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Revision 1 (MRP-418)
Direct Use of Master Curve Fracture Toughness Curve for Pressure-Retaining
Materials of Class 1 Vessels, Section XI
THE TECHNICAL CONTENTS OF THIS PRODUCT WERE NOT PREPARED IN ACCORDANCE WITH
THE EPRI QUALITY PROGRAM MANUAL THAT FULFILLS THE REQUIREMENTS OF 10 CFR 50,
APPENDIX B. THIS PRODUCT IS NOT SUBJECT TO THE REQUIREMENTS OF 10 CFR PART 21.
NOTE
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e-mail askepri@epri.com.
Electric Power Research Institute, EPRI, and TOGETHER…SHAPING THE FUTURE OF ELECTRICITY
are registered service marks of the Electric Power Research Institute, Inc.
Copyright © 2017 Electric Power Research Institute, Inc. All rights reserved.
ACKNOWLEDGMENTS
*
The statements, findings, conclusions and recommendations expressed in this report are those of
the authors and do not necessarily reflect the views of the U.S. Nuclear Regulatory Commission.
This report describes research co-sponsored by EPRI.
This publication is a corporate document that should be cited in the literature in the following
manner:
Technical Basis for ASME Code Case N-830, Revision 1 (MRP-418): Direct Use of Master
Curve Fracture Toughness Curve for Pressure-Retaining Materials of Class 1 Vessels, Section
XI. EPRI, Palo Alto, CA: 2017. 3002010332.
iii
This document was prepared as part of the ASME Code, Section XI Working Group on Flaw
Evaluation. The authors would like to thank the volunteer members of the ASME Code, Section
XI Working Group on Flaw Evaluation for their valuable input, feedback, and review of this
report, as well as their help and participation in solving the sample problems associated with this
effort.
Working Group on Flaw Evaluation Members Who Contributed to This Report:
• Russell Cipolla Intertek
• Yil Kim GE POWER
• Mark Kirk & Mike Benson U.S. NRC
• Darrell Lee BWXT
• Cheng Liu & Steven Xu Kinectrics
• Do Jun Shim Structural Integrity Associates, Inc.
iv
ABSTRACT
Section XI of the ASME Boiler and Pressure Vessel Code (ASME Code) provides KIc and KIa
fracture toughness models for ferritic steels. These models are based on linear elastic fracture
mechanics (LEFM) methods, and were initially developed in the 1970s for incorporation into the
ASME Code. The models have remained largely unchanged since their original incorporation
into the code. Since the publication of the technical bases documents for the fracture toughness
equations contained in Section XI, considerable advancements to the state of theoretical and
practical knowledge have occurred, particularly with respect to the amount of available fracture
toughness data. The Electric Power Research Institute (EPRI) now has a fracture toughness
database containing well over 9,000 fracture toughness values ranging across specimen sizes, test
temperatures and strain rates. As part of the pressurized thermal shock (PTS) re-evaluation
program, the U.S. Nuclear Regulatory Commission (NRC) and the industry used this database to
develop an integrated model that predicts the mean trends and scatter of the fracture toughness
behavior of ferritic steels throughout the temperature range from the lower shelf to the upper
shelf fracture regions. This integrated model includes the transition fracture toughness Master
Curve approach that describes the temperature dependence and scatter in KJc in the lower
transition temperature region, a new model for describing the temperature dependence and
scatter of JIc on the upper shelf, and includes identification of a temperature at which the KJc
curve transitions to upper shelf behavior, marking the upper limit of applicability for the KJc
transition curve. This collection of models was used by the NRC to establish the index
temperature screening limits adopted in the Alternate PTS Rule documented in Title 10 to the
U.S. Code of Federal Regulations (CFR), Part 50.61a (10CFR50.61a).
The ASME Section XI Working Group on Flaw Evaluation (WGFE) has an ongoing effort
intended to implement the KJc Master Curve (MC) into Section XI of the ASME Code. This
effort began with indirect implementation of the MC through use of a transition reference
temperature, RTT0, defined by using the KJc T0 value to replace RTNDT for indexing the ASME KIc
curve. In Revision 0 of Code Case N-830, direct use of the MC was defined as an alternative to
using the ASME KIc curve. Revision 1 to Code Case N-830 (N-830-1) incorporates the complete
and self-consistent suite of fracture toughness models developed over the last decade to
completely describe the temperature dependence, scatter, and interdependencies between all the
fracture toughness metrics (i.e., KJc, KIa, JIc, J0.1, and J-R) from the lower shelf through the upper
shelf regimes. This report describes the technical basis for Code Case N-830-1.
v
Keywords
Master curve
Fracture toughness model
T0 fracture toughness reference temperature
RTNDT fracture toughness reference temperature
ASME Section XI Appendix A flaw evaluation procedures
vi
EXECUTIVE SUMMARY
PRIMARY AUDIENCE: ASME Boiler & Pressure Vessel Code, Section XI, Committees
SECONDARY AUDIENCE: Engineers using Master Curve fracture toughness for vessel integrity evaluations
RESEARCH OVERVIEW
The ASME Section XI Working Group on Flaw Evaluation (WGFE) has an ongoing effort intended to
implement the KJc Master Curve (MC) into Section XI of the ASME Code. This effort began with indirect
implementation of the MC through use of a transition reference temperature, RTT0, defined by using the KJc
T0 value to replace RTNDT for indexing the ASME KIc curve. In Revision 0 of Code Case (CC) N-830, direct
use of the MC was defined as an alternative to using the ASME KIc curve. The proposed Revision 1 to CC N-
830 (N-830-1) incorporates the complete and self-consistent suite of fracture toughness models developed
over the last decade to completely describe the temperature dependence, scatter, and interdependencies
between all the fracture toughness metrics (i.e., KJc, KIa, JIc, J0.1, and J-R) from the lower shelf through the
upper shelf regimes. This report describes the technical basis for Code Case N-830-1. This document was
prepared by a small task group to provide information to the Working Group on Flaw Evaluation to support
finalization and decision-making on CC N-830-1.
KEY FINDINGS
• The technical bases for the fracture toughness models contained in ASME CC N-830-1 are presented
in this report. The suite of best estimate fracture toughness models provides a complete description
of fracture toughness crack initiation and arrest behavior from lower shelf, through transition, to ductile
upper shelf regimes for all ferritic steels.
• The best estimate models used for CC N-830-1 are based on updated techniques and available data,
sound physical bases, and extensive empirical evaluations that collectively promote confidence in their
use for flaw assessment following Nonmandatory Appendix A of ASME Section XI and similar
methods.
• These models are appropriate for use in both deterministic and probabilistic assessments, as each
model describes the full distribution in values about the mean for any temperature and material
condition.
vii
EXECUTIVE SUMMARY
• Equations that allow an analyst to determine any percentile value of interest for any of the fracture
toughness parameters KJc, KIa, JIc, J0.1, and J-R are presented for each fracture toughness model.
Specific values of these parameters may be used in deterministic assessments, or the entire
distributions may be sampled for use in probabilistic assessments.
1
Master Curve is only capitalized when referring to the KJc Master Curve. In all other cases, “master” is used as an
adjective to describe the type of curve-fit.
ix
Category Symbol Unit Description
x
CONTENTS
ABSTRACT ................................................................................................................................v
NOMENCLATURE ....................................................................................................................ix
1 INTRODUCTION ..................................................................................................................1-1
1.1 ASME Section XI, Appendix A Approach .......................................................................1-2
1.1.1 Summary of ASME Section XI, Appendix A Flaw Evaluation Procedures ..........1-2
1.1.2 Treatment of Uncertainties in Appendix A ..........................................................1-4
1.1.3 Technical Basis for the Appendix A Methodology ..............................................1-5
1.1.4 Issues with Appendix A Methodology ................................................................1-8
1.2 Objectives of Proposed Code Case N-830-1 ...............................................................1-10
xi
3.2 Cleavage Crack Arrest Fracture Toughness, KIa ............................................................3-7
3.2.1 Description of Model ..........................................................................................3-7
3.2.2 Basic Form ........................................................................................................3-7
3.2.3 Distribution ........................................................................................................3-7
3.2.4 Theoretical Basis ...............................................................................................3-8
3.2.5 Model Validation ................................................................................................3-9
3.2.6 Limits of Applicability .........................................................................................3-9
3.3 Ductile Crack Initiation Fracture Toughness, JIc .............................................................3-9
3.3.1 Description of Model ........................................................................................3-10
3.3.2 Basic Form ......................................................................................................3-10
3.3.3 Distribution ......................................................................................................3-10
3.3.4 Theoretical Basis .............................................................................................3-11
3.3.5 Empirical Basis ................................................................................................3-12
3.3.6 Model Validation ..............................................................................................3-13
3.3.7 Limits of Applicability .......................................................................................3-15
xii
5 IMPLICATIONS OF PROPOSED CHANGES .......................................................................5-1
5.1 Introduction....................................................................................................................5-1
5.2 Sources of Uncertainties in Fracture Mechanics Analyses.............................................5-1
5.2.1 Flaw Size Uncertainty ........................................................................................5-2
5.2.2 Stress and Stress Intensity Factor Uncertainty ..................................................5-2
5.2.3 Fracture Toughness Uncertainty........................................................................5-3
5.3 Treatment of Uncertainties ............................................................................................5-3
5.3.1 Treatment of Uncertainty Due to Flaw Size and Location ..................................5-3
5.3.2 Treatment of Uncertainty Due to Stress .............................................................5-6
5.3.3 Treatment of Uncertainty on Fracture Toughness ..............................................5-8
5.4 CC N-830 ....................................................................................................................5-11
5.5 Code Case N-830-1 Uncertainty Treatment .................................................................5-12
5.6 Summary .....................................................................................................................5-14
9 REFERENCES .....................................................................................................................9-1
xiii
C DRAFT CC N-830-1 (VERSION USED FOR SAMPLE PROBLEM 2)................................. C-1
Direct Use of Fracture Toughness for Flaw Evaluations of Pressure Boundary
Materials in Class 1 Ferritic Steel Components .................................................................. C-1
Section XI, Division 1 ..................................................................................................... C-1
-1000 Scope............................................................................................................. C-1
-2000 Reference Temperature ................................................................................. C-2
-3000 Toughness Variability ..................................................................................... C-3
-4000 Toughness Curves ......................................................................................... C-4
-4100 Cleavage Crack Initiation toughness, KJc ................................................... C-4
-4200 Cleavage Crack Arrest Toughness, KIa ...................................................... C-5
-4300 Ductile Crack Initiation Toughness, JIc ....................................................... C-5
-4400 Ductile Crack Extension Toughness, J-R and JX........................................ C-6
-5000 Applicability Limits .......................................................................................... C-7
-5100 Ductile Crack Extension Range ................................................................. C-7
-5200 Lower Temperature Limits on KJc and KIa................................................... C-7
-5300 Upper Temperature Limits on JIc, J-R, and Jx............................................. C-7
-5400 Intermediate Temperature Limits ............................................................... C-7
-6000 Units Conversions .......................................................................................... C-8
-7000 Nomenclature ................................................................................................. C-8
xiv
LIST OF FIGURES
xv
Figure 5-8 Plot of KJc, 1% MC bound, 99% MC bound, the 0.5% MC bound (CC N-830-
1), the 5% MC bound divided by √10 (CC N-830), and the RTT0-indexed KIc curve
divided by √10 (Appendix A) for normal/upset operating conditions. ...............................5-14
Figure A-1 Sample Problem Properties ................................................................................... A-2
Figure C-1 Illustration of Intermediate Temperature Limits when 5th Percentile Bounding
Curves are used .............................................................................................................. C-8
xvi
LIST OF TABLES
xvii
1
INTRODUCTION
Historically, the safety of nuclear power plant pressure-retaining components has been
demonstrated using the rules of the ASME Boiler and Pressure Vessel Code (ASME Code, or
Code). Section III of the ASME Code provides Rules for Construction of Nuclear Facility
Components, and Section XI provides Rules for In-Service Inspection of Nuclear Plant
Components. Both sections of the Code provide methods for assessing stresses and moments
contributing to the forces available to drive crack growth in components containing postulated or
detected flaws. The Code primarily makes use of linear elastic fracture mechanics (LEFM)
methods to calculate stress intensity factors, and has fracture toughness models based on
empirical data to estimate material resistance to crack extension. Much of the current Code is
based on LEFM models of material behavior in the presence of flaws that were developed more
than 40 years ago at a time when drop-weight tests [1] and Charpy V-notch (CVN) impact tests
[2] were the accepted standards used to estimate metrics that correlate with fracture toughness,
such as the nil-ductility temperature (NDT) or ductile-to-brittle transition temperature (DBTT).
The ferritic steels used to fabricate nuclear power plant reactor pressure vessels (RPVs) were
selected to have sufficient strength and toughness to provide adequate safety margins against
overload failure and catastrophic crack extension at all operating temperatures and conditions.
To ensure adequate toughness, the RPV steels selected for power plant construction in the 1960s
and 1970s, were chosen to have a DBTT well below the expected operating conditions of the
plant. The CVN and the drop-weight tests were among the most commonly used test methods
for characterizing the DBTT temperature of these steels at that time. However, these tests do not
directly provide the specimen-independent measures of fracture toughness required to support an
ASME Code analysis. These test results can only be correlated to the measure of the material’s
resistance to crack extension. Linear-elastic plane-strain fracture toughness testing, as prescribed
by ASTM Standard E399 [3], was developed to provide a direct measure of a material’s
resistance to crack extension using a measure of the critical stress intensity factor required for
crack extension, KIc. Such a value allows for more direct comparison to the crack driving force
in stress intensity factor calculations.
Linear-elastic plane-strain fracture toughness testing for RPV materials often requires large
specimens to ensure that validity criteria for small scale yielding are met, and the test specimens
and procedures are often expensive. As such, testing an adequate number of specimens to fully
define a fracture toughness transition curve and reference temperature is expensive. Because of
this, the nil-ductility test (used to define NDT) and the CVN test, both of which use smaller test
specimens and simpler test procedures compared to those required for valid KIc determination,
became the dominant methods for characterizing material toughness transition temperature,
RTNDT, defined as the reference temperature for nil ductility transition to signify the reference
temperature below which a material exhibits limited ductility in the presence of a notch.
Calculation of RTNDT from a combination of data from NDT and CVN testing is described in
Paragraph NB-2331 of Section III of the ASME Code [4]. The prevalence of NDT and CVN
1-1
Introduction
data, combined with work performed to correlate these values with KIc [5, 6], resulted in an
RTNDT-referenced KIc curve that was adopted into the ASME Code, Section XI, Appendix A
flaw assessment procedures [7].
There is uncertainty inherent in both the RTNDT and KIc values determined for a specific material.
This uncertainty is caused by the natural material inhomogeneity that controls fracture behavior,
and the uncertainties surrounding modeling assumptions, test procedures, and analytical methods
used for determining these values. These uncertainties can be treated explicitly by quantifying
the uncertainties in these values (defining their distributions) and then either taking a lower
bound value, or assigning a factor that is applied to the best-estimate value that directly accounts
for the uncertainties. If the distributions in the data are not well established, the uncertainties can
be treated implicitly by making conservative assumptions about the operating conditions or using
conservative models of material behavior. Explicit treatments of uncertainties are preferred, as
they are more transparent, their impact more easily understood, and they can more readily be
changed as knowledge and information are expanded. The method employed in ASME Code,
Section XI, Appendix A uses both implicit and explicit treatments of uncertainties, which
obscures accurate representation of material behavior and increases the difficulty of taking
advantage of increased knowledge of material properties.
1-2
Introduction
1-3
Introduction
Figure 1-1
Appendix A Flaw Evaluation Procedure to Evaluate the Continued Serviceability of Ferritic
Components.
1-4
Introduction
KIa = 13.675 exp [0.0261 (T- TNDT)] + 29.4 (in units of MPa√m, oC)
KIa = 1.223 exp {0.0145[T- (TNDT +160)]} + 26.8 (in units of ksi√in, °F) Eq. 1-2
This KIa curve was then termed the reference toughness KIR curve and was indexed using TNDT to
eliminate the need for performing expensive KIc tests.
• To ensure that the transition temperature used to reference the KIa curve was well below the
upper shelf temperature for the material of interest, a criterion was described that combined
nil-ductility test results to establish TNDT, and CVN tests to define the temperature at least
33°C (60°F) above TNDT at which Charpy specimens exhibited at least 0.89 mm (35 mils =
0.35 in.) of lateral expansion. These two results were combined to define RTNDT as T0.89(mm) –
1-5
Introduction
33°C (T35(mils) - 60°F), such that RTNDT was defined as the higher of TNDT or T0.89(mm) – 33°C
(T35(mils) - 60°F). An alternate requirement involving both 0.89 mm (35 mils) of lateral
expansion and a minimum CVN energy of 68 J (50 ft-lb) was also suggested, i.e., T68J – 33°C
(T50(ft-lb) - 60°F). The minimum of the CVN energy and the lateral expansion criteria were
recommended to eliminate materials that might have a low transition temperature or very low
upper shelf energies from consideration using the KIR-RTNDT procedure.
• A very conservative defect size that included a depth of one-quarter of the wall thickness
(¼t), a length of six times the depth (or 1.5t), a sharp crack tip, and an orientation
perpendicular to the maximum stress direction was recommended.
• A safety factor was recommended for application to the crack driving force stresses along
with a flaw size safety margin by recommending a reference flaw size considerably larger
than the actual or anticipated maximum flaw size.
• Procedures for calculating the allowable loading were presented in an Appendix to WRC 175
[5] that involved primary membrane stresses due to pressure and secondary thermal stresses
caused by thermal gradients near the crack tip.
• Additional safety factors on loading beyond safety factors between 1.0 and 2.0 applied to
stresses were not recommended as these were believed to be outside the scope of the PVRC.
The recommendations presented in WRC 175 [5] were modified by Marston, et al. [6] of the
newly formed ASME Section XI Working Group on Flaw Evaluation before they were
implemented into Appendix A. The modifications included using RTNDT to index the KIa curve
instead of TNDT. A bounding KIc curve was defined by drawing a curve beneath all the available
static plane strain fracture toughness data referenced to RTNDT for the same materials, in a
manner similar to that used to define the KIa curve, defining the temperature dependence of KIc
as:
KIc = 36.5 + 22.783 exp [0.036 (T - RTNDT)] (in units of MPa√m, °C)
KIc = 33.2 + 20.734 exp [0.02 (T - RTNDT)] (in units of ksi√in, °F) Eq. 1-3
1-6
Introduction
Figure 1-2
KIc Curve (top) and KIa [KID] Curve (bottom) Referenced to RTNDT ([6]).
1-7
Introduction
Because there have been no changes made to these material toughness curves since they were
originally published in the 1970s, they retain their inherent conservatisms. These two curves are
both similarly affected by degradation due to irradiation through ∆RTNDT. Because both curves
are referenced to T-RTNDT, and since irradiation embrittlement is characterized by the
temperature at which the CVN energy is 41 J (30 ft-lb), ∆T41J, the separation between KIc and KIa
does not change with irradiation. The upper limit of applicability for the linear elastic KIc curve
of 220 MPa√m (200 ksi√in), which is sometimes assumed by analysts, also does not change with
irradiation. However, upper shelf Charpy energy values falling below 68 J (50 ft-lb) 2 require an
Equivalent Margins Assessment (EMA) by Appendix G to 10 CFR Part 50 [9]. An EMA can be
performed using USNRC RG 1.161 [10], or using elastic-plastic fracture mechanics (EPFM) as
described in Appendix K of the ASME, Section XI Code, or using other similar methods that
have been developed, such as the Owner’s Groups evaluations representing different nuclear
steam supply system (NSSS) vendors.
1-8
Introduction
3
Throughout this report we adopt the common nomenclature used in the international literature of J0.1 (representing
the value of J at 0.1 inch of crack extension, and equivalently, representing the value of J at 2.54 mm of crack
extension). All formulas for Jx (J at x mm of crack extension) are in metric units with x representing the amount of
crack extension in millimeters.
1-9
Introduction
values. All these advances provide for superior modelling and a sound technical basis for
incorporating more accurate, T0-based models into Appendix A of the ASME Code.
1-10
2
OVERVIEW OF CODE CASE N-830-1
2.1 Introduction
With standardization of the test methodology for obtaining the T0 fracture toughness reference
temperature in ASTM E1921 [15] the stage was set for implementation of T0 into the ASME
Code. This implementation occurred via the adoption of two Code Cases: N-629 in Section XI
and N-631 in Section III [16, 17]. These Code Cases proposed use of a T0-based reference
temperature for use in indexing the ASME’s KIc curve in Section XI and Section III Code
applications. RTT0 is a T0-based transition toughness reference temperature defined by Equation
(1-1).
Code Case (CC) N-830 was approved by ASME in 2014, and was the first direct implementation
of the KJc Master Curve (MC) into the ASME Code [18]. The CC made use of the 5th percentile
lower bound of the Wallin Master Curve as an alternative to the ASME KIc curve to characterize
material resistance to fracture in flaw evaluations. Since that time, work has progressed within
the ASME Section XI Working Group on Flaw Evaluation (WGFE) to expand and improve the
original CC methods.
To take advantage of the best-estimate fracture toughness models recently developed and linked
to T0, CC N-830 was modified to include a suite of self-consistent fracture toughness models
describing material fracture toughness behavior from lower shelf, through transition, to upper
shelf behavior [19]. These models include linkage models that describe the inter-relationships
controlling changes in toughness behavior for all toughness parameters with irradiation. The
proposed Revision 1 of CC N-830 incorporates a complete suite of best-estimate models that
completely describe the temperature dependence, scatter, and interdependencies (such as those
resulting from irradiation or other hardening mechanisms) between all fracture toughness metrics
(i.e., KJc, KIa, JIc, J0.1, and J-R). By incorporating both a statistical characterization of fracture
toughness, and the ability to estimate a toughness curve for any percentile bound, CC N-830-1
provides a consistent basis for the conduct of both conventional deterministic flaw evaluations,
as well as probabilistic evaluations. Additionally, both transition and upper shelf toughness
properties are defined in a consistent manner in one document to provide the analyst an easy
means to determine what fracture behavior (i.e., transition or upper shelf) can be expected for
any condition.
2-1
Overview of Code Case N-830-1
2.2.1 Inquiry
The inquiry for CC N-830-1 is as follows:
“What current best-estimate (alternative) fracture toughness models and
relationships may be used for flaw evaluations performed in accordance with
Nonmandatory Appendix A and/or Nonmandatory Appendix K in lieu of the
current requirements of these Appendices for the values of KIc, KIa, JIc, J0.1,
and J-R?”
2.2.2 Reply
The initial portion of the reply for CC N-830-1 is as follows:
“It is the opinion of the Committee that the fracture toughness models based on
the Master Curve Method in accordance with ASTM E-1921 may be used in lieu
of the current requirements of Nonmandatory Appendices A or K when
determining values for KIc, KIa, JIc, J0.1, and J-R using the procedures and
equations given below.”
CC N-830-1 uses a T0 value measured in accordance with ASTM Standard E1921, “Standard
Test Method for the Determination of Reference Temperature, To, for Ferritic Steels in the
Transition Range” [15]. Using T0, it is possible to estimate the variation of fracture toughness
with temperature across the entire range of interest to operating vessels for Class 1 ferritic
reactor pressure vessel (RPV) materials. This estimate can be used as an alternative to:
• The crack initiation fracture toughness curve, KIc, of Nonmandatory Appendix A, Subarticle
A-4200 for pressure retaining materials other than bolting, and
• The crack arrest fracture toughness curve, KIa, of Nonmandatory Appendix A, Subarticle
A-4200 for pressure retaining materials other than bolting, and
• The J-integral fracture resistance for the material at a ductile flaw extension of 0.1-in.
(2.5 mm), J0.1, of Nonmandatory Appendix K for pressure retaining materials other than
bolting.
• The J-integral fracture resistance for the material and its variation with ductile flaw
extension, Δa, J-R, of Nonmandatory Appendix K for pressure retaining materials other than
bolting.
The remaining content of the reply to CC N-830-1 defines all these relationships.
2-2
Overview of Code Case N-830-1
These models are based on large databases of measured fracture toughness values such that
uncertainties in values are well understood, characterized, quantified and validated. Full
distributions are defined for each fracture toughness parameter to enable consistent and explicit
treatment of uncertainties in both deterministic and probabilistic assessments.
CC N-830-1 defines bounding values for percentiles of interest for use in deterministic
evaluations. The linkage models ensure consistent data bounds for all material hardening
conditions provided the same percentiles are selected for the transition and upper shelf toughness
models. The distributions defined for all parameters provide the information required to sample
across the expected range of values at each temperature for probabilistic assessments, with the
linkage models ensuring that these distributions change synchronously, as material conditions
change.
The materials fracture toughness models presented in CC N-830-1 are meant to be used in lieu of
those described in Article 4000 of the current Appendix A for describing material resistance to
fracture. Lower bounding values of the distributions are recommended for use in deterministic
flaw analyses. Use of the same percentile bounding value for all toughness curves from lower
shelf through upper shelf, coupled with elimination of structural factors, ensures consistent
representation of material behavior for all fracture modes. While these recommendations for CC
N-830-1 apply explicitly only to the fracture toughness parameter, we argue in Chapter 5 that
explicit factors applied to stress and flaw size are not needed due to the conservatisms inherent to
non-destructive flaw sizing and the analytical determination of stresses.
To ensure that the uncertainties inherent in all aspects of flaw analysis are treated appropriately
and consistently, the WGFE plans to develop explicit partial structural factors to apply to each
parameter (flaw characterization, driving force analysis and material resistance) in the flaw
analysis to more accurately reflect the uncertainties in that specific parameter. The
recommendations contained in CC N-830-1 for appropriate bounding values to use for material
fracture toughness only account for the uncertainties in the fracture toughness parameter.
The best estimate fracture toughness models, linkage models, and technical bases for the models
contained in CC N-830-1 are presented in Chapters 3 and 4. The model temperature dependence
and distributions are described, along with a summary of their development and validation,
including limitations on their use.
2-3
3
FRACTURE TOUGHNESS MODELS IN CC N-830-1
There are three basic fracture toughness models presented in CC N-830-1; KJc, and JIc to describe
the initiation fracture toughness in the transition region and on the upper shelf, and KIa to
describe the crack arrest fracture toughness. Measured values of KJc and KIa are used to define
indexing temperatures (T0 and TKIa, respectively) that are material specific. These indexing
temperatures were used to normalize the KJc and KIa curves to establish a single temperature
dependence for each curve. The JIc curve was normalized to establish the temperature
dependence of JIc for all ferritic steels based on the JIc value at 288 °C, JIc288. Each of these
models was empirically derived from large databases of toughness values, but the model forms
were informed from a mechanistic understanding of the fracture process that provides a
theoretical underpinning to identify empirical trends. The assumption used for all models was
that applied energy absorption by dislocation motion prior to fracture is the mechanism
controlling the temperature dependence of the fracture toughness. Therefore, these models are
applicable only to ferritic steels, and only in temperature regions where deformation is
dislocation-dominated.
3-1
Fracture Toughness Models in CC N-830-1
Code in both Appendices A and G, and Code Case N-631 is in the process of being included in
Section III in NB-2300 [26]. Research, and test and evaluation programs, aimed at enhancing the
wealth of information collected on the applicability of the MC and the MC methodology, provide
support for direct implementation of the MC and T0 for use in assessing the fracture safety of
critical RPV components.
where B0 and K0 are normalization constants, KI is measured toughness and Kmin is taken as
20 MPa√m. B0 can be set to any desired specimen reference thickness but is usually taken as
25.4 mm. K0 is the temperature dependent scale parameter taken as the 63.2% probability of
fracture for a specimen of thickness B0. The shape parameter is defined by the exponent of 4.
where T is the test temperature and T0 is the temperature at which the measure KJc value is 100
MPa√m. The median cleavage crack initiation toughness, KJc(median), curve was then defined as:
𝑲𝑲𝑱𝑱𝑱𝑱(𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎) = 𝟑𝟑𝟑𝟑 + 𝟕𝟕𝟕𝟕 ⋅ 𝒆𝒆𝒆𝒆𝒆𝒆[𝟎𝟎. 𝟎𝟎𝟎𝟎𝟎𝟎(𝑻𝑻 − 𝑻𝑻𝒐𝒐 )] Eq. 3-3
3.1.3 Distribution
The distribution of data at any given temperature follows a Weibull distribution with a slope of
four and Kmin equal to 20 MPa√m [20, 23], as shown in Eqn. (3-1). The cleavage crack initiation
toughness, KJc, curve can be defined at any percentile, p, as follows:
𝒑𝒑
𝑲𝑲𝑱𝑱𝑱𝑱 = 𝟐𝟐𝟐𝟐 + (𝑲𝑲𝒐𝒐 − 𝟐𝟐𝟐𝟐){−𝒍𝒍𝒍𝒍(𝟏𝟏 − 𝒑𝒑)}𝟏𝟏/𝟒𝟒 Eq. 3-4
Eqn. (3-4) can be used to produce both lower and upper bound curves. For example, using a
value of 0.05 for p would produce a 5% lower bound curve, while using a value of p equal to
0.95 would produce a 95% upper bound curve. The scale factor, K0, is given by Eqn. (3-2).
There is no effect of product form or irradiation on Eqn. (3-4).
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Fracture Toughness Models in CC N-830-1
Eqn. (3-4) assumes a crack front length of 25.4 mm (1 in.) in laboratory test specimens with
straight crack fronts. While an adjustment to Eqn. (3-4) that accounts for different crack front
lengths in laboratory test specimens was developed, currently there is insufficient basis to
recommend a generic equation that applies to non-straight cracks fronts (e.g., surface breaking
cracks, fully embedded cracks, etc.) that are of interest in structural analyses. CC N-830-1
therefore uses Eqn. (3-4) unless the user can demonstrate that a crack front length other than
25.4 mm (1 in.) is appropriate to the structural situation of interest.
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Fracture Toughness Models in CC N-830-1
cleavage fracture dating to the 1950s. The idea that cleavage fracture of ferritic steel occurs
when a critical tensile stress is exceeded at a critical particle evolves from the work of McMahon
and Cohen, Curry and Knott, and Smith, among others [31-37]. In the 1970s, Ritchie, Knott, and
Rice (RKR), and Curry and Knott incorporated these observations into models that predict,
respectively, how toughness changes with temperature, and the scatter of fracture toughness at a
single temperature [32-34, 38, 39]. The WST model begins with the notion, most commonly
attributed to RKR, that cleavage fracture will initiate and propagate to failure when a critical
opening mode stress is exceeded over some critical distance ahead of the crack tip. WST
combined an RKR-type model with Curry and Knott’s idea that cleavage fracture is controlled
by a “statistical competition between crack nuclei of varying sizes and frequencies in the rapidly
changing stress gradient ahead of a {sharp} crack tip” [38]. The most significant contribution of
the WST model is not the introduction of a new understanding of cleavage fracture, but rather
the important generalizations WST made concerning the cleavage fracture behavior of all ferritic
steels.
3-4
Fracture Toughness Models in CC N-830-1
3-5
Fracture Toughness Models in CC N-830-1
• Between 2000 and 2005, a group of laboratories working under European Commission
funding performed extensive KJc characterization of a single RPV-grade forging to validate
the MC. Key papers from this work include [50, 51].
• In the early 2000s, the NRC sponsored a study at the University of California at Santa
Barbara focused specifically on the size-effect aspect of the MC. This study featured an
extensive KJc characterization using ex-vessel (Shoreham) materials [52, 53].
Across the board these efforts found no substantial deviations from the Master Curve model as
originally proposed by Wallin [20-22] and as represented within E1921.
Over the past 15 years, various publications have suggested possible further refinements of the
MC concept that are useful in specific situations. These include the following:
• On temperature dependence, References [54] and [55] provide information on how the
exponential slope of 0.019 is affected by various factors. There is considerable dispersion in
the data, but even so, a tendency to a reduction of the value of 0.019 with increasing
embrittlement can be seen. Reference [55] provides a formula to estimate this effect.
• On Kmin, a method proposed in Reference [56] enables estimation of a data-set specific value
for Kmin. However, large amounts of KJc data are needed to use the procedure, and the value
of Kmin of 20 MPa√m is still seen as a practicable estimate.
• Methods have been developed when it is suspect that a particular KJc dataset may not have
been obtained from a homogeneous population of cleavage crack initiators. These methods
are particularly useful in application to T0 values measured on welds [57].
• Some empirical evidence demonstrates that, as embrittlement occurs and the crack initiation
and crack arrest distributions merge, the constant Weibull shape parameter of four becomes
less accurate. EricksonKirk and co-workers [58, 59] postulated that the cause of this
behavior might be stable micro-arrests in high embrittlement materials.
All the foregoing reports were reviewed and form the basis for the limits on the applicability of
CC-N-830-1, as appropriate. As additional information comes to light, more refined models may
be developed for implementation into a subsequent revision of CC N-830-1.
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Fracture Toughness Models in CC N-830-1
• The MC KJc model cannot be used at temperatures above which crack extension occurs by
dislocation motion, void initiation growth, and coalescence (i.e., upper limit of applicability
of the MC).
• The MC KJc model may not be applicable at temperatures below which deformation occurs
predominantly by twinning (T0-160oC).
Assessment of additional data combined with the nine datasets used by Wallin further confirmed
the temperature dependence described by Eqn. (3-5) [61, 62]. Moreover, the data suggest that,
similar to the initiation MC, the temperature dependence of KIa is not affected strongly by
irradiation [62].
3.2.3 Distribution
Wallin observed that the scatter in KIa data was less than that observed for KJc. He assumed a
log-normal distribution so that the proportional scatter in KIa was constant, matching the
empirical evidence. A log normal distribution with a variance equal to 18% of the mean value
was found to match the data well [60]. Using Wallin’s log normal distribution the crack arrest
toughness curve at percentile, p, is defined as:
3-7
Fracture Toughness Models in CC N-830-1
𝒑𝒑
for lower bound curves: 𝑲𝑲𝑰𝑰𝑰𝑰 = 𝑲𝑲𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎
𝑰𝑰𝑰𝑰 �𝟏𝟏 − 𝟎𝟎. 𝟏𝟏𝟏𝟏𝑴𝑴𝒑𝒑 � Eq. 3-7
(𝟏𝟏−𝒑𝒑)
𝑲𝑲𝑰𝑰𝑰𝑰 = 𝑲𝑲𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎 �𝟏𝟏 + 𝟎𝟎. 𝟏𝟏𝟏𝟏𝑴𝑴𝒑𝒑 � Eq. 3-8
for upper bound curves: 𝑰𝑰𝑰𝑰
Using Eqn. (3-7), a value for p of 0.05 will produce a 5% lower bound curve. A 95% upper
bound curve is similarly defined using Eqn. (3-8). When using either of these equations, the
value of p cannot exceed 0.5 (0 < p < 0.5). There is no effect of component thickness, crack
front length, or product form on Eqns. (3-7) and (3-8).
3-8
Fracture Toughness Models in CC N-830-1
in RPV applications. The size effect observed in crack initiation toughness is due to the weakest
link nature of the initiation event, but crack arrest is not a weakest-link phenomena.
3-9
Fracture Toughness Models in CC N-830-1
𝑱𝑱𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎
𝑰𝑰𝑰𝑰 = 𝟏𝟏. 𝟕𝟕𝟕𝟕{𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏 ∙ 𝐞𝐞𝐞𝐞𝐞𝐞[−𝟎𝟎. 𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎(𝑻𝑻 + 𝟐𝟐𝟕𝟕𝟑𝟑. 𝟏𝟏𝟏𝟏)] − 𝟑𝟑. 𝟑𝟑𝟑𝟑𝟑𝟑} + 𝑱𝑱𝒄𝒄(𝑼𝑼𝑼𝑼) − 𝚫𝚫𝑱𝑱𝑰𝑰𝑰𝑰(𝑼𝑼𝑼𝑼) Eq. 3-9(a)
Where T is the temperature in oC and the reference JIc value is taken at 288o C. Jc(US) and ∆JIc(US)
are given by:
𝟏𝟏−𝝊𝝊𝟐𝟐
𝑱𝑱𝒄𝒄(𝑼𝑼𝑼𝑼) = {𝟑𝟑𝟑𝟑 + 𝟕𝟕𝟕𝟕 × 𝐞𝐞𝐞𝐞𝐞𝐞[𝟎𝟎. 𝟎𝟎𝟎𝟎𝟎𝟎(𝟒𝟒𝟒𝟒. 𝟖𝟖𝟖𝟖𝟖𝟖 − 𝟎𝟎. 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝑻𝑻𝒐𝒐 )]}𝟐𝟐 Eq. 3-9(b)
𝑬𝑬𝑼𝑼𝑼𝑼
𝚫𝚫𝑱𝑱𝑰𝑰𝑰𝑰(𝑼𝑼𝑼𝑼) = 𝟏𝟏. 𝟕𝟕𝟕𝟕{𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏 ∙ 𝐞𝐞𝐞𝐞𝐞𝐞[−𝟎𝟎. 𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎(𝑻𝑻𝑼𝑼𝑼𝑼 + 𝟐𝟐𝟐𝟐𝟐𝟐. 𝟏𝟏𝟏𝟏)] − 𝟑𝟑. 𝟑𝟑𝟑𝟑𝟑𝟑} Eq. 3-9(c)
{𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐−𝟕𝟕𝟕𝟕.𝟒𝟒𝑻𝑻𝑼𝑼𝑼𝑼 }
𝑬𝑬𝑼𝑼𝑼𝑼 = Eq. 3-9(d)
𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏
3.3.3 Distribution
The distribution on JIc is a function of both temperature and prior hardening, as defined by the
mean value of JIc at 288o C. Based on the work presented by Kirk, et al. [65], the standard
deviation for JIc, σΔJIc , is defined in CC N-830-1 as:
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Fracture Toughness Models in CC N-830-1
𝑱𝑱𝑰𝑰𝑰𝑰(𝟐𝟐𝟐𝟐𝟐𝟐)
𝑷𝑷𝟏𝟏 = − 𝟎𝟎. 𝟒𝟒𝟒𝟒 Eq. 3-10(e)
𝟏𝟏𝟏𝟏𝟏𝟏
𝑱𝑱𝑰𝑰𝑰𝑰(𝟐𝟐𝟐𝟐𝟐𝟐)
𝑷𝑷𝟐𝟐 = + 𝟎𝟎. 𝟓𝟓𝟓𝟓 Eq. 3-10(f)
𝟖𝟖𝟖𝟖𝟖𝟖
The ductile crack initiation toughness curve at percentile, p, or (1-p), is defined as follows:
𝒑𝒑
𝑱𝑱𝑰𝑰𝑰𝑰 = 𝑱𝑱𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎 − 𝝈𝝈𝚫𝚫𝑱𝑱𝑰𝑰𝑰𝑰 𝑴𝑴𝒑𝒑 Eq. 3-11(a)
for lower bound curves 𝑰𝑰𝑰𝑰
(𝟏𝟏−𝒑𝒑)
𝑱𝑱𝑰𝑰𝑰𝑰 = 𝑱𝑱𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎 + 𝝈𝝈𝚫𝚫𝑱𝑱𝑰𝑰𝑰𝑰 𝑴𝑴𝒑𝒑 Eq. 3-11(b)
for upper bound curves: 𝑰𝑰𝑰𝑰
As an example, a value for p of 0.05 would produce a 5% lower bound curve using Eqn. (3-11a),
and a 95% upper bound curve using Eqn. (3-11b). When using Eqns. (3-11a) and (3-11b), the
value of p should not exceed 0.5 (0 < p < 0.5).
where:
σG = the prior hardening term
kd-1/2 = the Hall-Petch grain boundary hardening term
Kε1/2 = the strain hardening term
B0 and β0 = material constants
𝛽𝛽1 𝑙𝑙𝑙𝑙𝜖𝜖̇ = term that accounts for dynamic strain aging in BCC materials
T = temperature (K)
All three of the terms in the <brackets> are athermal terms, and the terms in [square brackets] are
the thermal terms.
Only the thermal terms were used in characterizing the upper shelf fracture behavior. JIc is
characterized using quasi-static test rates, so the dynamic strain aging term was set to a constant
3-11
Fracture Toughness Models in CC N-830-1
using 𝜀𝜀̇ equal to 0.0004/sec. To develop an empirical fit to identify the constants, the data was
characterized relative to a reference JIc value, arbitrarily chosen as the JIc at 288o C, and
compared to the difference in flow stress between that predicted by the Z-A equation and the
flow stress measured at a reference temperature:
Where α has units of mm to convert from stress units (MPa) inside the {brackets} to J units of
kJ/m2.
Substituting the Z-A thermal flow equation for ∆𝜎𝜎𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 , and taking the reference temperature as
288oC for both JIc and σflow, gives the temperature-dependence equation for JIc as:
∆𝑱𝑱𝑰𝑰𝑰𝑰 ≡ 𝑱𝑱𝑰𝑰𝑰𝑰 (𝑻𝑻) − 𝑱𝑱𝑰𝑰𝑰𝑰(𝟐𝟐𝟐𝟐𝟐𝟐) = 𝜶𝜶�𝑩𝑩𝟎𝟎 𝒆𝒆𝒆𝒆𝒆𝒆[−𝜷𝜷𝟎𝟎 𝑻𝑻 + 𝜷𝜷𝟏𝟏 𝑻𝑻𝑻𝑻𝑻𝑻(𝜺𝜺̇ )] − 𝝈𝝈𝒇𝒇𝒇𝒇𝒇𝒇𝒇𝒇(𝟐𝟐𝟐𝟐𝟐𝟐) � Eq. 3-14
This Z-A dislocation mechanics-based equation was used as the basis for the empirical fitting
performed to develop the JIc versus temperature equation as described in detail in References
[11, 64]. The empirical basis for the model is described in the following section of this report.
The expected scatter in the JIc data at a given temperature can be understood in the context of
dislocation mechanics. Ductile fracture occurs by accumulation of dislocations at defects in the
material upon loading. When a critical dislocation density is reached, voids initiate, followed by
growth of the void and coalescence with other voids to form a crack. The energy absorbed by
dislocation motion leading to ductile crack initiation in a specimen, and therefore the energy
defining the upper shelf fracture toughness, is controlled by the strain history and defect density
of the material prior to loading, as well as the ease with which dislocations move within the
material. Dislocation motion is controlled by the temperature-dependent Peierls-Nabarro stress,
which in turn is controlled by the short-range obstacles to dislocation motion provided by the
lattice atoms (BCC crystal structure in the case of ferritic steels). The total energy absorbed
prior to crack initiation is controlled by the long-range barriers to dislocation motion, i.e., the
defects in the material (vacancies/interstitials, other dislocations and precipitates/particles) [11].
The higher the initial defect density in the material, the less energy is absorbed by movement of
dislocations upon loading before the critical dislocation density is obtained for void initiation and
growth. As a result, materials that have a higher yield strength and hardness have a lower JIc at
any given test temperature and show less scatter in the data compared to specimens that have a
lower yield strength and hardness. The microstructural features controlling hardness and yield
strength will not affect the temperature-dependence of dislocation motion for the reasons stated
in the KJc Theoretical Basis Section, but they will affect the scatter in the JIc data at any given
temperature. Based on this understanding of the dislocation-based, ductile fracture process, it is
expected that scatter in JIc data varies with temperature and the mean value of JIc at any given
temperature.
3-12
Fracture Toughness Models in CC N-830-1
Navy. The data were filtered to ensure that only data obtained at quasi-static loading rates were
used, that each dataset had at least five JIc values, and that each dataset contained JIc values
obtained from at least two different temperatures. This filtering resulted in a total of 809 JIc
values that were appropriate to use in the development of the upper shelf fracture toughness
model.
Starting with Eqn. (3-14), an iterative process was used to determine the constants in Eqn. (3-14)
[64]. A reference temperature, Tref, was arbitrarily set to 288oC, as there was a significant
amount of data at this test temperature. Both ∆σflow and ∆JIc are zero at Tref, resulting in σT (the
value of the thermal part of the flow stress at 288 oC) equal to 3.3 MPa using starting values for
the constants in the Z-A equation for ferritic steels of B0 = 1,000 MPa, β0 = 0.0074 K-1, and
β1 = 0.004 K-1 [66], and taking α to be 2.1 mm based on a preliminary analysis of a small
dataset. The equation was fit to individual datasets using a least squares method, thereby
establishing a value of JIc at 288oC for every data set. The value of α was then adjusted to
minimize the sum of squares residuals between each measured ∆JIc value (∆JIc = JIc(T) – JIc(288))
and each predicted value of ∆JIc (∆JIc=α{B0exp[-β0T+β1Tln𝜀𝜀̇]-σflow(288)}), which required 15
iterations to converge. Once α was minimized for all datasets, the 809 values were considered
together, and a final iteration was performed to adjust the constants to define a best estimate
model to represent all ferritic steels. Inserting the constants determined from the least squares
fitting method into Eqn. (3-14) gives the temperature dependence of the JIc MC:
𝒌𝒌𝒌𝒌
∆𝑱𝑱𝑰𝑰𝑰𝑰 ≡ 𝑱𝑱𝑰𝑰𝑰𝑰 (𝑻𝑻) − 𝑱𝑱𝑰𝑰𝑰𝑰(𝟐𝟐𝟐𝟐𝟐𝟐) = 𝟏𝟏. 𝟕𝟕𝟕𝟕{𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏[−𝟎𝟎. 𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎 + 𝟎𝟎. 𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎(𝜺𝜺̇ )] − 𝟑𝟑. 𝟑𝟑} � � 𝟐𝟐 � Eq. 3-15
𝒎𝒎
The original work to develop Eqn. (3-15) did not consider characterization of the scatter in the
data at any one temperature [11]. Follow-on work by Kirk, et al. [63] using the same data
demonstrated the scatter in ∆JIc to be temperature-dependent, with the standard deviation given
by:
3-13
Fracture Toughness Models in CC N-830-1
explanations for this outlier data set. A more quantitative assessment of the scatter in the EURO
Forge specimens was performed to confirm the observations made in plotting the data relative to
the model predictions. The outcome of that assessment was a finding that the scatter in the
EURO Forge data was higher than predicted by the model, and that the scatter had an athermal
component that had not been observed previously. This athermal component of the scatter was
found to scale in proportion to the mean upper shelf toughness of the dataset, i.e., higher
toughness materials (such as the EURO Forge material) exhibited higher scatter than did lower
toughness materials [65]. This aspect of the scatter may not have been observed in the upper
shelf model development study due to the limited amount of JIc values at higher temperatures in
the original database.
Figure 3-1
Comparison of the temperature dependence exhibited by the JIc data for the EURO Forge
with the model proposed in [65] (i.e., Eqn. (3-15) with uncertainty bounds based on Eqn
(3-16)).
A detailed quantitative assessment of the scatter in the EURO Forge data, combined with the
data used in the original model development, was performed relative to both the temperature and
mean value of JIc for each dataset [65]. The TUS model [11] (described in Chapter 4) was used to
censor data at low upper shelf temperatures that may have cleavage components to the fracture
mode, and the JIc data was divided into five bins based on the percentile of the total distribution
of JIc(288) for all datasets the average JIc(288) value for each dataset fell into. Datasets for which
the JIc(288) value fell between the zero and 20th percentiles were placed into the first bin, between
the 20th and 40th percentiles were placed in the second bin, and so on (the JIc(288) value of 283
kJ/m2 of the EURO Forge placed it at the 83rd percentile or the fifth bin). The standard deviation
for each bin was calculated, and this showed a trend of increasing standard deviation with
increasing JIc(288). Based on this analysis, a fit of the form:
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Fracture Toughness Models in CC N-830-1
σ ∆J = A ⋅ e (B⋅T )
ˆ
Ic
Eq. 3-17
was identified to represent the standard deviation in JIc. In this equation, A and B are fitting
parameters, and 𝑇𝑇� is the test temperature expressed relative to 288oC, which was the reference
temperature used to define the bins. Fitting this equation to the data in each of the five bins
resulted in definitions of the A and B as shown in Eqn. (3-10).
The distribution model described by Eqn. (3-10) was developed using all the available JIc data
(the original 91 datasets and the additional EURO Forge 45 JIc values). In Figure 3-2, the JIc
temperature dependence model from Eqn. (3-9) is combined with the JIc scatter model of Eqn.
(3-10) and compared to three data sets having considerably different upper shelf toughness
levels. This comparison demonstrates the ability of the combined model from Eqns. (3-9) and
(3-10) to represent the temperature dependence and scatter of a wide range of toughness
conditions. Further validation efforts await additional JIc data.
3-15
Fracture Toughness Models in CC N-830-1
Figure 3-2
Comparison of the revised JIc model, Eqns. (3-9) and (3-10), with JIc data from steels
having three different upper shelf toughness (JIc(288)) levels [65].
3-16
4
FRACTURE TOUGHNESS LINKAGE MODELS IN CC N-
830-1
While the models summarized in Chapter 3 describe the temperature dependence and scatter
inherent to different measures of the fracture toughness of ferritic steels, they do not describe the
interrelationship of the different toughness measures. While general relationships have long
been recognized (e.g., steels with low transition temperatures tend to have high toughness on the
upper shelf), it is only in the last 10 to 15 years that systematic trends common to all ferritic
steels have been noted.
In this chapter, three models that link the KJc, KIa, and JIc toughness models described in Chapter
3 are summarized. These linkage models include the relationship between cleavage crack
initiation (KJc) and upper shelf (JIc) fracture toughness data, the relationship between cleavage
crack initiation (KJc) and cleavage crack arrest (KIa) fracture toughness data, and the relationship
between upper shelf (JIc) crack initiation and upper shelf crack growth (J-R) fracture toughness
data. These three linkage models, taken together, provide the relationships that link all
toughness values to a single reference value, T0.
4.1 The Relationship Between Cleavage Crack Initiation (KJc) and Upper
Shelf (JIc); TUS
Conventionally, the transition fracture toughness and upper shelf fracture toughness of ferritic
steels have been viewed as either separate properties or as properties between which only
general/qualitative relationships exist. Information presented in 2004 by EricksonKirk [11] and
further developed in 2006 by EricksonKirk, et al. [14] demonstrated the opposite to be true. The
EricksonKirk studies [11, 14] showed transition fracture toughness and upper shelf fracture
toughness to be directly related because the microstructural features responsible for both the
temperature dependence of fracture toughness and for the magnitude of fracture toughness at any
given temperature are the same in both transition and on the upper shelf. Data from several
dozen steels demonstrated a consistent linear relationship between T0 and the temperature at
which KJc (converted to Jc) and JIc are equal, termed TUS, over a range of T0 values exceeding
300°C (-180°C < T0 < +140°C).
4-1
Fracture Toughness Linkage Models in CC N-830-1
200
TUS [ C] 50
o
Weld
0 Plate
Forging
-50 HSLA
Mild Steel
-100 All
Linear (All)
-150
-200 -150 -100 -50 0 50 100 150 200
T o [oC]
Figure 4-1
Relationship between TUS and T0 [11, 14]
4-2
Fracture Toughness Linkage Models in CC N-830-1
100 MPa√m
TUS
To
Temperature
Figure 4-2
Schematic illustrating the relationship between the transition and upper shelf toughness,
and defining TUS as the intersection of the Wallin MC and the upper shelf MC.
4-3
Fracture Toughness Linkage Models in CC N-830-1
which T0 and TUS can be determined from measured data. This accuracy is strongly influenced
by the size of individual KJc and JIc data sets and not by the material variability. The KJc MC is
very steep at the transition from cleavage to upper shelf behavior, so predictions of upper shelf
behavior from T0 are very sensitive to very small variations, or uncertainties, in T0. This was
confirmed by EricksonkKirk, et al. [14] in their investigation that studied the effects of dataset
size (i.e., how many KJc and JIc values were available for determining T0 and TUS) on the fitting
error of Eqn. (4-1). They found that the error in the fit was inversely proportional to the number
of both KJc and JIc values in the dataset; the higher the number of values, the smaller the fit error.
The conclusion was that the uncertainty in the TUS model is not a material-dependent effect, but
rather is due to epistemic uncertainties on measured T0 and TUS determinations.
4.2 The Relationship Between Cleavage Crack Initiation (KJc) and Arrest
(KIa)
It is generally recognized that steels with higher amounts of hardening (that is, a higher T0 value)
tend to have less separation between the cleavage crack initiation (KJc) and cleavage crack arrest
(KIa) curves. This relationship was first shown by Wallin and Rintamma in 1998 [60] using a
large quantity of data. Further work on this concept, which added more data and provided a
physical basis for the observation, was reported in 2002 and 2014 by Kirk, et al. [61, 73]. Kirk’s
2014 work included a large amount of data that was used to refine the models presented in the
1998 and 2002 studies [60, 61]. However, it should be noted that even though the 2014 work
included considerably more data than that reported in either 1998 or 2002, the relationship did
not change significantly.
4-4
Fracture Toughness Linkage Models in CC N-830-1
160
120 Base
TKIa - To [°C]
Weld
HAZ
80
High Yield
Low Yield
40 Original Fit
All Data Fit
RPV Data Fit
0
-200 -100 0 100 200
To [°C]
Figure 4-3
Illustration of variation in the temperature separation between the KIa and KJc master
curves as a function of T0 [73].
Eqn. (4-2) is represented by the dashed black line labeled “All Data Fit.”
4-5
Fracture Toughness Linkage Models in CC N-830-1
Figure 4-4
Illustration of the effects of strain rate increase on yield strength elevation for materials
having different degrees of prior strain hardening [61].
4-6
Fracture Toughness Linkage Models in CC N-830-1
where A and B are fitting parameters and TKIa and T0 are in oC. The authors compared the
results to the original fit [61], including a statistical assessment relative to fit bias, trend with T0,
and uncertainty, or scatter, about the mean to assess the log-normal distribution fit the data.
The conclusions of the statistical assessment [73] were as follows:
• the original TKIa/T0 relationship [60, 61] well-represented each of the datasets (well within
the margin of error),
• there were no trends exhibited by any of the data that clearly differed from trends exhibited
by all the data, and
• limiting the data to only RPV steels did not change the fit. The trends observed for only the
RPV data were the same as trends observed for all or the data.
This statistical assessment validates the use of Eqn. (4-2) for use in assessment of all ferritic
steels.
4.3 The Relationship Between Upper Shelf (JIc) Crack Initiation and Upper
Shelf Crack Growth (J-R)
All other models used in Code Case N-830-1, and summarized above, predict toughness values,
or link different toughness values, as a function of T0. However, prior to efforts undertaken
within the WGFE to develop Code Case N-830-1, all J-R curve models were formulated as a
function of Charpy upper shelf energy (USE) instead of T0 [74-76]. Therefore, in 2015 Kirk,
Erickson, and Stevens [77] undertook development of a model to predict the J-R curve from
information on JIc and the product form of the material. JIc, and its temperature dependence are
predicted from T0 as shown in Eqns. (3-9). Combining the models in Eqns. (3-9) with those
presented earlier in this section provides a means to estimate J-R curves from T0.
4-7
Fracture Toughness Linkage Models in CC N-830-1
Where C and n are parameters fit to the J vs. ∆a data for a particular tested specimen. The
database used in Reference [74] showed strong correlations between JIc and both the C and n
fitting parameters. The following model was developed from the data summarized in Table 4-1
[77].
𝑱𝑱𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎
𝑿𝑿 = 𝑪𝑪 × ∆𝒂𝒂𝒏𝒏 Eq. 4-4(b)
𝑪𝑪 = 𝟏𝟏. 𝟔𝟔 × 𝑱𝑱𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎
𝑰𝑰𝑰𝑰 Eq. 4-4(c)
In these equations, “X” is used as a subscript for compactness and signifies a particular amount
of ductile crack extension, or Δa, in mm. Values of J at a particular ductile crack extension (for
example, the value of J at 2.54 mm (0.1 inch)) can be determined by using these equations.
Also, the entire J-R curve can be produced by solving these equations for a range of Δa values.
Lower and upper bounds on J-R can also be predicted using the following formula:
𝒑𝒑
𝑱𝑱𝑿𝑿 = 𝒆𝒆𝒆𝒆𝒆𝒆�𝒍𝒍𝒍𝒍[𝑱𝑱𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎 ] − 𝑴𝑴𝒑𝒑 × 𝑹𝑹𝑹𝑹𝑹𝑹𝑹𝑹� Eq. 4-5(a)
for lower bound curves: 𝑿𝑿
(𝟏𝟏−𝒑𝒑)
= 𝒆𝒆𝒆𝒆𝒆𝒆�𝒍𝒍𝒍𝒍[𝑱𝑱𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎 ] + 𝑴𝑴𝒑𝒑 × 𝑹𝑹𝑴𝑴𝑴𝑴𝑴𝑴� Eq. 4-5(b)
for upper bound curves: 𝑱𝑱𝑿𝑿 𝑿𝑿
The value of p should not exceed 0.5. Values of root mean square deviation (RMSD) for
different product forms appear in Table 4-1. There is no effect of component thickness or crack
front length on Eqns. (4-4) and (4-5).
Table 4-1
RMSD values for different product forms.
It is noted that the values of the coefficients contained in Eqns. 4-4(c) and 4-4(d) and the RMSD
values in Table 4-1 differ from those presented in [77]. Analyses subsequent to those described
in [77] identified errors which have been corrected here, as explained in [101].
4-8
Fracture Toughness Linkage Models in CC N-830-1
where C, D, n, n1 and n2 are fitting parameters used to fit individual sets of J-∆a data. Both
equations were determined to fit the data well for small amounts of crack extension, but the three
fitting-parameter form shown in Eqn. (4-6b) provided a more accurate representation of the data
at larger crack extensions. Based on these findings, Kirk, et al. developed the J-R/T0 model
using Eqn. (4-6b).
Correlations were identified between JIc and the J-R curve fitting parameter C, and between the
J-R curve fitting parameters C and n. The goal was to develop a correlation between J-R and T0
since it was already established that JIc is correlated to T0.
Best fit parameters were developed using the two-parameter and three parameter models, with
and without variability due to product form. Based on comparisons of the model predictions to
measured data relative to bias and scatter, the two-parameter model, which accounts only for the
effects of product form in predicting the scatter about the mean, was selected for incorporation
into CC N-830-1. This is the model defined by Eqns. (4-4) and (4-5).
Table 4-2
Composition of the J-R curve database.
# of Unirradiated # of Irradiated
Product Form Totals
Specimens Specimens
Forging (A508) 55 7 62
Plate (A533B) 62 18 80
RPV Welds 30 29 59
4-9
Fracture Toughness Linkage Models in CC N-830-1
4-10
5
IMPLICATIONS OF PROPOSED CHANGES
5.1 Introduction
The changes adopted in Code Case (CC) N-830-1 are an alternative to the RTNDT-indexed KIc
fracture toughness curve prescribed in Section XI, Nonmandatory Appendix A with curves that
better reflect the scatter and temperature dependence observed in material fracture toughness
from lower shelf, through transition to upper shelf behavior, including crack arrest. The RTNDT-
indexed KIc curve bounds most, but not all, of the available fracture toughness data [12] because
it does not fully account for the uncertainty inherent in using the Charpy-based RTNDT to index a
fracture toughness curve, and the KIc curve was developed based on a limited fracture toughness
dataset. Using the updated CC N-830-1 fracture toughness models eliminates the implicit
conservatism inherent in the RTNDT-indexed KIc curve method, and replaces it with a full
distribution of toughness curves that more consistently and accurately represents fracture
toughness behavior and enables selection of a bounding value that explicitly and quantitatively
accounts for uncertainties. This chapter discusses the sources and treatments of uncertainties in
the Appendix A flaw evaluation methodology, in the original CC N-830 method adopted in
2014, and in the new CC N-830-1 method and compares the material fracture toughness curves
contained in each their ability to represent measured fracture toughness data.
5-1
Implications of Proposed Changes
In this chapter, the sources and treatment of uncertainties defined by relevant flaw evaluation
codes are discussed with regard to the implications of the changes in CC N-830-1, and compared
to provide a foundation for the proposed treatment of uncertainties in a future revision to CC N-
830-1. This discussion is included to help place context on the new fracture toughness models
incorporated into CC N-830-1 and their intended use.
The typical uncertainties associated with FFS assessments are divided into three parts for this
discussion: (1) uncertainty due to flaw size, (2) uncertainty due to applied stress, and (3)
uncertainty due to the material resistance to crack extension characterized by the material
fracture toughness. These three sources of uncertainties are described in the following sections,
followed by a discussion of how these uncertainties are treated in various flaw evaluation codes.
5-2
Implications of Proposed Changes
through the component thickness (whether the stresses are fit using a polynomial or linear stress
distribution, interpolated), non-linear behavior (e.g., plasticity), etc. These analyst-dependent
factors can significantly alter the calculated applied stresses, and therefore lead to variations in
the estimate of critical flaw size. This is particularly true when the crack driving force, KI-applied,
calculated from the stresses, flaw size and location are compared to the allowable toughness,
KJcmaterial, in the steep part of the fracture toughness transition curve [79].
5-3
Implications of Proposed Changes
flaw. Generally, smaller flaws are oversized by UT equipment, and larger flaws are undersized.
These differences are, in part, caused by the physical characteristics of the equipment. For
example, flaws that are smaller than the UT wavelength cannot be sized; in this situation, an
echo from the UT equipment will typically be sized as the wavelength of the UT beam (see
Figure 5-1, top). For large indications that interact with the UT beam on multiple scans, flaw
size is more difficult to estimate because it is more difficult to precisely locate the flaw tips (see
Figure 5-1, bottom). While other factors not discussed here influence UT estimates, and while
some examples exist of flaw under-sizing by UT, the factors discussed here make the probability
of an overcall (over-estimating the physical size of the flaw) more likely than that of an
undercall. If the flaw size is overestimated the ligament either between one flaw and another
situated nearby, or between the subject flaw and the free surface of the component will be
underestimated. Under-estimation of the ligament increases the likelihood of adjacent flaws
being treated as a single larger flaw, or of near-surface flaws being classified as surface-breaking
via the application of flaw interaction rules, as will be discussed in the following paragraphs.
Figure 5-1
Schematic illustration of physical causes for systematic over-estimation of flaw size using
UT.
5-4
Implications of Proposed Changes
Article IWA-3000 contains procedures for characterizing flaws detected during NDE. IWA-
3300 provides methods to conservatively bound flaw sizes, and provides proximity rules for
determining when subsurface flaws should be treated as surface flaws, and for when multiple
flaws should be combined and treated as a single, larger flaw. These proximity rules are based
on fracture mechanics assessment of interacting flaws, and generally combine two adjacent flaws
when the stress intensity factor of one flaw affects the adjacent flaw by more than about 15%.
Thus, the simplification of combining adjacent flaws tends to be conservative. A subsurface
flaw is treated as a surface flaw if the distance between the flaw and the component surface is
less than or equal to 0.4d, where 2d is the through-thickness measured depth of the flaw. Two
flaws (either surface or internal) are combined, with the overall flaw dimension given by the
rectangle encompassing both flaws, if the smallest distance between the flaws is less than or
equal to the larger of the two flaw depths. The Section XI proximity rules have been shown to
be conservative in work that assessed surface flaw interactions [80, 81].
Much of the conservatism in the Section XI flaw evaluation procedure arises from the
simplifications made to what is, essentially, a complex problem, as described in Section B-2 of
EPRI NP-719-SR [6]:
“Recognizing the limits of ultrasonic examination techniques to define precisely
the dimensions, areas, and orientation of flaws, the code rules incorporate many
simplifications that obviate the need to determine the precise flaw size and
orientation”
Section XI flaw evaluation assumes that all observed indications, such as crack-like defects, slag
inclusions, porosity, lack of weld fusion, laminations, and any combinations thereof should be
treated as planar cracks. In addition, to simplify the analyses of detected flaws, irregularly
shaped flaws are represented by idealized simple geometric shapes. Thus, the development of
flaw standards criteria was simplified to facilitate the application of the principles of fracture
mechanics [6]. Such considerations were based, in large part, on judgements rather than precise
science, and their continued use is supported by field observations.
Experimental evidence suggests that the stress fields of two surface cracks will begin to interact
when the distance between them is between 0.0d and 0.75d, where d is the depth of the surface
flaws. This is less than the value of d adopted in IWA-3300. The interaction of the stress fields
of two subsurface flaws is more constrained than for surface flaws, so using the surface flaw
proximity criterion for subsurface flaw spacing is even more conservative [81]. Dulieu and
Lacroix provide further evidence of this conservatism in their assessment of the flaw interaction
rules for quasi-laminar hydrogen flakes [80]. They show that when flaws grouped by interaction
rules are instead analyzed as separate flaws, the resultant driving force on the un-grouped flaws
drops by a factor of 2 to 3.
To date, the best available quantitative treatment of the total uncertainties associated with NDE
may be estimated from the work performed by the EPRI NDE Center. EPRI’s Performance
Demonstration Initiative (PDI) estimates NDE uncertainties, and includes development of
models that describe the probability of detection (POD) and sizing accuracy of flaws using UT
techniques [78]. Although this work provides quantitative characterization of the uncertainty
inherent in the NDE procedures, it does not assess the uncertainties associated with the IWA-
3300 flaw proximity rules.
5-5
Implications of Proposed Changes
ASME Appendix A does not currently address NDE uncertainties. Flaw sizes estimated from
UT exams are used as input to ASME Code flaw evaluations. ASME Appendix A requires that
the end-of-evaluation-period flaw size be used, so the UT flaw size must be increased by the
amount of crack growth anticipated over the evaluated period of operation before additional
inspection or repair is performed. As a result, most UT flaw sizes are increased by some amount
for flaw assessment. For these reasons, it is recommended that the future revision of CC-N830-1
consider NDE uncertainties associated with flaw size and characterization based on EPRI’s POD
and sizing accuracy work [78]. It is anticipated that the next revision of CC N-830-1 will adopt
partial structural factors (PSFs) to enable an explicit accounting of flaw size uncertainty.
5-6
Implications of Proposed Changes
persists throughout the transient. This is very conservative compared to the more
complex method of evaluating time-varying thermal stresses throughout a transient,
which tend toward zero as isothermal conditions are achieved. Thus, for portions of
transients, the recommendations of G-2214.3 can be very conservative.
– Section XI Appendix K: For Service Level A and B loadings, K-2200(a) recommends
that the applied pressure inside the vessel be estimated as 1.15 times the accumulation
pressure (PACCUM) 4 for assessment of ductile crack initiation and 1.25 times PACCUM for
assessment of ductile crack growth stability. This guidance is grossly conservative, as
demonstrated by the following facts:
o The Code defines PACCUM as 1.1 times the design pressure, PDESIGN (again see
footnote 3).
o The operating pressure, POPERATING, is 0.9 times the PDESIGN.
o POPERATING is therefore 0.9÷1.1 = 0.81×PACCUM. Combining this with the
recommendations of K-2200(a) to use a pressure of either 1.15×PACCUM or
1.25×PACCUM, the result is that K-2200(a) recommends use of a pressure between 1.4
and 1.52 times higher than POPERATING. Additionally, it should be noted that the
safety relief valves prevent the RPV pressure from ever reaching PACCUM.
• Structural Factors: Structural factors appear in various places in the Code. These structural
factors normally increase the applied value of stress to introduce a margin between the
allowed flaw size and the critical flaw size. Some examples that apply exclusively to stress
estimation are as follows:
– Section XI Appendix G: G-2215 specifies a structural factor of 2.0 on pressure for
normal heat-up and cool-down loading. For hydro-test loading, G-2400(b) specifies a
structural factor of 1.5 on pressure.
The structural factors of √10 (for normal operating conditions) and √2 (for emergency
and faulted conditions) appear in IWB-3600 and, thus, are used in flaw evaluations
performed according to Section XI Appendix A. Since the √10 or √2 structural factors
reduce the allowable toughness, they impose a conservatism on the maximum allowed
value of applied stress times the square-root of flaw size.
In summary, the conservative nature of engineering stress analysts is further compounded by
ASME Code requirements that lead to conservative stress estimates. In all cases, the use of
structural factors increases the estimated applied stress to account for unknown-unknowns.
These factors all ensure that current stress estimates achieved following Code procedures are
conservative. It is anticipated that the next revision of CC N-830 will adopt PSFs to minimize
unnecessary conservatism and enable an explicit accounting of uncertainties associated with
stress estimation. The experience by other Code bodies that have implemented PSFs [82-84] is
4
In a PWR, PACCUM represents the maximum overshoot pressure that could result from a mass imbalance. A
mass imbalance could occur during an event when the low-temperature overpressure protection (LTOP) system and
the relief values open because the injection rate is too high. In ASME Code terminology PACCUM is defined as
being equal to 1.1 times the design pressure (1.1×PDESIGN). While BWRs have safety relief values there is no
clear equivalent to an “accumulation” pressure, so for BWRs the Code definition of PACCUM = 1.1×PDESIGN is
used along with the guidance of K-2200(a).
5-7
Implications of Proposed Changes
expected to help support the development of PSFs within ASME Section XI in a revision to CC
N-830-1.
5-8
Implications of Proposed Changes
Figure 5-2
Cumulative probability distribution function showing the relationship between RTNDT and
T0.
Figure 5-3
Plot of KJc, 1% MC bound, 99% MC bound, the RTNDT-indexed KIc curve, and the RTT0-
indexed KIc curve.
5-9
Implications of Proposed Changes
Figure 5-4
Plot of KJc, 1% MC bound, 99% MC bound, the RTNDT-indexed KIc curve divided by √2, and
the RTT0-indexed KIc curve divided by √2 (for emergency/faulted operating conditions).
Figure 5-5
Plot of KJc, 1% MC bound, 99% MC bound, the RTNDT-indexed KIc curve divided by √10, and
the RTT0-indexed KIc curve divided by √10 (for normal/upset operating conditions).
5-10
Implications of Proposed Changes
5.4 CC N-830
The original version of CC N-830 was adopted by ASME in 2014, and permits the 5th percentile
T0-indexed KJc MC to be used in lieu of either the RTNDT- or RTT0-referenced KIc curve for
determining the fracture toughness for comparison to the applied stress intensity factor in IWB-
3612. Following the procedure in IWB-3612, the value of fracture toughness determined using
CC N-830 is divided by the structural factors described in Eqn. (5-1) to account for uncertainties
from all sources. In contrast, the T0-indexed KJc MC provides a best-estimate model of material
fracture toughness, so using a 5th percentile lower bounding value from this curve provides a
conservative estimate of material fracture toughness that is consistent with two-sigma bounds
commonly adopted in regulatory assessments. When combined with the structural factors in
IWB-3612, the conservatism in the estimate of material fracture toughness increases
substantially as shown in Figure 5-6.
Dividing the 5th percentile CC N-830 MC by √2 to assess emergency/faulted operating
conditions results in a bounding value of the data approximately equal to the 1st percentile MC
bound. Therefore, this curve bounds 99% of the toughness data and accounts for 99% of the
expected scatter. Dividing the 5th percentile CC N-830 MC by √10 to assess normal/upset
operating conditions results in excessive conservatism; the resulting curve bounds all known KJc
toughness data and is equal to the conservatism present in the ASME Appendix A RTT0-indexed
KIc curve divided by √10 (shown in red in Figure 5-6).
Figure 5-6
Plot of KJc, 1% MC bound, 99% MC bound, the CC N-830 5% MC bound, the CC N-830 5%
MC divided by √2, and the CC N-830 5% MC divided by √10 (for emergency/faulted and
normal operating conditions, respectively).
5-11
Implications of Proposed Changes
5-12
Implications of Proposed Changes
Figure 5-7
Plot of KJc, with the 1% MC bound, 99% MC bound, the CC N-830-1 1% MC bound, the CC
N-830 5% MC bound divided by √2, and the Appendix A RTT0-indexed KIc curve divided by
√2 (all for emergency/faulted operating conditions).
Note that the 1% MC and the 5% MC divided by a √2 structural factor coincide over most of the
temperature region shown.
5-13
Implications of Proposed Changes
Figure 5-8
Plot of KJc, 1% MC bound, 99% MC bound, the 0.5% MC bound (CC N-830-1), the 5% MC
bound divided by √10 (CC N-830), and the RTT0-indexed KIc curve divided by √10 (Appendix
A) for normal/upset operating conditions.
5.6 Summary
The method described in ASME Section XI, Non-Mandatory Appendix A for evaluating the
fracture tolerance of flaws is a deterministic procedure containing many implicit and explicit
conservatisms to account for the known and unknown sources of uncertainty inherent in the
fracture mechanics evaluation. Implicit conservatisms are contained in NDE sizing and location
procedures, flaw proximity rules, and stress analysis methods. Implicit conservatisms are also
contained in the methods used to define a material fracture toughness, including use of a lower
bound linear elastic fracture toughness curve indexed by a Charpy-based reference temperature,
or by a fracture toughness-based reference temperature with additional margin added.
Additional conservatism is explicitly applied to the material fracture toughness term by dividing
the lower bound value by a √2 or √10 structural factor depending on whether emergency/faulted
or normal operating are being evaluated.
The best-estimate models of fracture toughness contained in CC N-830-1 provide a much more
consistent representation of an extensive database of fracture toughness values than does either
the RTNDT or RTT0-indexed KIc curve, eliminating much of the implicit conservatism inherent to
the older, linear-elastic-based model. The full distribution fracture toughness curves defined in
CC N-830-1 enables selection of a bounding value that explicitly and quantitatively accounts for
uncertainties and can thus readily support not only deterministic evaluations but also
probabilistic methods.
5-14
Implications of Proposed Changes
The1st percentile bounding KJc MC curve for the emergency/faulted accident conditions is
approximately equivalent to the combination of structural factors and the 5th percentile fracture
toughness curve in accounting for uncertainties. The 0.5th percentile bounding KJc toughness
MC, without the explicit use of structural factors, provides a conservative lower bound sufficient
to account for all uncertainties. The use of the 1% and 0.5% bounding curves without structural
factors would provide a much more consistent representation of material fracture toughness
across all temperatures and conditions compared to curves reduced by structural factors. It
would be an improvement to Appendix A procedures to eliminate the existing structural factors
through the selection of an appropriate statistical bound to the fracture toughness curve or
through a combination of partial structural factors that reflect a consistent margin requirement
over the operating temperature range.
5-15
6
POTENTIAL CODE/REGULATORY APPLICATIONS OF
CC N-830-1
6.1 Introduction
CC N-830-1 provides a complete description of the fracture toughness of ferritic steel, including
all fracture toughness metrics, from the lower shelf through the upper shelf. These best-estimate
equations define the full distribution of expected toughness values, defining the temperature
dependence and scatter inherent to fracture toughness behavior. These equations can be used to
define any bounding curve to provide the desired level of conservatism in a deterministic fracture
mechanics evaluation, or they can be used to define input distributions for ferritic steel fracture
toughness for probabilistic assessments. In principle, the CC N-830-1 fracture toughness
equations can be used to define material resistance to fracture in any fracture mechanics, FFS
evaluation. Thus, the potential Code / Regulatory applications of the Code Case include any
instance for which fracture toughness is an input to an assessment or analysis. These include the
following:
Within the ASME Code
• Section XI
– The IWB 3500-1 table of allowable planar flaws.
– The acceptance criteria of IWB-3612 for regions remote from geometric discontinuities,
or of IWB 3613 for regions near geometric discontinuities
• Assessment of found flaws following the requirements of Nonmandatory Appendix A
• Evaluation of unanticipated operating events using Nonmandatory Appendix E [85]
• Assessment of pressure temperature limits using Nonmandatory Appendix G [86], including:
– G2215 Allowable pressure for shell regions
– G-2216, Risk-Informed allowable pressure
– G2223 Allowable pressure for nozzles
– G2400 for Hydrostatic Test Temperature determination
• Assessment of RPVs having low upper-self energy levels using Nonmandatory Appendix K
[8].
Within the Requirements of the NRC as Outlined within the Code of Federal Regulations
and Related Regulatory Guides
• In support of analysis of pressurized thermal shock following 10 CFR 50.61 or 10 CFR
50.61a [87]
6-1
Potential Code/Regulatory Applications of CC N-830-1
6-2
Potential Code/Regulatory Applications of CC N-830-1
Laboratory [89] on the WF-70 weld harvested from the cancelled Midland Nuclear Power Plant
in Michigan. The comparison showed that the KIR and KIc curves bounded the data, and
ultimately the NRC approved use of the -48 and 8.2°C values based on this justification. BAW-
2202 does not mention why a TNDT value was used to index the KIR and KIc curves, but it may
have had something to do with the fact that the ASTM standard was still a draft, and that there
was, at the time, no context within the ASME Code to use T0 values or KJc data.
In follow-on work first submitted to the NRC in 2002, the BWOG expanded the BAW-2202
work to establish alternative unirradiated RTNDT values, and associated σ terms, for different
heats of Linde 80 welds present in the beltline regions of B&W fabricated vessels. The topical
report, BAW-2308, uses the Master Curve reference temperature approach for determining RTT0
as described in ASME Code Case N-629 and based its generic RTT0 values on large KJc data
populations for each weld wire heat [90]; in total over 300 KJc specimens were tested. The NRC
reviewed this topical report, but required plant-specific submittals for each application of the
approach. To date the following thirteen units have been granted exemptions to use the RTT0-
based RTNDT values to demonstrate compliance with the requirements of the PTS rule (10 CFR
50.61a):
• Arkansas Nuclear Unit 1
• Davis Besse
• Oconee Units 1, 2, and 3
• Three Mile Island Unit 1
• Crystal River Unit 3
• Turkey Point Units 1 and 2
• Surry Units 1 and 2
• Point Beach Units 1 and 2
In their calculation of generic RTT0 values to use with each heat the BAW-2308 approach
includes the following factors to account for uncertainties:
• An added factor (bias) of +10°C when data from precracked Charpy specimens is used to
account for the constraint differences between bend and compact tension specimens.
• A factor included in the square-root sum-of-squares (SRSS) margin calculation of between
4°C -9.5°C to account for variability associated with test procedure and material
inhomogeneity, and
• A factor included in the SRSS margin calculation of between 1°C to 6°C to account for lack
of T0 estimation precision due to finite sample sizes.
Table 6-1 summarizes the outcome of the BAW-2308 effort, and indicates a reduction of
estimated unirradiated index temperature from 15°C to 55°C depending on the weld wire heat.
Similar to the data in Figure 5-2, these data attest to the conservatism implicit to RTNDT indexing
procedures.
Beginning in 1998 the Kewaunee Nuclear Power Plant used Master Curve data and CC N-629
[91] to obtain a license amendment to use these data in its assessment of the PTS screening
criteria (10 CFR 50.61a), in setting pressure-temperature limits (10 CFR 50 Appendix G), and as
6-3
Potential Code/Regulatory Applications of CC N-830-1
part of the surveillance program (10 CFR 50 Appendix H) [92]. Kewaunee used both irradiated
and unirradiated KJc data for the limiting circumferential weld wire heat, 1P3571. Kewaunee
was the first application to the NRC using CC N-629. For this reason, Kewaunee undertook
extensive efforts to address NRC staff questions concerning the applicability of the Master Curve
to RPV material characterization in general [46]. Kewaunee’s initial submittal to the NRC
argued that the irradiated RTNDT-based index temperature for 1P3571 could be reduced by
26.7°C. Staff concerns regarding use of KJc data from pre-cracked Charpy specimens, use of
sister plant data, and material variability changed this value to 5°C in the final safety evaluation
report.
Table 6-1
Summary of unirradiated RTT0 value for various Linde 80 weld wire heats.
** Includes 20oF addition to address NRC’s concerns with the equivalency of bounding provided by a
RTT0 indexed KIc curve.
6-4
Potential Code/Regulatory Applications of CC N-830-1
each variable, and allows adjustment of the values of the structural factors used to directly
reflect the state of knowledge concerning each variable. PSFs also provide a linkage
between deterministic and probabilistic assessments (see [91] for details).
• Nozzles: The PWROG has an effort underway entitled “Pressurized Water Reactor, Reactor
Pressure Vessel Appendix G Margins” [94]. The purpose of this project is to address an
issue identified in NRC Regulatory Issue Summary (RIS) 2014-11 [95], which states that
“All licensees should ensure that P-T limits sufficiently address all ferritic materials of the
reactor vessel, including the impact of structural discontinuities, and address the impact of
neutron fluence accumulation in accordance with the requirements of 10 CFR Part 50,
Appendix G.” This RIS identified the need for fracture toughness data for the RPV nozzle
course, which in some cases is not available in construction records. The PWROG effort has
therefore proposed to use a generic RTT0 value for nozzle-course forgings, and to also
account for the systematic through-thickness variation of RTT0 known to be responsible for
greater fracture toughness near the inner-diameter surface of the nozzle where flaws are
postulated to exist.
• PWROG Direct Fracture Toughness Initiative: The PWROG has an effort underway
entitled “Transitioning RV Integrity to Direct Fracture Toughness, Phase 1” [96]. The
topical report from this phase, which will be submitted to the NRC for review and approval,
will propose a method to use irradiated fracture toughness data to improve or demonstrate
margin in pressure-temperature limit curves. The report will address the generation of
irradiated T0 data, methods to account for material variability, and, because the irradiated T0
data will be generated in test reactors, a discussion of and, if necessary, and accounting for
flux effects.
• EPRI Effort for Multi-Data T0 Estimation: The PWROG proposed plan to measure T0 for
RPV materials will provide a large database of BOL T0 values as well as irradiated T0 values.
However, there are many critical materials for which archival test material is unavailable. In
addition, because testing of irradiated specimens is expensive, not all available archival
materials will be tested. These factors necessitate the development of alternative methods for
estimating T0 values for these materials. EPRI is supporting a program to define the
correlations necessary to enable estimation of T0 from any combination of material toughness
properties already available through previous testing, including NDT, T30, USE, KIa,
instrumented Charpy, JIc and J0.1, and strength properties. Correlations between some of
these properties have been clearly demonstrated [11, 12, 14, 64, 73, 77, 97, 98]. This
program focuses on establishing correlations between NDT, T30 and USE, and to link these
approximate measures of toughness to T0 to enable estimation of any toughness parameter
from some combination of other toughness parameters.
• EPRI T0-based Embrittlement Trend Curve: In the development of large-scale,
probabilistic models to assess fracture safety of RPVs, it is desired to move towards direct
use of fracture toughness properties instead of a correlative approach. However, this
requires development of a fracture toughness-based embrittlement trend curve (ETC), and
wide-spread acceptance of fracture toughness models. The current CC N-830-1 initiative to
implement more rigorous fracture toughness models into the ASME Code provides best
estimate models of fracture toughness in all fracture mode regimes, but it does not include a
T0-based ETC. The largest impediment to development and acceptance of a T0-based ETC
6-5
Potential Code/Regulatory Applications of CC N-830-1
is limitations on the T0 data available for materials for which Charpy data is also available
for the same or similar exposure conditions that would enable direct comparison of the
current Charpy-based ETC models. The T0 ETC program compiled a large database
containing both CVE and KJc data that was used to define both a TCVE ETC [99] and a T0
ETC [100]. Most of the fracture toughness data available to use in ETC development was
research data with varying exposures, environments and heat treatments. A T0-based ETC
was developed that was shown to fit all the available fracture toughness data with little bias;
however, the scatter about the mean was almost double that of Charpy-based ETCs. The
cause of the larger-than-expected scatter observed in the fracture toughness data was found
to be lack of descriptor fields in the fracture toughness database relative to the more
prescriptively acquired Charpy surveillance data. This is due, in large part, to the fact that
much of the fracture toughness data was developed as part of research programs whose
primary goal was in understanding a variety of effects on the measure of fracture toughness
and not specifically in monitoring radiation degradation. For this reason, the fracture
toughness database contains toughness data measured using many different specimen
configurations, test apparatus, and many exposure conditions including some post-
irradiation annealing, the details of which were not always captured in the database fields.
Comparison of the T0-based ETC with 4 Charpy-based ETCs supports the 1:1 correlation
between Charpy shift and fracture toughness shift that is often cited [100]. Due to the
inherent scatter observed in the fracture toughness data, a 1:1 correlation on the uncertainty
is harder to support.
6-6
7
SAMPLE PROBLEMS AND RESULTS
7.1 Introduction
Two sample problems were developed and solved within the WGFE to support the development
of CC N-830-1. The first sample problem was conducted in late 2015 and focused exclusively
on calculation of the allowable toughness values as outlined by the CC, with the objective of
ensuring that the CC provided sufficient clarity to enable ready implementation of the equations
contained therein. The Sample Problem 1 statement is provided in Appendix A of this report.
A second sample problem was conducted in 2016 with two objectives:
5. Calculation of allowable toughness values (same as in the first sample problem).
6. Calculation of allowable flaw sizes from these allowable toughness values.
While CC N-830-1 pertains only to determination of allowable toughness, calculation of the
allowable flaw size was performed in Sample Problem II to enable comparison of the effects of
the implementation of the CC N-830-1 allowable toughness equations with calculations made
using the current Appendix A allowable toughness metrics.
The second sample problem fully contains the first sample problem; its conduct and results were
documented in a technical paper presented at the 2017 ASME Pressure Vessel and Piping
Conference [79]. This chapter provides a synopsis of the full results described in detail in [79].
The full Sample Problem 2 statement is provided in Appendix B of this report. Since CC N-830-
1 has not yet been adopted by Section XI of the ASME Code and is still subject to change, the
version used in the conduct of Sample Problem 2 is included as Appendix C to provide context.
The following individuals solved the two sample problems:
• Yil Kim GE POWER
• Mark Kirk U.S. NRC
• Darrell Lee BWXT
• Cheng Liu & Steven Xu Kinectrics
• Do Jun Shim & Gary Stevens Structural Integrity Associates, Inc.
7-1
Sample Problems and Results
Method 3: Using the toughness equations in ASME Section XI Appendix A divided by √10.
Methods 1 and 2 represent allowable toughness values being considered by the WGFE for use in
CC N-830-1, while Method 3 represents the current ASME Code Appendix A calculation. For
Method 3, since the ASME Code does not specify a method to estimate J0.1 values for different
steels, the participants were allowed to specify the method they used (e.g., Regulatory Guide
1.161), or simply state that the results were “undefined” according to Section XI Appendix A.
For each method nine material Case IDs were defined, as outlined in Table 7.1. These cases
explore the full range of epistemic uncertainty inherent to the relationship between RTNDT and T0
(see Figure 5-1).
Once allowable toughness values were calculated using these three Methods and nine Case IDs,
the participants were asked to calculate allowable flaw sizes for a typical PWR at operating
pressure and under isothermal conditions at 50 °C (see Appendix B for full details). This single
allowable flaw size calculation does not represent all conditions of interest; it was performed
only to give WGFE members a sense of how changes in allowable toughness scale to changes in
allowable flaw size. Also, it should be noted that CC N-830-1 does not specify or propose to
change the Code’s allowable flaw size calculations. Thus, the allowable flaw size part of the
sample problem is not directly pertinent to the proposed revision of the Code Case; it was
performed for the information of WGFE members.
Table 7-1
Material Properties for use in Appendix A and Proposed Code Case N-830-1 Sample
Problem 2.
7-2
Sample Problems and Results
7-3
Sample Problems and Results
7-4
8
SUMMARY AND CONCLUSIONS
The technical bases for the fracture toughness models contained in ASME CC N-830-1 are
presented in this report. The suite of best estimate fracture toughness models provides a
complete description of fracture toughness crack initiation and arrest behavior from lower shelf,
through transition, to ductile upper shelf regimes for all ferritic steels.
The best estimate models used for CC N-830-1 are based on updated techniques and available
data, sound physical bases, and extensive empirical evaluations that collectively promote
confidence in their use for flaw assessment following Nonmandatory Appendix A of ASME
Section XI and similar methods. These models are appropriate for use in both deterministic and
probabilistic assessments, as each model describes the full distribution in values about the mean
for any temperature and material condition.
Equations are presented for each fracture toughness model that allow an analyst to determine any
percentile value of interest for any of the fracture toughness parameters KJc, KIa, JIc, J0.1, and J-R.
Specific values of these parameters may be used in deterministic assessments, or the entire
distributions may be sampled for use in probabilistic assessments. Collectively, these fracture
toughness models provide a consistent, best-estimate representation of ferritic steel fracture
toughness behavior, including uncertainties, to allow for quantitative fracture toughness
assessments that ensure the safety of nuclear (and other) ferritic components.
Sample problem assessments were performed to ensure the adequacy of the technical content in
CC N-830-1, to verify the accuracy of the CC content, and to ensure that the CC could be applied
by knowledgeable engineers to produce reasonable and reliable results in typical flaw
evaluations.
This document is provided to the ASME Section XI Working Group on Flaw Evaluation for their
use to support moving forward with direct implementation of best-estimate fracture toughness
curves.
8-1
9
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Against Failure,” 2013.
87. Code of Federal Regulations, 10 CFR 50.61, “Fracture Toughness Requirements for
Protection Against Pressurized Thermal Shock Events.”
88. K.K. Yoon, “Fracture Toughness Characterization of WF-70 Weld Metal,” Report to the
B&W Owners Group Materials Committee, BAW-2202, September 1993.
89. D. E. McCabe, R. K. Nanstad, S. K. Iskander, R. L. Swain, “Unirradiated Material Properties
of Midland Weld WF-70,” United States Nuclear Regulatory Commission Report
NUREG/CR-6249, October 1994.
90. “Initial RTNDT of Linde-80 Weld Materials,” Report to the PWR Owners Group, BAW-2308
Rev. 2A, March 2008.
91. NRC Safety Evaluation Report on Kewaunee Master Curve Submittal, Letter of 1st May 2001
from Lamb to Reddemann, ADAMS ML011210180.
92. Code of Federal Regulations 10 CFR 50 Appendix H, “Reactor Vessel Material Surveillance
Program Requirements,” Published by the Office of the Federal Register, National Archives
and Records Administration, Washington, D.C., 2000.
93. Erickson, M.A., and M. T. Kirk, “Development of a Partial Structural Factor Approach for
Direct Fracture Toughness Implementation into the ASME Boiler and Pressure Vessel
Code,” 2017 ASME Pressure Vessel and Piping Conference, July 16-20, 2107, Waikoloa
Hawaii, PVP2017-66148.
94. Chris Koehler, Heather Malikowski, Brian Hall, and Justin Webb, “PWR RPV Nozzle
Appendix G Margins,” presentation at 19 January 2016 NRC meeting, ADAMS ML
16021A002.
95. NRC Regulatory Issue Summary 2014-11, “Information on Licensing Applications for
Fracture Toughness Requirements for Ferritic Reactor Coolant Pressure Boundary
Components,” October 14, 2014, ADAMS ML14149A165.
96. J. Brian Hall, Elliot Long, Ben Mays, Heather Malikowski, and Chris Koehler, “Plan for
Transitioning RV Integrity to Direct Fracture Toughness,” presented at the International
Light Water Reactors Material Reliability Conference, Chicago, August 2016.
97. Kirk, M., and M. Erickson, “Assessment of the Temperature Dependence of Ferritic Steel
Fracture Toughness on or Near the Lower Shelf,” Proceedings of PVP2015 2015 ASME
Pressure Vessels and Piping Division Conference, July 19-23, 2015, Boston, Massachusetts,
USA, PVP2015-45850.
9-7
References
98. Kirk, M.T., M. Erickson, G. Stevens, H. Gustin and W. Server, “Options for Defining the
Upper Shelf Transition Temperature (Tc) for Ferritic Pressure Vessel Steels,” Proceedings of
PVP2015, 2015 ASME Pressure Vessels and Piping Division Conference, July 19-23, 2015,
Boston, Massachusetts, USA, PVP2015-45307.
99. Materials Reliability Program: Developing an Embrittlement Trend Curve Using the Charpy
“Master Curve Transition Reference Temperature (MRP-289). EPRI, Palo Alto, CA: 2011,
1020703.
100. Materials Reliability Program: Development of a T0 –Based Embrittlement Trend Curve
and Comparison With the Charpy Master Curve Embrittlement Trend Curve (MRP-389).
EPRI, Palo Alto, CA: 2014. 3002003040.
101. Kirk, M.T., “Evaluation and/or Validation of the J-R Curve Prediction Model Proposed
for use in Revision 1 to ASME Code Case N-830,” presentation at the International Group on
Radiation Damage Mechanisms (IGRDM) 20th Meeting, Santiago de Compostela, Spain,
October 2017. (ADAMS ML17271A110).
9-8
A
SAMPLE PROBLEM 1 STATEMENT
Purpose: The purpose of this document is to define a sample problem to test the procedures of
proposed Code Case N-830-1. This problem will be solved in two phases. Phase I
involves developing solutions for allowable toughness (e.g., JIc, KIc) using two
different methods: (A) those proposed by the proposed revision to Code Case N-830,
and (B) those used by existing ASME Code Appendix A rules. Phase II (LATER)
will include developing solutions for allowable flaw size for these two methods.
Inputs: Figure B-1 defines the inputs needed for Phase I of the sample problem.
Requested Outputs:
A. Calculate the variation with temperature of allowable toughness (i.e., of KJc, KIa, JIC, and J0.1)
for the nine (9) cases identified in Figure B-1 (Case ID-s are given in RED TYPE) using the
proposed Code Case methodology (Attachment 1) for Emergency and Faulted operating
conditions.
B. Calculate the variation with temperature of allowable toughness (i.e., of KIc, KIa, and J0.1) for
the nine (9) cases identified in Figure B-1 (Case ID-s are given in RED TYPE) using the
existing Code Appendix A methodology for Emergency and Faulted operating conditions.
Note: The ASME Code does not currently specify a method to estimate J0.1 values
for different steels. In the past, the equations in USNRC Regulatory Guide
1.161 have been used. A Member solving this Sample Problem may elect to
use Regulatory Guide 1.161, or another method. If another method is used it
should either be documented or adequately referenced.
C. Make graphs to compare the results of the (A) and (B) calculations for each of the nine (9)
cases.
D. Fill out the attached spreadsheet with one worksheet, labelled with the Case ID, for each test
case.
A-1
Sample Problem 1 Statement
Figure A-1
Sample Problem Properties
A-2
B
SAMPLE PROBLEM 2 STATEMENT
Proposed Code Case N-830-R1, “Direct Use of Fracture Toughness for Flaw
Evaluations of Pressure Boundary Materials in Section XI, Division 1, Class 1
Vessels”
Code Action No. 14-1073
Purpose: The purpose of this document is to define the Phase II sample problem to test the
procedures described in proposed Code Case N-830-R1. The Phase I sample problem
involved developing solutions for allowable toughness (e.g., JIc, KIc) using two
different methods: (A) those of the proposed revision to Code Case N-830, and (B)
those of Nonmandatory Appendix A of ASME Code Section XI. Phase II includes
developing solutions for allowable flaw size using these three methods (two based on
CC N-830-R1 and one using the procedures of Appendix A). In the interest of
simplicity, a low temperature isothermal pressurization is analyzed. Because at this
time Nonmandatory Appendix A of ASME Code Section XI applies only to
conditions in fracture mode transition (that is, NOT on the upper shelf) the
temperature to be analyzed is arbitrarily set at 50o C.
Inputs: This problem pertains to a typical PWR: a 0.2032 m thick pressure vessel (A508
Grade 2 Class 3) with an inner radius of 2.032 m. A semi-elliptical ID surface flaw
of depth 0.01 m and length 0.0333 m has been found, oriented axially in the vessel.
The vessel operating pressure is 15.3 MPa and the analysis temperature is 50o C. The
vessel is made from an A508 Grade 2 Class 3 forging that has a specified minimum
yield strength of 450 MPa. Assume isothermal conditions at the pressure and
temperature to be used in this analysis. Ignore the plastic zone correction (for
simplicity).
The material property inputs for nine cases are defined in Table B-1.
5
Sections of the problem statement in red are additions that were made to the original problem statement to provide
clarification and more detailed instructions to the participants.
B-1
Sample Problem 2 Statement
Table B-1
Material Properties for use in the Sample Problem 2
Requested Outputs:
E. Calculations: Calculate the allowable toughness and critical flaw size for each of the nine
sets of material properties using the three different methods described below. For each of the
three methods (a) use the standard ASME Code Appendix A methodology to define the
driving force, and (b) assume that the aspect ratio of the critical flaw is fixed at a/ℓ =0.3. For
Method 1 and 2 use J0.1 for upper shelf calculations. Use the 1% lower bound for Method 1
and the Median J0.1/√10 for Method 2. For critical flaw size evaluations for all three
methods, use 75% as the cut-off for a/t.
The three methods are distinguished by how the allowable toughness is calculated, as
described below:
Method 1: Determine the allowable toughness using the equations in CC-N-830-R1
using 1st percentile toughness values (i.e., for normal operating conditions).
Method 2: Determine the allowable toughness using the mean or median toughness
values from CC-N-830-R1 divided by √10.
Method 3: Determine the allowable toughness using the toughness equations in
Appendix A divided by √10.
Note on Method 3: The ASME Code does not currently specify a method to estimate J0.1 values
for different steels. In the past, most analysts made use of the equations in USNRC Regulatory
Guide 1.161. Problem solvers may elect to use Regulatory Guide 1.161, or another method, or
simply state that the answer is “undefined” according to Appendix A. If another method is used,
it should be referenced.
F. Tabular output format: The output is requested in the tabular format as shown in Table
C-2. For any case for which the input flaw size exceeds the allowable flaw size, please
highlight the allowable flaw size in red.
G. Please provide a step-by-step description of how you determine the critical flaw size
(method of driving force determination, etc.) so that we might better understand any
discrepancies.
B-2
Sample Problem 2 Statement
Table B-2
Table for Presentation of Results of the Phase II Sample Problem
Ratio Ratio
Per CC N-830-R1 Per CC N-830-R1 Per ASME SC-XI
Case # Desired Results Method 1/ Method 1/
Method 1 Method 2 Method 3
Method 3 Method 3
Allowable Toughness (MPa√m)
L5
Allowable Flaw Size (mm)
Allowable Toughness (MPa√m)
L50
Allowable Flaw Size (mm)
Allowable Toughness (MPa√m)
L95
Allowable Flaw Size (mm)
Allowable Toughness (MPa√m)
M5
Allowable Flaw Size (mm)
Allowable Toughness (MPa√m)
M50
Allowable Flaw Size (mm)
Allowable Toughness (MPa√m)
M95
Allowable Flaw Size (mm)
Allowable Toughness (MPa√m)
H5
Allowable Flaw Size (mm)
Allowable Toughness (MPa√m)
H50
Allowable Flaw Size (mm)
Allowable Toughness (MPa√m)
H95
Allowable Flaw Size (mm)
B-3
C
DRAFT CC N-830-1 (VERSION USED FOR SAMPLE
PROBLEM 2)
Case
14-1073 N-830-1
Editor’s Note: This proposal replaces
Rev. 0 N-830 in its entirety
11/8/2016
Case N-830-1
-1000 Scope
(a) This Case applies to Division 1, Class 1 ferritic steel components subject to the scope of
applicability of the ductile crack extension toughness equations based on product form.
(b) This Case defines the variation of fracture toughness as a function of temperature over the
entire material toughness range of interest to operating Class 1 vessels (lower shelf, transition
region, and upper-shelf).
(c) This Case may be used as an alternative to the determination of the following:
(1) Crack initiation fracture toughness reference curve, KIc, of Nonmandatory Appendix A,
Paragraph A-4200 for pressure retaining materials other than bolting,
(2) Crack arrest fracture toughness reference curve, KIa, of Nonmandatory Appendix A,
Paragraph A-4200 for pressure retaining materials other than bolting,
C-1
Draft CC N-830-1 (Version Used for Sample Problem 2)
(3) J-integral fracture resistance for the material at a ductile flaw extension of 0.1 in. (2.5
mm), J0.1, of Nonmandatory Appendix K Class 1 for pressure retaining materials other
than bolting, and
(4) J-integral fracture resistance curve for the material and its variation with ductile flaw
extension, Δa, J-R, of Nonmandatory Appendix K Class 1 for pressure retaining materials
other than bolting.
(d) When using this Case as part of an analytical evaluation, it is the responsibility of the user to
account for the variability inherent to the fracture toughness properties. For traditional
deterministic analysis, variability in the fracture toughness curve can be accounted for
through the selection of a statistical limit associated with a particular percentile of the
toughness distribution. For a probabilistic assessment, the variability about the mean and
median trends is evaluated through a sampling simulation using a suitable numerical method
such as the Monte Carlo method or other techniques. Guidance on this subject is given in -
3000 and -4000.
(e) This Case provides the fracture toughness information necessary to support both
deterministic and probabilistic assessments and is organized in seven sections, as follows:
-1000 Scope: provides the applicability and organization of the Case
-2000 Reference Toughness Temperature: describes data needed to use this Code
Case.
-3000 Toughness Variability: describes values that can be used along with the
equations of -4000 to account for toughness variability.
-4000 Toughness Curves: provides equations describing the variation with
temperature of, and variability associated with, cleavage and ductile crack
initiation toughness, and of cleavage crack arrest toughness.
-5000 Applicability Limits: provides the limits over which the curves of -4000 can be
applied.
-6000 Unit Conversions: input values and equations within this Code Case are
expressed in System International (SI) units. Conversions to US Customary
(USC) units are provided.
-7000 Nomenclature: symbols and abbreviations used in this Code Case are defined.
C-2
Draft CC N-830-1 (Version Used for Sample Problem 2)
The value of T0 may be adjusted to account for the effects of measurement or material
uncertainty6. Also, the value of T0 shall be adjusted to account for the effects of irradiation if the
component of interest is exposed to neutron irradiation in excess of 1×1017 n/cm2 (E > 1 MeV) 7.
The equations in -4000 assume that the value of T0 has been adjusted appropriately for these
effects. The cognizant regulatory authority may specify margins or adjustments to T0 intended to
account for these effects.
p Mp
0.005 2.58
0.010 2.33
0.015 2.17
0.020 2.05
0.025 1.96
0.030 1.88
0.035 1.81
0.040 1.75
0.045 1.70
0.050 1.64
0.055 1.60
0.060 1.55
6
Methods to perform adjustments for measurement uncertainty can be found in ASTM Standard Test Method
E1921-14, “Standard Test Method for Determination of Reference Temperature, To, for Ferritic Steels in the
Transition Range.”
7
Methods to perform adjustments for irradiation can be found in ASTM Standard Guide E900-15, “Standard Guide
for Predicting Radiation-Induced Transition Temperature Shift in Reactor Vessel Materials.”
C-3
Draft CC N-830-1 (Version Used for Sample Problem 2)
p Mp
0.065 1.51
0.070 1.48
0.075 1.44
0.080 1.41
0.085 1.37
0.090 1.34
0.095 1.31
0.100 1.28
𝑱𝑱⋅𝑬𝑬
𝑲𝑲 = � Eq. C-1 (a)
𝟏𝟏−𝝂𝝂𝟐𝟐
where,
{𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐−𝟕𝟕𝟕𝟕.𝟒𝟒𝟒𝟒}
𝑬𝑬 = Eq. C-1 (b)
𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏
C-4
Draft CC N-830-1 (Version Used for Sample Problem 2)
Eq. C-2(b) can be used to produce both lower and upper bound curves. For example, using a
value of p=0.05 would produce a 5% lower bound curve while using a value of p=0.95 would
produce a 95% upper bound curve.
In eq. C-2(b),
𝑲𝑲𝒐𝒐 = 𝟑𝟑𝟑𝟑 + 𝟕𝟕𝟕𝟕 ⋅ 𝒆𝒆𝒆𝒆𝒆𝒆[𝟎𝟎. 𝟎𝟎𝟎𝟎𝟎𝟎(𝑻𝑻 − 𝑻𝑻𝒐𝒐 )] Eq. C-2 (c)
(𝟏𝟏−𝒑𝒑)
𝑲𝑲𝑰𝑰𝑰𝑰 = 𝑲𝑲𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎 �𝟏𝟏 + 𝟎𝟎. 𝟏𝟏𝟏𝟏𝑴𝑴𝒑𝒑 � Eq. C-3 (b)
for upper bound curves 𝑰𝑰𝑰𝑰
where,
𝑲𝑲𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎
𝑰𝑰𝑰𝑰 = 𝟑𝟑𝟑𝟑 + 𝟕𝟕𝟕𝟕 ⋅ 𝒆𝒆𝒆𝒆𝒆𝒆[𝟎𝟎. 𝟎𝟎𝟎𝟎𝟎𝟎(𝑻𝑻 − 𝑻𝑻𝑲𝑲𝑲𝑲𝑲𝑲 )] Eq. C-3 (c)
As an example, a value for p of 0.05 will produce a 5% lower bound using eq. C-3a and a
95% upper bound using eq. C-3b. When using eq. C-3, the value of p shall not exceed 0.5
(0 < p < 0.5). There is no effect of component thickness, crack front length or product form
on eq. C-3.
(𝟏𝟏−𝒑𝒑)
𝑱𝑱𝑰𝑰𝑰𝑰 = 𝑱𝑱𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎 + 𝝈𝝈𝚫𝚫𝑱𝑱𝑰𝑰𝑰𝑰 𝑴𝑴𝒑𝒑 Eq. C-4 (b)
for upper bound curves 𝑰𝑰𝑰𝑰
As an example, a value for p of 0.05 would produce a 5% lower bound using eq. C-4a and
a 95% upper bound using eq. C-4b. When using eq. C-4, the value of p shall not exceed
0.5 (0 < p < 0.5).
C-5
Draft CC N-830-1 (Version Used for Sample Problem 2)
𝑱𝑱𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎
𝑰𝑰𝑰𝑰 = 𝟏𝟏. 𝟕𝟕𝟕𝟕{𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏 ∙ 𝐞𝐞𝐞𝐞𝐞𝐞[−𝟎𝟎. 𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎(𝑻𝑻 + 𝟐𝟐𝟐𝟐𝟐𝟐. 𝟏𝟏𝟏𝟏)] − 𝟑𝟑. 𝟑𝟑𝟑𝟑𝟑𝟑} + 𝑱𝑱𝒄𝒄(𝑼𝑼𝑼𝑼) − 𝚫𝚫𝑱𝑱𝑰𝑰𝑰𝑰(𝑼𝑼𝑼𝑼) Eq. C-4 (c)
𝟏𝟏−𝝊𝝊𝟐𝟐
𝑱𝑱𝒄𝒄(𝑼𝑼𝑼𝑼) = {𝟑𝟑𝟑𝟑 + 𝟕𝟕𝟕𝟕 × 𝐞𝐞𝐞𝐞𝐞𝐞[𝟎𝟎. 𝟎𝟎𝟎𝟎𝟎𝟎(𝟒𝟒𝟒𝟒. 𝟖𝟖𝟖𝟖𝟖𝟖 − 𝟎𝟎. 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝑻𝑻𝒐𝒐 )]}𝟐𝟐 Eq. C-4 (d)
𝑬𝑬𝑼𝑼𝑼𝑼
𝚫𝚫𝑱𝑱𝑰𝑰𝑰𝑰(𝑼𝑼𝑼𝑼) = 𝟏𝟏. 𝟕𝟕𝟕𝟕{𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏 ∙ 𝐞𝐞𝐞𝐞𝐞𝐞[−𝟎𝟎. 𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎(𝑻𝑻𝑼𝑼𝑼𝑼 + 𝟐𝟐𝟐𝟐𝟐𝟐. 𝟏𝟏𝟏𝟏)] − 𝟑𝟑. 𝟑𝟑𝟑𝟑𝟑𝟑} Eq. C-4 (e)
{𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐−𝟕𝟕𝟕𝟕.𝟒𝟒𝑻𝑻𝑼𝑼𝑼𝑼 }
𝑬𝑬𝑼𝑼𝑼𝑼 = Eq. C-4 (f)
𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏
𝑱𝑱𝑰𝑰𝑰𝑰(𝟐𝟐𝟐𝟐𝟐𝟐)
𝑷𝑷𝟏𝟏 = − 𝟎𝟎. 𝟒𝟒𝟒𝟒 Eq. C-4 (l)
𝟏𝟏𝟏𝟏𝟏𝟏
𝑱𝑱𝑰𝑰𝑰𝑰(𝟐𝟐𝟐𝟐𝟐𝟐)
𝑷𝑷𝟐𝟐 = + 𝟎𝟎. 𝟓𝟓𝟓𝟓 Eq. C-4 (m)
𝟖𝟖𝟖𝟖𝟖𝟖
The value JIc(288) in eqs. C-4l and C-4m is calculated using eq. C-4c and a value of 288°C for T.
There is no effect of component thickness or crack front length on eq. C-4.
(𝟏𝟏−𝒑𝒑)
= 𝒆𝒆𝒆𝒆𝒆𝒆�𝒍𝒍𝒍𝒍[𝑱𝑱𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎 ] + 𝑴𝑴𝒑𝒑 × 𝑹𝑹𝑹𝑹𝑹𝑹𝑹𝑹� Eq. C-5 (b)
for upper bound curves 𝑱𝑱𝑿𝑿 𝑿𝑿
As an example, a value for p of 0.05 would produce a 5% lower bound using eq. C-5a and a 95%
upper bound using eq. C-5b. The value of p used in eqs. C-5a and C-5b shall not exceed 0.5.
In eqs. C-5a and C-5b,
𝑱𝑱𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎
𝑿𝑿 = 𝑪𝑪 × 𝚫𝚫𝒂𝒂𝒏𝒏 Eq. C-5 (c)
C-6
Draft CC N-830-1 (Version Used for Sample Problem 2)
Here X is used as a subscript for compactness; X signifies a particular amount of ductile crack
extension, or Δa. Values of J at a particular ductile crack extension, for example the value of J
at 2.54 mm (or, equivalently 0.1 in.), can be determined by using these equations. The entire J-R
curve can be produced by solving these equations for a range of ∆a values
The mean toughness, JIcmean is defined in -4300. Values of root mean square deviation (RMSD)
depends on product form as shown in Table C-2. There is no effect of component thickness or
crack front length on eq. C-5.
Table C-2
RMSD values for different product forms.
* A default of 0.180 is assumed unless the user can justify a lower value.
As expressed in eq. C-6c and eq. C-3 for KIa may be used to temperatures of (TKIa - 100°C).
𝐓𝐓 ≥ 𝑻𝑻𝑲𝑲𝑲𝑲𝑲𝑲 − 𝟏𝟏𝟏𝟏𝟏𝟏 °𝐂𝐂 Eq. C-6 (c)
C-7
Draft CC N-830-1 (Version Used for Sample Problem 2)
concerning the temperature at which analysis should transition from linear elastic fracture
mechanics (i.e., from using KJc and KIa) to elastic plastic fracture mechanics (i.e., using JIc, Jx,
and J-R).
Figure C-1
Illustration of Intermediate Temperature Limits when 5th Percentile Bounding Curves are
used
Multiply SI by this
Toughness Curve Symbols SI Units USC Units
factor to determine USC
-7000 Nomenclature
Tables C-4 and C-5 contains a list of symbols and definitions.
C-8
Draft CC N-830-1 (Version Used for Sample Problem 2)
Table C-4
Symbols
C-9
Draft CC N-830-1 (Version Used for Sample Problem 2)
Table C-5
Definitions
Word Definition
C-10
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