. It
is clear that when the stress is increased, the time
to reach the stabilisation shortens and the SCF
increases. Above a certain level of stress the SCF
reaches a stable value. The stable value for this
material is found to be about 1.6. These results
explain to some extent the decrease in the weld
strength reduction factors (J factors) with the life
as recommended in the French code RCC-MR
196 P. Chellapandi, S.C. Chetal / Nuclear Engineering and Design 195 (2000) 189196
(1993 edition). For the higher life, the minimum
creep rupture stress is lower and hence the effect
of mis-match of creep properties is less. How-
ever, to fully explain the reason, studies on the
damage assessment taking into account mis-
match of damage law is necessary which is not
the scope of this paper.
5.3. For the material modified 9Cr-1Mo (P91)
Unlike the materials 2.25Cr-1Mo and SS
316LN, the P91 material has creep hard weld,
i.e. ow/ob B 1. The effect of this is; the critical
location lies on the outer surface (Fig. 10). The
stress concentration factor is insignificant for
this material as seen in Fig. 11.
6. Conclusions
Possible mis-match of the creep properties of
welds produces significant effects for 2.25Cr-
1Mo, because a high stress concentration factor
( 1.5) is developed within one tenth of design
life. For P91 material the effects are insignifi-
cant. Even though SS 316 LN weldment devel-
ops a similar SCF as that of 2.25Cr-1Mo, it
develops very slowly till the end of design life
and hence the increase in the cumulative creep
damage due to mis-matched weld will not be
significant particularly for the lower stresses
However, for the higher stresses which have
lesser rupture lives, these effects are significant.
This explains to some extent, the reason for the
decreasing trend of the weld strength reduction
factors, called J factors for the higher creep
life, as recommended in the RCC-MR.
While for creep soft materials (2.25Cr-1Mo
and SS 316 LN), stress concentration develops
at the weld fuse line on the neutral plane of the
pipe wall, for weld hard material (P91), the
stress concentration develops at the outer sur-
face.
The stress concentrations are highly local in
nature which will not affect the global stresses,
i.e. membrane and bending stress intensities
(terms used in nuclear pressure vessel codes)..
The design can be done for L seam joints based
on the creep properties of weld, if the weld is
weaker than the base metal. In addition to this,
the major concern is the strain concentration at
the weld which may exceed the current limit on
the acceptable creep ductility under some critical
situations. Further continuum damage analysis
incorporating the appropriate damage models in
the material constitutive equations will throw
more light on the weld failures whose common
occurrences are causing a great concern to the
designers and plant operators.
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