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Abstract
An assessment of the creep-fatigue crack bahaviour for a cylindrical structure with weldments has been carried out by using a
structural test and an evaluation with an assessment procedure. The structural specimen with a diameter of 600 mm and thickness of
7 mm is a welded cylindrical shell made of 316L stainless steel (SS) for one half of the cylinder and 304 SS for the other half. Eight
articial defects were machined and the defect behaviours were examined. In the creep-fatigue test, the hold time was 1 h at 600 1C and
the primary nominal stress was 45 MPa. The evaluation results for the creep-fatigue crack initiation and crack propagation were
compared with those of the observation images from the structural test. The assessment results for the creep-fatigue crack behaviour by
using the French A16 procedure showed that the A16 guide is reasonably conservative but overly conservative for the creep-fatigue crack
propagation in the case of a short hold time. It was shown that the crack initiation and propagation were dominated by a creep.
r 2006 Elsevier Ltd. All rights reserved.
Keywords: Creep-fatigue; Crack initiation; Crack propagation; Weld; Stress intensity factor
1. Introduction
An evaluation of the creep-fatigue crack behaviour is
one of the key factors in the design and assessment of a
high-temperature structure such as a liquid metal reactor
(LMR) subjected to a high temperature above 500 1C. The
design of a reactor structure under a creep-fatigue load can
be carried out by using high temperature design codes such
as ASME-NH [1], RCC-MR [2], and DDS [3], which
provide the linear damage summation rule on an evaluation of the creep-fatigue damage, mainly based on the
simplied inelastic analysis methods.
For a defect free structure operating at high temperature,
ASME-NH [1] provides the procedures of an elastic
analysis and an inelastic analysis for the creep-fatigue
damage limits. In the design by the analysis rule of RCCMR RB-3200 [2], the evaluation procedure for the zones
with geometrical discontinuities is provided for a fatigue
initiation but no procedure is given as yet for a creepfatigue crack initiation. Instead, the A16 [4] guide which
Corresponding author. Tel.: +82 42 868 2956; fax: +82 42 861 7697.
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2. Structural test
2.1. Structural specimen
The creep-fatigue structural test facility used in present
study is shown in Fig. 1. The test facility is composed of a
hydraulic actuator of a 1MN capacity and a high frequency
induction heater with a capacity of 50 kW [6]. The
inductance coil has six turns as shown in Fig. 1(b), and
its outer diameter is about 650 mm with clearances of
around 15 mm between the test cylinder and the coil.
The structural test specimen has the dimensions of a
600 mm diameter, a 500 mm height and a 7 mm thickness.
The specimen is a welded cylindrical shell with one half a
304 stainless steel (SS) shell and the other half a 316L SS
one as shown in Fig. 2. Similar cylindrical shell specimens
90
SMAW
304
GTAW
GTAW
0
60
270
304
GTAW
304
5
SMAW
SMAW 8
GTAW 4
2
1
316L
SMAW
GTAW
316L
316L
(b)
Fig. 2. Creep-fatigue test model and its development gure.
500mm
500
200
304
(a)
360
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T(C)
600
HT=1hr
70
9
69
90
t (min)
1 cycle (90min)
P=60ton
(n=45 MPa)
2
3
(a)
(b)
Fig. 4. Load and boundary condition of FE model, and principal stress distribution (300 ).
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829
Here the elasticplastic strain range (Delpl ) is determined by adding the four terms according to the A16
procedure(1) strain range by an elastic analysis, (2)
plastic strain increase due to the primary stress range at the
point examined, (3) plastic strain increase according to the
Neuber rule, and (4) a plastic strain increase due to a
triaxiality.
The creep strain range (Dfl ) is the one due to a hold time
during one creep-fatigue load cycle. The creep strain (e)
formula for 304SS is given as the Blackburn type of Eq. (2)
and that for 316L is the BaileyNorton type of Eq. (3) [4].
fl t 1 ert x 1 est m t,
(2)
(3)
,
(4)
A W 304 SS;base
572:5 13:2
n
t
.
(5)
170:0 8:7
It should be noted that an assessment according to the
A16 guide for a creep-fatigue damage provides less damage
for a base metal than a weld metal as shown in Eqs. (4) and
(5). The present creep-fatigue problem is creep dominant
and a crack initiation would occur mainly due to creep (W)
as shown at point P in Fig. 5.
For the weld metal part, the creep-fatigue damage
according to the A16 procedure is calculated as follows.
The allowable stress of the base material Sr is replaced by
JrSr where Jr is the coefcient of the weld rupture
characteristics. As for the fatigue, the curve is divided by
the ordinates D of the reference curve for the base metal
by the coefcient of the weld fatigue characteristics, Jf.
Here Jr is 0.94 and Jf is 1.25. The fatigue endurance limit
A W 316L SS;weld
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25
Weld_200
W (creep damage)
20
Base_200
15
Weld_100
10
Base_100
5
Creep-fatigue damage envelope
P
1
0
0
2
3
A (fatigue damage)
Fig. 5. Evaluation results for creep-fatigue damage for base and weld
metal.
and the rupture time for the weld metal were calculated as
Nd 170, Td 8.7, respectively. Thus the creep-fatigue
crack initiation envelope is given as in Eq. (5), which means
that a creep-fatigue crack would initiate in about eight
cycles and the initiation would be dominated by a creep
rather than a fatigue.
As the number of cycles is added, the calculated creepfatigue damage at the weld metal and base metal of defect
#3 are shown in the creep-fatigue damage envelope
in Fig. 5. The assessment results according to the A16
procedure shows a reasonable conservatism when compared with the observed results (described in next section)
between 100 and 200 cycles. For the present assessment
according to A16, it should be noted that the creep-fatigue
damage for the weld metal was larger due to the weld
strength reduction factors although the total strain range
was less.
3.2.2. Creep-fatigue crack propagation
A creep-fatigue crack propagation should be evaluated if
the number of cycles for the creep-fatigue crack initiation is
less than the actual load cycles. In the A16 procedure,
creep-fatigue crack propagation is calculated by adding the
crack increments due to a fatigue and a creep.
In the calculation of the fatigue crack growth (dafa), the
maximum effective stress intensity factor (SIF) range
should be determined to calculate the updated size of the
defect. The fatigue crack growth is estimated from the Paris
law with a SIF range of DKeff derived from a simplied
cyclic J value of DJ during the cycle based on the reference
stress concept and a factor q for the closure effects.
p
DK eff q E DJ ,
(6)
(8)
(9)
C i t
(11)
(12)
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Fig. 6. Observed image of the vertical defects (#2, #6; 200 cycles, 350 ).
Fig. 7. Observed image of the surface defects (#1, #5; 300 cycles, 350 ).
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0.8
base metal (304)
0.7
0.5
0.4
0.3
0.2
0.1
0
100
200
300
400
No. of cycles
500
600
Fig. 12. Observed images of 304 and 316L steel near the weld defect #8
(after 100 cycles, 1050 ).
400
400
350
0.6
304LN
316LN
300
250
200
150
304
300
316
250
200
150
100
100
0
200
400
600
800
1000
350
RCC-MR[2]
200
400
600
800
ASME-NH[1]
1000
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Acknowledgements
This work was performed under the long-term nuclear
R&D program sponsored by the Ministry of Science and
Technology of Korea.
References
[1] ASME Boiler and Pressure Vessel Code, Section III. Rules for
construction of nuclear power plant components, Div. 1, Subsection
NH, Class 1 Components in Elevated Temperature Service. New
York: ASME; 2004.
[2] Design and Construction Rules for Mechanical Components of FBR
Nuclear Islands, RCC-MR, 2002 Edition, AFCEN; 2002.
[3] DDS. Structural design guide for class 1 components of prototype
fast breeder reactor for elevated temperature service. Japan: JAPC;
1998.
[4] Technical Appendix A16 of RCC-MR. Guide for leak before break
analysis and defect assessment. AFCEN; 2002.