Professional Documents
Culture Documents
IIW/EWF Diploma -
Design and Construction (Advanced)
Contents
Section Subject
1 Introduction
1.1 Background
1.2 Course aim - Construction design modules
1.3 Course objectives – European Welding Engineer
2 Design Considerations for Aluminium
2.1 Aluminium alloys
2.2 Choosing the appropriate filler metal
2.3 Properties of aluminium
2.4 Design of weld joints
2.5 Limit state design
2.6 Friction stir welding (FSW)
2.7 Heat affected zone softening
2.8 Summary
2.9 Revision questions
2.10 Bibliography
3 Different Types of Loading.
3.1 Different loadings causes different ways to fail
3.2 Static strength
3.3 Ductile failure
3.4 Stress concentrations
3.5 Lamellar tearing
3.6 Thickness
3.7 High temperature
3.8 Creep
3.9 Cyclic loading and fatigue failure
3.10 Impact behaviour
3.11 Low temperature
3.12 Brittle fracture
3.13 The significance of flaws
3.14 Fitness for service or engineering critical assessment
3.15 Fracture mechanics
3.16 LEFM and EPFM
3.17 Fracture mechanics testing
3.18 Calculating fracture toughness
3.19 Testing welds
3.20 BS 7910 ECA procedure
3.21 ECA case study
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Section 1
The present course is the third of these levels and is intended to cover the
scope appropriate for a European Welding Engineer. Two other courses
address the scope of the other qualifications.
Be able to design welded joints to withstand static and cyclic loads and
low temperatures.
Be able to design both steel and aluminium joints.
Understand the principles of design for pressure vessels.
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Section 2
The temper tells how the product was fabricated and applies to both cast
and wrought products. The temper can be as-fabricated (F), annealed (O),
strain-hardened (H) or heat-treated (T). T is always followed by at least one
digit specifying the conditions of tempering. Only heat-treatable alloys will be
seen with the T temper designation. Non heat-treatable alloys will tend to
have H designation instead.
Heat-treatable alloys gain strength from cold work and from precipitation
hardening. Non heat-treatable alloys gain strength from cold work only.
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In the naturally aged (T4) condition, these alloys have mechanical properties
similar to mild steel, with a typical proof stress of 250N/mm², UTS
approaching 400N/mm² and good ductility. In the full strength (T6) condition,
the proof and ultimate stress can reach 375 and 450N/mm² respectively, but
with reduced ductility. The good mechanical properties of the 2xxx series
alloys are offset by various adverse factors, such as inferior corrosion
resistance, poor extrudability, unsuitability for arc welding (since they are
prone to liquation and solidification cracking) and higher cost. However, the
corrosion resistance of thin material can be improved by using it in the form
of clad sheet.
The American civil engineering structures of the 1930s were all in 2xxx type
alloy, using the ductile T4 temper. After 1945 the 2xxx series was
superseded by 6xxx for such use despite its lower strength. Today there is
little non-aeronautical use of 2xxx alloys.
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The 5xxx alloys appear mostly as sheet or plate. At the lower end of the
range they have good formability and are the natural choice for sheet-metal
fabrications. At the upper end, they are used in welded plate construction,
typically in the hot-formed condition. Such plate is tough and ductile with
possible tensile strengths exceeding 300N/mm².
The 5xxx series is little used for extrusions, which are only available in the
annealed and hot-formed conditions with a rather low proof stress.
Extrudability is poor compared with 6xxx and very thin sections are
impossible. An acceptable practice is to use 5xxx series plating with 6xxx
extrusions as stiffeners.
The stronger type of 6xxx material in the T6 condition (ie solution treatment
followed by artificial ageing) is sometimes described as the mild steel of
aluminium because it is the natural choice for stressed members. In fact it is
a weaker material than mild steel with a similar proof or yield stress
(250N/mm²), but a much lower tensile strength (300N/mm²) and is less
ductile.
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The weaker type of 6xxx alloy is not normally offered as sheet or plate, is
the extrusion alloy par excellence. It is more suitable than any other alloy for
the extrusion of thin difficult sections and is a common choice for members
that operate at a relatively low stress level especially when good surface
finish is important. Typical examples are when design is governed by
stiffness (rather than strength) as with many architectural members or when
fatigue is critical, for example in the structure of railcars.
The weaker type of 7xxx material is a different proposition and in the non-
aeronautical field is a valid alternative to the stronger type of 6xxx material,
especially for welded construction. It has superior mechanical properties to
6xxx material and HAZ softening at welds is less severe. But corrosion
resistance, although much better than for the stronger kind of 7xxx alloy, is
not as good as for 6xxx alloy. Also there can be a possibility of stress-
corrosion. Extrudability is not quite as good as for the 6xxx series, but
hollow (bridge-die) extrusions are still possible. An important factor when
using 7xxx series alloy as against 6xxx alloy, is the need for greater
expertise in fabrication to avoid cracking.
Table 3 Filler type to use for the welding of different aluminium alloys.
Parent alloy Filler metal Comments
1XXX For corrosion resistance
1XXX
4XXX For strength and crack prevention
3XXX For corrosion resistance
3XXX
4XXX For strength and crack prevention
5XXX 5XXX Select consumable based on parent composition
4XXX For crack prevention
6XXX
5XXX For better weld strength
7XXX 5XXX Select consumable based on parent composition
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Corrosion resistance
Aluminium has excellent corrosion resistance due to a thin but compact self-
healing oxide layer and can normally be used unpainted. Higher strength
alloys will corrode in some hostile environments and may need protection.
Extrusion process
The standard way of producing aluminium sections, is vastly more versatile
than the rolling procedures in steel and is a major feature in aluminium
design.
Weldability
Most of the alloys can be arc welded using gas-shielded processes, but are
susceptible to fusion welding defects. The main welding defects in
aluminium are porosity due to the presence of hydrogen, lack of fusion due
to oxide inclusions, solidification cracking due to susceptible weld metal
composition and softening of the HAZ (see Section 2.7). Due to the lower
melting point (ie 660ºC), welding speeds are fast compared with steel. Laser
welding and friction stir welding are now used extensively for joining
aluminium components with the advantage of high processing speeds, ease
of automation and low heat input (low distortion).
Machinability
Milling can be an economic fabrication technique for aluminium because of
the high metal removal rates possible, hence, U or J preparations are much
easier to produce. The use of machined preparations leads to tighter
tolerances and better joint fit-up, reducing the amount of weld metal required
to fill the preparation and avoiding possible weld defects caused by
mismatch.
Adhesive bonding
Adhesive bonding is well established for making structural joints in
aluminium and does not produce residual stresses or other defects, which
can occur during welding. Unfortunately, adhesive bonded joints have
limited life as most adhesive systems degrade rapidly when the joint is both
highly stressed and exposed to a hot, humid environment.
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Electrical conductivity
Aluminium has a high coefficient of electrical conductivity, which combined
with a lower price per kg compared with copper, makes it the standard
material for overhead transmission lines conductors (with a central steel
strand which carries the weight of the cable) and welding cables. Aluminium
alloys have electrical conductivity approximately 65% that of copper but
because of their density can carry double the electricity
Thermal conductivity
Aluminium has a high coefficient of thermal conductivity (237W/m°C - about
four times greater than steel). As a result, pure aluminium can be used in
heat exchangers as an alternative to copper tubes.
Magnetic properties
Aluminium is non-magnetic which allows its use in applications where no
electromagnetic interference is allowed. These applications include base
plates for Metal oxide semiconductor field effect transistors (MOSFETs) and
cases for avionic devices. Unfortunately, this means that magnetic particle
examination cannot be used as a NDT method to detect surface/near
surface defects in an aluminium weldment.
Cost
The cost of aluminium (sections, sheet and plate) is typically about 1.5 times
that of structural steel, volume for volume. For aircraft grade material, the
differential is much more. However, fabrication costs are lower because of
easier handling, use of clever extrusions, easier cutting or machining, no
painting and simpler erection. In terms of total cost the effect of switching to
aluminium is usually much less than one would expect and an aluminium
design can even be cheaper than a steel one.
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Young’s modulus
Aluminium exhibits a low Young’s modulus value, 0.7×105N/mm2, a third
that of steel. The failure load for an aluminium component due to buckling is
lower than for an equivalent steel one. Since Young’s modulus is a measure
of stiffness, a lower value means less rigidity of an aluminium structure
compared to an equivalent steel one. Consequently, elastic deflection
becomes more of a factor than in steel and in aluminium it is often the
limiting failure condition in beam design, whereas an identical structural
steel component subjected to the same stress would be limited by yielding
rather than buckling.
Fatigue
Aluminium components are more prone to failure by fatigue than steel ones.
The stresses required producing the same rate of fatigue crack propagation
in steels and aluminium alloys are roughly in proportion to their respective
Young’s modulus, ie three to one. As a consequence, all standards have
different S-N lines for aluminium welds (see BS 8118 and AWS D1.2).
It may observed that the yield strength, fatigue crack propagation rate and
Young’s modulus of aluminium is roughly a third those of steel. Therefore
one third is often accepted as an approximate to obtain the equivalency
between steel and aluminium.
Limit stress
Aluminium does not present a clear yield point; instead its stress-strain
curve shows continuously rising smooth behaviour once it deviates from the
linear elastic region. So to define a useable limit for stress, proof stress is
used (ie the stress at which the material undergoes a certain permanent
strain, commonly 0.2%).
Thermal expansion
Aluminium expands and contracts with temperature approximately twice as
much as steel – its coefficient of thermal expansion being 24 × 10-6ºC-1
compared with only 11 × 10-6ºC-1 for steel. Greater thermal expansion leads
to greater distortion after welding; twice as much distortion for an aluminium
structure compared with a steel one. Because of the lower Young’s
modulus, thermal residual stresses in a restrained member are only two-
thirds those in steel, the rest being locked in distortions.
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Tensile strength
Pure aluminium has a modest ultimate tensile strength (UTS) (70-150N/mm2
depending on delivery condition - annealed or cold worked). For structural
applications aluminium is alloyed with different elements, thus increasing its
tensile strength up to 650N/mm2 (see Section 2.1).
Affinity to oxygen
Aluminium forms a tenacious oxide film, which has a melting point some
three times higher than that of aluminium. Failure to remove this oxide both
before and during welding results in entrapment of oxides and/or incomplete
fusion, giving a joint with impaired mechanical properties. The importance of
gas shielding when welding aluminium over a wider weld width requires
larger diameter gas nozzles for TIG and MIG welding which leads to an
increase in included angle and/or of land in the case of U preparation.
If present on the weld preparation surface, the oxide layer can prevent
proper melting of the parent material, leading to wetting problems and lack
of fusion. To produce a sound weld the oxide layer needs to be removed by
mechanical or chemical methods. Chemical cleaning must be considered
from the design stages as the reagents are highly corrosive so permanent
backing strips and lap joints should be assembled after chemical cleaning
due to possible entrapment.
Alloys which gain their strength by cold work are softened by welding.
Alloys which are precipitation hardened are overaged by the effects of
welding.
The weld metal may not match the strength of the parent metal because
of its as-cast structure and perhaps because of its composition which
may have been selected to reduce the risk of hot tearing (for example
using a crack-resistant Al-Si filler to weld Al-Cu alloys).
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If the root gap is greater than 1.5mm, a backing bar is recommended (this
can allow for a reduction of included angle and consequently a reduction of
distortion). Remember that a backing bar can be a location for crevice
corrosion if cleaning flux has not been removed before welding.
Use intermittent welds rather than a continuous run (for example, when
welding stiffeners), can reduce the amount of welding and therefore
distortion. For these kinds of joints, it can be possible to still obtain adequate
joint strength from an intermittent weld.
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To mitigate the effects of HAZ softening, the weld area cross-section can be
increased locally by using an extruded section.
When members must be joined at locations of high stress, the welds should
be parallel to the main stress in that member. Transverse welds in tension
members should be avoided if possible.
Welding can often be eliminated at the design stage by forming the plate or
using an extruded section, as shown below.
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2.5.3 Deflection
The limit state of elastic deflection (sometimes called serviceability) ensures
the structure has adequate stiffness. It is important in beam design since the
low Young’s modulus of aluminium causes it to be more of a concern than in
steel. Calculations are usually performed with the structure subjected to
nominal loading (ie dead weight of the structure, imposed loads, wind loads,
forces due to thermal expansion/contraction, etc). This limit state is usually
about the performance of members rather than joints. In elastic deflection
calculations, the allowable stress is reduced to allow for buckling.
2.5.4 Fatigue
Fatigue must be considered for all cases of repeated loading since fatigue in
aluminium structures is more critical than for steel. The usual checking
procedure is to identify potential fatigue sites and determine the number of
loading cycles to cause failure. The design is acceptable if the predicted life
at each site is not less than that required. The number of cycles to failure is
normally obtained from an endurance curve, selected according to the local
geometry and entered at a stress range based on the nominal loading.
Alternatively, for a mass produced component, the fatigue life can be found
by testing.
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the melting point and allows the tool to traverse smoothly along the weld
line. The plasticised interface material is mixed by being transferred from the
leading edge of the tool to the trailing edge of the tool probe and is forged by
intimate contact of the tool shoulder and the pin profile. It leaves a solid
phase bond between the two pieces.
No fume or spatter.
No filler or shielding gas required.
Very good weld quality.
Low distortion.
Excellent mechanical properties (no HAZ softening).
Can operate in all positions.
Energy efficient.
Low shrinkage.
Can weld above 50mm thickness in one pass.
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FSW is now largely used for the manufacture of car body trains, cars, ship
hulls and fuel tanks for aerospace applications and provides a significant
advantage to the aluminium extrusion industry. However, the cost of a FSW
machine is still significant and research is ongoing to design low cost
machines.
a) Square butt.
b) Combined butt and lap.
c) Single lap.
d) Multiple lap.
e) Three piece T butt.
f) Two piece T butt.
g) Edge butt.
h) Possible extrusion design to enable corner fillet weld to be made.
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To determine the width of nominal HAZ, the one inch rule was devised
which states that the nominal HAZ extends 1 inch (25mm) in every direction
from an appropriate reference point in the weld. For a butt weld the
reference position is the centre line of the weld while for a fillet weld it is at
the root. With fillet welds on thick plate, the one inch rule allows the HAZ
boundary to be taken as an arc.
It may be assumed that the material in the HAZ of aluminium welds has the
same properties as those for annealed material, so for cold worked alloys
the kz factor becomes the ratio of the proof strength for the annealed and
cold worked conditions. In precipitation hardened alloys, it’s the ratio of
strength in the annealed and hardened conditions.
teffective = kz × treal
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The resistance of the weld joint is based on the effective section instead of
the actual one, assuming it to be entirely composed of full strength
(unsoftened) material.
2.8 Summary
At the end of this module you should be able to design aluminium profiles
and weld joints for a given use. You should be able to discuss how to avoid
common imperfections in aluminium joints and interpret softening in the
HAZ. You ought to be able to explain the strength of different alloys and
select alloys for given applications.
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Revision Questions
1 For a structure requiring corrosion resistance and good strength what type of
heat treatable aluminium alloy should be chosen?
2 What joining techniques can be used for aluminium, what are the advantages and
disadvantages of each?
3 How do you determine the severity of HAZ softening? What can you assume
about the extent of softening?
5 What causes lack of fusion defects in aluminium welds? How can they be
avoided?
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Bibliography
Aluminum Design Manual’: by The Aluminum Association Ltd, 2000.
Gene Mathers 2002: ‘The welding of aluminium and its alloys’. by Woodhead
Publishing Ltd, UK.
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Section 3
There are failure modes which occur in an Instant, such as buckling, fracture
or overload (although some deformation or bulging might give a little
warning of failure). Time-dependent failure processes occur over time and
with sufficient in-service inspection, the damage might be detected before it
reaches critical conditions for failure. These failure modes include fatigue
(and corrosion fatigue), stress corrosion cracking and creep. The designer
must be sure that the design will not suffer from an instantaneous failure
mode during service.
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Figure 3.1 Ductile rupture of a component. Figure 3.2 Ductile fracture surface.
Figure 3.4 shows the stress concentration effect of a circular hole in a large
flat plate under tension. Even this simple detail increases the stress at the
edge of the hole by a factor of 3. This means that close to the edges of
holes (such as bolt holes), the maximum stress in the plate is about three
times the nominal applied stress. Sharper notches concentrate the stress by
much more and very sharp notches, such as cracks have a very high
concentration of stress at their tips.
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Welds often lead to geometric stress concentrations at the weld toe. This
feature is especially common in oversized welds as depicted in Figure 3.5a)
and these welds can be ground down to reduce the severity of the stress
concentration at the weld toes (Figure 3.5b).
a b
Figure 3.5a Oversized weld with stress concentrations and 3.5b mitre weld.
The cracks can appear at the toe or root of the weld but are always
associated with points of high stress concentration. The surface of the
fracture is fibrous and woody with long parallel sections which are indicative
of low parent metal ductility in the through-thickness direction as can be
seen in Figure 3.7.
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Transverse strain
Shrinkage strains on welding must act in the short direction of the plate ie
through the plate thickness.
Weld orientation
Fusion boundary will be roughly parallel to the plane of the inclusions.
Material susceptibility
Plate must have poor ductility in the through-thickness direction.
The risk of lamellar tearing will be greater if the residual stresses generated
from welding act in the through-thickness direction, most likely to occur in T-
joints, corner joints or cruciform joints. Lamellar tearing is more likely to
occur in large welds typically when the leg length in fillet and T butt joints is
greater than 20mm. The welding process, consumables and preheating are
also related to and can all help reduce the risk of tearing. In butt joints, as
the stresses on welding do not act through the thickness of the plate, there
is little risk of lamellar tearing.
Lamellar tearing is only encountered in rolled steel plate and not forgings
and castings. There is no one grade of steel that is more prone to lamellar
tearing but steels with a low short transverse reduction in area (STRA) will
be susceptible. As a general rule, steels with STRA over 20% are
essentially resistant to lamellar tearing whereas steels with below 10 to 15%
STRA should only be used in lightly restrained joints. Steel suppliers can
provide plate which has been through-thickness tested with a guaranteed
STRA value of over 20%, this is sometimes called Z-grade steel.
3.6 Thickness
The relationship between component thickness and mode of failure is
somewhat counter intuitive. Thicker sections, although able to carry greater
load, do not better resist crack propagation.
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Although near the plate surfaces under plane stress the plastic zone will still
be large, in thick plate the proportion of plane strain conditions along the
middle of the crack front can dominate the behaviour of the crack
(Figure 3.10). Therefore the same material but in a thicker plate will have a
lower fracture toughness than thinner plate.
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Figure 3.10 Shape of the plastic zone ahead of the crack tip under plane stress
and plane strain.
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3.8 Creep
Creep is the progressive deformation of a material under constant stress.
For most steels, creep is a high temperature deformation mechanism and is
a function of:
A creep test can be carried out in a rig similar to that of a tensile testing
machine. The applied load is held constant and the temperature of the
sample is elevated through the use of a heated filament that surrounds the
sample as illustrated in Figure 3.12. The extension (or creep deformation) is
measured throughout the test. Failure occurs once the specimens has finally
necked down and ruptured.
Creep tests are plotted on a strain–time axis which takes the form of curve
as depicted in Figure 3.13.
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Three distinct stages exist within the creep curve. The first stage is known
as primary creep and is due to dislocations orienting themselves within the
microstructures. The second stage is called secondary creep or steady
state creep. The creep is linear and is due to the effects of both work
hardening and recovery of dislocations being balanced. Lastly, the third
stage is referred to as tertiary creep and the rapid increase in strain at this
stage is due to void formation, necking and general reduction in area which
further accelerates the rate of strain until creep fracture occurs. Creep
damage in structures is manifested by the formation and growth of creep
voids or cavities within the microstructure of the material due to tertiary
creep.
C-Mn steels.
0.5Mo steel.
1.25Cr-0.5Mo steel.
2.25Cr-1Mo-(V) steel.
5Cr-0.5Mo steel.
9Cr-1Mo steel.
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The rate of fatigue crack growth is not dependent on material strength but
only on load range and hence welded low and high strength materials can
have the same fatigue life. The benefit of material strength comes in the
crack initiation stage, which is effectively absent in the welded material. In
welded joints, fatigue cracks readily initiate and the majority of their fatigue
lives are spent propagating the crack. It should be noted that metal fatigue is
not associated with any change in material properties, but rather with crack
growth.
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Figure 3.15 The effect of the rate of loading on the stress-strain curve:
1) dynamic loading; 2) static loading.
Figure 3.16 The effect of the rate of loading on tensile strength and ductility.
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σ σ σ
ε ε ε
Temperature
The part of the curve where the material is ductile is called the upper shelf.
Where the material is brittle is called the lower shelf and there is a transition
region in between. Remember that transition behaviour only occurs for
ferritic steels and doesn’t occur for austenitic materials such as stainless
steel or aluminium. A designer needs to ensure that the material always
operates on the upper shelf in order to avoid brittle fracture.
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A b
Figure 3.22a Brittle fracture surface showing chevron marks and historical brittle
failures of 3.22b) the John Thompson pressure vessel.
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Figure 3.24 Two different weld flaws: Hydrogen crack and lack of sidewall fusion.
At any point in the life cycle of a structure (eg design, fabrication, operation),
it may be necessary to investigate whether it is fit for its intended service
conditions, or those which it will encounter in the future. For safety critical
items like pipelines, pressure vessels, on- and offshore platforms, rigs, wind
turbines, storage tanks, ships, bridges, aircrafts, buildings, etc, the failure of
a single component due to the presence of a flaw can threaten human life,
as well as presenting severe economic and environmental consequences.
Other flaws may be harmless, as they will not lead to failure during the
lifetime of the component. Replacement or repair of such insignificant flaws
is economically wasteful.
Insignificant flaws are not necessarily the smallest ones, or those which are
difficult to detect. The two welds in Figure 3.25 would not be passed as
acceptable when the slag inclusion or porosity had been detected from
NDT, but neither of these large defects has contributed to the failure, which
was due to fatigue cracking from the weld toe in both cases. The most
obvious flaws were insignificant with respect to fitness-for-service in these
cases.
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a b
Figure 3.25 Large but nonetheless insignificant flaws; a slag inclusion a and
porosity b which has not contributed to the fatigue cracking initiating from the weld
toes.
Figure 3.26 Crack detected underneath a repair weld, but is the structure still fit-
for-service?
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Figure 3.27 Basic principle of ECA in terms of input requirements and analytical
output.
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Design
Determine material properties requirements or stress levels.
Fabrication
Determine flaw acceptance criteria and inspection strategy or to justify
the avoidance of post-weld heat treatment or proof test.
Operation
Avoid unnecessary repair if flaws are detected and to define appropriate
maintenance and inspection strategies.
Investigate the causes of failure and therefore to avoid future similar
cases.
Support cases for life extension and change of service.
To carry out an ECA it is necessary to know the full details of each corner of
the assessment triangle, in terms of the material properties, geometry and
stresses, as detailed in the following table.
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a b
Figure 3.28 Design to prevent a plastic collapse and b brittle fracture, by balancing
the ‘driving force’ against the ‘material resistance’.
The method for carrying out the ECA is to first identify the type of flaw
(whether it is planar, non-planar, or a shape imperfection), then gather all
the essential data (from inspection records, mechanical test certificates,
published data, the operating conditions). The procedure then assesses the
significance of flaw. A second stage may be to iterate the size of the flaw to
find the limiting flaw size for failure avoidance. If fatigue is likely then any
sub-critical crack growth must be considered. Most procedures are validated
to be conservative, but if an additional safety margin is required this may be
added to the applied stress or fatigue cycles, or removed from the given
tolerable flaw size.
The benefits of using an ECA are on one hand to ensure safer structures,
due to the need for fewer weld repairs (weld repair can introduce more
severe defects) and the focus on design and materials selection. On the
other hand, this is driven by the economic benefits of reduced amounts of
repair welding, less rigorous, or better focused NDT demands and being
able to justify repair deferral, possibly indefinitely, or at least until it is
convenient to do so.
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Figure 3.29 Fracture mechanics is about calculating the crack driving force; the
ECA compares this to the material resistance.
In fracture mechanics, the highly stress concentrating effect of the crack tip
is accounted for in a parameter called the stress intensity factor, K. The
stress intensity factor is a single parameter which characterises the stress
field near the crack tip and the fracture event. It can be calculated in its
simplest terms by the following expression.
___
K = Y √ a [3-1]
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Figure 3.31 Geometrical factors for centre crack, edge crack and penny-shaped
crack.
Y depends not only on the geometry under consideration, but also the
loading mode. There are three possible loading modes, Modes I, II and III,
which relate to crack behaviour (crack opening, in-plane shear and out-of-
plane shear). Mode I tends to be the most severe loading type and gives the
highest stress intensity. Most fracture mechanics analyses are based on K
solutions for Mode I loading, which is identified by a subscript I (ie KI).
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However LEFM does not properly account for the plasticity effects at the
crack tip where the stresses are limited by the material’s yield strength.
Also, when testing ductile materials, it was realised that the amount of
energy to add to initiate crack propagation was significantly higher than
predicted by LEFM. This was explained by the role of the plastic zone in
which the crack propagates. For ductile materials where there is a large
plastic zone at the crack tip which affects the fracture mechanics of the
crack, instead of LEFM, Elastic-Plastic fracture mechanics (EPFM) is used.
EPFM considers the elastic behaviour of the material and the local plastic
deformation at the crack tip. This plastic zone absorbs energy from the
crack driving force as deformation occurs and makes the material tougher.
The equations governing EPFM are more complex than those for LEFM
(such as Equation 3-1) and beyond the scope of this course.
Figure 3.33 The plastic zone at the crack tip limiting the crack tip stress in EPFM,
compared the purely elastic assumption in LEFM.
If the plastic zone can extend across the entire ligament of the un-cracked
body in a test specimen, this can give a completely plastic net section of
material. The failure mode in this case is by plastic collapse. Large amounts
of energy are absorbed as the material work hardens and the plastic hinge
is formed. It is common for failure of both test specimens and structures to
occur via a combination of brittle and ductile failure modes, the latter being
recognised by the formation of shear lips on the fracture surface.
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Figure 3.34 A large plastic zone at the crack tip of a fracture mechanics test
specimen resulting in a plastic hinge across the remaining ligament.
Figure 3.35 Fracture mechanics specimen illustrating how J and CTOD are
measured.
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Figure 3.36 Fracture mechanics test specimens; a single edge notched bend
(SENB specimen and a compact tension (CT) specimen.
Full thickness specimens are used so that the thickness effect on fracture
toughness can be accounted for in the test. Specimens have a sharp crack-
like notch. The specimens are loaded under representative service
conditions. Usually three identical specimens are tested at a given
temperature. The principle of fracture mechanics testing is to load the
specimen and measure the displacement at the crack mouth using a clip
gauge (or sometimes a pair of clip gauges). SENB specimens can be used
to determine a value of K, J or CTOD depending on how the results of the
test are interpreted.
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Although these formulae are beyond the scope of this course, the three
methods for calculating the fracture toughness are given below. For CTOD
and J the overall toughness value is comprised of both an elastic and plastic
component.
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K
Y
a
Crack tip opening displacement, CTOD or :
e
l 2
p
l
K
1
/
2
E
rp
W
a
Vp
/
rp
W
a
a
z
︵
2 ︶
Y
J-integral:
J
Je K
Jp
l 2
l
1
/
E
U
/
B
b
2
︵ ︶
p
o
Figure 3.40 illustrates the various shapes of load-displacement curve that
may be produced from a fracture mechanics test at different temperatures
(and therefore different positions along the toughness transition curve). A
brittle result is characterised by toughness in terms of K and is explained
using linear elastic fracture mechanics. A more ductile result will instead be
characterised by toughness in terms of CTOD or J and is described using
elastic plastic fracture mechanics. Where the test piece has fractured in a
brittle manner with little or no plastic deformation the fracture result is
described with a subscript c, eg KIc. Where the specimen starts to tear in a
ductile manner and at least 0.2mm of tearing is measured, but the specimen
doesn’t reach maximum load before failure, the result is given a subscript u,
eg u. When the load-displacement curve shows completely plastic
behaviour and exceeds maximum load, the result is given a subscript m, eg
Jm.
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The fracture mechanics test standards include many checks to ensure that
results are valid. These include restrictions on the fatigue crack size,
position and shape, together with limitations on the maximum allowable
fatigue load. The final fatigue pre-crack shape and length is not determined
until after the test and the specimen is broken open. If the crack front it not
straight enough then the test may not be fully qualified to the standard. In
fracture mechanics testing it is not unusual to get results that are not fully
qualified because parameters like the fatigue pre-crack cannot be checked
until after test and are affected by weld residual stresses which could be
present. If some validity criteria are not met, the results may still be useable,
but expert advice is needed to justify this.
Figure 3.41 Choosing the specimen and notch orientation when testing welds.
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The location of the notch in the weld HAZ or parent metal is important as an
incorrectly positioned fatigue crack will not sample the required area,
making the test invalid. To be certain that the crack tip is in the correct
region, polishing and etching followed by a metallurgical examination are
often carried out prior to machining the notch and fatigue cracking. This
enables the notch to be positioned very accurately. This examination may
be carried out after testing as further confirmation of the validity of the test
results.
Figure 3.42 Surface notching and through-thickness notching into the HAZ to
target a specific microstructure.
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Figure 3.43 Failure modes for which BS7910 gives guidance for assessing flaws.
a b
Figure 3.44 a Flaw types and dimensions in BS 7910 to assess a real flaw b.
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The fracture toughness input value is the lowest result taken from three
similar specimens. Additional fracture mechanics testing is recommended if
the results from the set of three are too scattered; if the lowest value of
CTOD is less than half the average, or if the highest value is more than
twice the average. For values of K then more testing is recommended if the
minimum is below 0.7 times the average, or if the maximum is above 1.4
times the average.
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The failure assessment line, plotted from a point on the X-axis to a point on
the Y-axis shows the limit of safety for failure from either mode. If the
assessment point lies inside the curve, the flaw is acceptable and if it is
outside the curve it is unacceptable (Figure 3.46). A critical calculation can
be made by making iterations until the assessment point lies on the failure
assessment line.
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Figure 3.48 Validation of the BS 7910 procedure with full-scale tests and wide
plate tests.
The FAD is a useful visual tool for assessing a single flaw size and
determining whether is can be considered safe or not. However, when a
structure is experiencing fatigue, the crack grows from a sub-critical size
until it is sufficiently large to cause failure. In the BS 7910 procedures the
rate the fatigue crack grows can be estimated and an initial tolerable flaw
size can be derived if the lifetime is known and hence the final (critical)
crack size calculated.
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3.23 Summary
At the end of this module you should be able to describe the risks for brittle
fracture, ductile failure, creep and fatigue etc based on the different types of
loading experienced in service and select suitable materials to be resistant
to these failure modes. You should know the difference between Charpy
testing and fracture mechanics testing of welds and describe them. You
should understand the basics of fracture mechanics in terms of the
behaviour of cracks in materials, LEFM and EPFM. You should know how to
carry out an engineering critical assessment (ECA), what input data is
required and how the assessment point is plotted on an FAD for different
assessment levels. You should be able to explain the benefits of fitness-for-
service assessment
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Revision Questions
1 What do LEFM and EPFM stand for and what are the differences between them?
2 Sketch a failure assessment diagram and describe how you would determine
where to plot the failure assessment point.
3 What are the advantages and disadvantages of using very thick steel in a
structure?
4 Sketch a ductile to brittle transition curve for ferritic steel and austenitic stainless
steel. How would you determine the ductile to brittle transition temperature for the
ferritic steel?
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Section 4
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400
Stress 300
range,
range 200
N/mm2 100
50
Steel
350 N/mm2 yield
10
105 106 107 108 Cycles
Figure 4.3 Fatigue performance of welded joints compared with unwelded material.
Stress range for life of 106
500
400
cycles, N/mm2
300
200
100
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This means that for a structure under fatigue loading, using a higher grade
of steel will not extend its lifetime at all. In fact using thinner sections under
higher stress will reduce the fatigue performance for higher strength steels.
Evaluation of a great deal of experimental work has led to the development
of design S-N curves that are relevant to individual joint geometries, as
shown in Figure 4.5.
Stress range,
N/mm 2
300
static design limit
200
100
30
10 5 10 6 10 7
Endurance, cycles
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Class A
Plain steel with all surfaces machined and polished with a uniform or
smoothly varying cross section (no guidance given in the standard).
Class B
As-rolled steel with no flame cut edges. Full penetration butt welds free of
defects. The weld must be parallel to the direction of stress with smooth
dressed faces.
Figure 4.7 Class B welded joint: Longitudinal, butt weld with smooth surface
(ground flush cap).
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Class C
Full or partial penetration butt or fillet welds which are parallel to the
direction of stress. These must have been made by mechanised welding
and have no start/stop locations. This class also includes butt welds made
from both sides transverse to the direction of stress, which are proved
defect free by inspection and machined flush.
a b
Figure 4.8 Class C: a and c Longitudinal fillet welds and b Transverse, ground
flush butt welds.
Class D
Full or partial penetration butt or fillet welds which are parallel to the
direction of stress with a stop/start point. Full penetration butt welds made
from both sides transverse to direction of stress with a smooth weld-plate
transition.
A b
Figure 4.9 Class D: (a) Longitudinal butt weld and (b) Transverse butt weld.
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Class E
Full penetration butt welds transverse to the direction of stress with an
abrupt weld-plate transition. Such welds are usually found in overhead or
vertical butt welds. This class also includes intermittent welds parallel to the
stress direction.
Figure 4.10 Class E joint: Transverse butt weld with large toe angle.
Class F
Butt welds on backing strip, transverse to the stress direction. Member
carrying fillet or butt welded attachments clear of edge. Cruciform or T-joints
made with full penetration butt welds.
a b
Figure 4.11 Class F welded joints: a butt weld with backing strip; b longitudinal and
transverse fillet welded attachments; c Full penetration transverse fillet welds.
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Class F2
Cruciform or T-joints made with partial penetration butt or fillet welds. Butt
welds between two rolled or built-up sections.
a b
Figure 4.12 Class F2: a Cruciform joint with fillet welds and b butt weld between
two built-up sections.
Class G
Members with attachments welded to a free edge or closer than 10mm to
the edges.
Class W
Weld metal in load carrying fillet or partial penetration butt welds, regardless
of direction of stressing. Stress used in calculating the fatigue life is the
nominal stress on the weld throat.
A b
Figure 4.14 Class W: a Weld root cracking in a fillet weld, b weld root cracking in a
partial penetration butt weld.
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Figure 4.15 What are the fatigue classifications of the welds in this detail?
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Figure 4.19 Small scale fatigue test specimen as representative of full scale
structures.
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By design.
By a postweld treatment.
Broadly speaking, there are two main methods for postweld fatigue
improvement:
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The most widely used technique is weld toe grinding, using either a burr
grinder or disc grinder. The fatigue lives of welded joints which are likely to
fail from the weld toe can be improved by weld toe grinding. The aim is to
remove the sharp discontinuities (intrusions) due to welding and to blend the
region to reduce the stress concentration factor. Burr grinding is the most
effective method, but disc grinding (with great care to avoid deep notching
and the introduction of deep scratches) can be effective.
Other techniques such as remelting the weld toe with a TIG torch or plasma
torch are also available but are more difficult to control and are less widely
used.
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Figure 4.22 A weld with toes that have been burr ground.
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Other techniques include the use of a needle tool peening (Figure 4.31) and
ultrasonic impact treatment (Figure 4.32).
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One additional benefit of weld toe improvement methods is that they tend to
be more effective when applied to welds in high strength material. Thus,
they offer the possibility of utilising high strength materials in fatigue-loaded
welded structures (Figure 4.35).
400
Mild steel
R=0
300
Hammer peened
Stress
range 200 Burr ground
N/mm2
Shot peened
150
As welded Plasma dressed
100
5 6 7 7
10 10 10 5x10
Endurance, cycles
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Figure 4.35 Effect of fatigue improvement techniques over a range of steel yield
strength.
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Figure 4.39 The recovered top section of the mooring failure (now upside down).
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Some of the tubulars showed classic brittle fracture surfaces (Figure 4.40).
Others were found to show fatigue cracking (Figure 4.41). Final ductile
overload was also observed. From these failure mechanisms the engineers
could formulate a sequence of failure (Figure 4.42).
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A reasonable hypothesis for the cause of the fatigue crack initiation was that
the weld was significantly misaligned, which would act as a stress
concentration (Figure 4.43). However, much later on when the other half of
the failed structure was recovered from the sea bed, the other half of the
weld could be placed next to the initial half, which disclosed the reason why
that weld had initiated a fatigue failure. Although no misalignment would
have been measured on the outer surface, a significant part of the wall
thickness had been removed to allow this fit-up (Figure 4.44). This would
result in much higher stresses in the thinner wall, increasing the risk of
fatigue cracking.
Figure 4.43 Reasonable theory for the initiation of fatigue in this weld.
Figure 4.44 Both recovered halves of the failed weld showing actually that there
was significantly reduced wall thickness, causing the fatigue to initiate.
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The design of the bridge was decisive in it collapse. Previous bridges were
constructed with thick deck sections which meant that wind loading would
not produce resonance loading. For the Tacoma Narrows Bridge the
designers opted for a slim deck section which made the bridge look ‘better’,
but this meant that the bridge was in danger of entering resonance loading
due to wind (this was not known at the time of the design).
The bridge was rebuilt in 1950 with an improved design due to the lessons
learned from the first bridge and is now nicknamed Sturdy Gertie. Modern
suspension bridges use a box section for the deck, with a cross section
specially designed to avoid this form of resonant excitation.
4.11 Summary
At the end of this section you should understand the practical aspects of
fatigue cracking, being able to explain its initiation from weld toe intrusions
and its appearance on a fracture face. You should be able to describe a
number of possible post-weld fatigue improvement techniques and explain
how they improve the fatigue life.
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Revision Questions
1 What are the weld classes shown in this joint?
Answer:
2 Draw a fillet weld under cyclic loading and sketch fatigue cracks at the locations
they will initiate.
3 You need to carry out postweld fatigue improvement on a stiffened ship structure.
Which method would you choose and why?
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Section 5
Static Loading
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Static Loading
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5 Static Loading
5.1 Review
This section of the course shows how to develop principles of design for
static loading. When a metal is loaded under increasing force there is a
period of elastic deformation, where the material resumes its original
dimensions once the load has been removed. The limit of elastic behaviour
is the material’s yield point, after which plastic deformation and ultimately
necking and tensile rupture occurs. These features are seen on a stress-
strain curve (Figure 5.1).
The Elastic Design Method ensures that the stresses in structure do not
exceed the yield stress (ie that only elastic deformation occurs, not plastic
deformation). However, it is not usually possible to design a structure to be
loaded up to yield stress safely due to factors including material defects,
joint/weld mismatches, unforeseen loads (weather conditions etc), or
degradation. For structures that have to withstand principally static loading,
the maximum allowable stress is limited to a proportion of the material yield
strength.
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In the more general case, the maximum allowable stress is restricted such
that all criteria for failure are satisfactorily avoided, with an appropriate
margin of safety. This permits a very limited degree of plastic deformation in
some cases. Additionally, it considers other potential ‘failure modes’; for
example the allowable elastic deformation may correspond to a stress less
than ⅔ yield strength. This is called Limit State Design.
A
N N
N
A
where:
= axial stress (N/mm2 or MPa)
N = load or axial force (N)
A = cross section area (mm2)
A second form of loading may cause the material to slide over itself; this is
known as shear loading, which gives rise to a shear stress, Figure 5.3.
T
T
A
A
where: T
= shear stress (N/mm2 or MPa)
T = transverse force (N)
A = cross section area (mm2)
In the general case, a two dimension square may be subject to two normal
stresses at right angles and a shear stress. This may be extended to three
dimensions.
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Fillet welds are often used because they are the simplest and cheapest type
of welded design. Fillet welds require less joint preparation and may be
made in flat or horizontal positions by semi-skilled operators. Welds can be
completed with any number of passes
There can be possible problems with penetration into the parent metal and
they are difficult to examine by NDT methods for subsurface defects.
Once the required size of fillet weld has been calculated it is important to
stick to it, the volume or weight of weld metal increases as the square of leg
length and it is surprisingly easy to over-weld fillet welds, with associated
cost and time implications.
When calculating fillet weld sizes, not only is it assumed that the weld metal
matches (or overmatches) the strength of parent metal, but it is also
assumed that the weld will fail across the throat. The weld throat dimension
is the shortest distance between the root and the chord between the toes or
profile face (whichever is less), see Figure 5.4. Excess weld metal is
neglected and for calculation use the design throat instead actual throat.
Adequate weld quality is assumed, ie the weld is defect-free and stress
concentrations due to bead shape and residual stresses are neglected.
A b
Figure 5.4 The throat dimension in a fillet weld a and for a single bevel Tee butt
weld b.
The design stress is half the yield strength when it is not explicitly given in
the applicable standard. This is lower than a butt weld because fillet welds
tend to experience high shear forces rather than axial forces. The effective
yield under shear is lower than for axial loading, while fillet welds, being
difficult to inspect for root fusion defects, tend to be designed with a more
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Force, F
Fy
M
Fx
The bending moment is not constant along the length of the beam; it is
highest at the fixed end of the beam and drops to zero at the point of
loading. The shear force experienced, however, is constant across the
length of the beam. These can be illustrated by constructing a bending
moment diagram, Figure 5.8.
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L
x
BM +PL
SF +P
Figure 5.8 A typical bending moment (BM) diagram for a cantilever beam of length
L under an applied force, P, also showing the shear force (SF).
It is possible to calculate the tensile stress on the outer fibre of the beam in
bending using the engineers bending formula. The stress at a distance y
from the neutral axis is given by:
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M I
y
where:
M = bending moment.
I = second moment of area, or moment of inertia.
Maximum values for bending stress are obtained on the extreme fibres of
the beam. For example, an I beam has flanges to resist bending while the
web resists shear. The moment of inertia depends on the geometry of the
beam. For a beam of width b and depth d,
b 1
d 2
3
I
The section modulus (Z) is a geometric property only which relates stress
and internal moment during elastic bending. The bigger the value of section
modulus for a particular cross-section the bigger the bending moment which
it can withstand for a given maximum stress.
where ymax is the distance from the neutral axis to the extreme fibres of the
beam. Using the section modulus makes the engineers bending formula
simplified into = M/z. Figure 5.11 shows improvements to beam cross
sections to increase the section modulus. The intention is to move material
further from the neutral axis and centre of gravity.
Figure 5.11 Ways to improve the stiffness of beams, by increasing the section
modulus.
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The maximum distance to the outer fibre, y, is the distance from the neutral
axis (middle of the beam) to the top surface in tension, or half the height, ie
h/2
Using the engineers bending formula, stress equals My/I. The bending
moment, M is 6,000Nm. y is half the height, which equals 150mm. The
second moment of area, I is calculated by:
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This is the maximum stress on the outer fibre of the beam under bending.
This bending stress decays to zero at the middle of the beam along its
neutral axis, where it becomes negative or compressive stress towards the
inner fibre of the beam. This is illustrated below.
F = 9x105/50 = 1.8x104N
The stress in each fillet weld is the force divided by the cross section area
= F/(t.w), where t is the throat thickness and w is beam width (20mm). This
stress must equal the allowable stress in the welds, 250MPa. Remember
that the throat, t = L/√2, where L is the leg length
250 = (F√2)/(L.w)
So, L = (1.8x104 √2)/(250.20)
= (2.54x104)/(5000)
= 5.1mm
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In answer to the second part pf the question, the beam length makes no
difference to required weld size because the applied loading is a bending
moment. That is, F is independent of beam length.
5.6 Torsion
Torsion is similar to bending, but acts on round tubes and bars. The
torsional stress, , calculation for the stress on the outer surface of a beam
under torsion (which is valid only for round shape transverse section such
as beams, bars or tubes) is given by:
Mt
τ
Zp
Where Mt is the torsion moment and Zp is the polar section modulus of the
transverse section (equivalent to second moment of area and can be looked
up for given cross section shapes).
The largest values of stress are obtained on the extreme fibres of the beams
while in centre of section, stress is zero. The stress has a continuous linear
variation throughout entire transverse section.
The fillet weld in Figure 5.13 is subject to torsion loading. The weld area is
given by x D x t, where D is the diameter and t is throat thickness.
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The stress is the force over the cross section area, ie the torsional force
over the weld area. The overall calculation is therefore given by:
Longitudinal stress =
The hoop stress, ie the stress acting at right angles to the longitudinal stress
is given by:
p
r t
Hoop stress =
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One advantage of using steel for this purpose is that the coefficients of
thermal expansion of steel and concrete are very nearly equal so, any
change in temperature will result in the steel and concrete expanding or
contracting at the same rate, minimising deformation stresses.
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Ribbed bars are characterised by the dimensions and the number and
configuration of transverse and longitudinal ribs which influences the bond
with the concrete.
5.8.3 Joints
Reinforcing bar is available from 6mm - 50mm diameter. Depending on the
size of the concrete casting a whole assembly of reinforcing bars will usually
be used. Three methods are used to join reinforcing bars together:
Welded joint.
Wire joint.
Rebar coupler.
The most common types of joint are welded and wire. Wire joints are simply
connected by metal wire wrapped around the bars and tightened and are
used on non-load bearing joints. Rebar couplers are mechanical fixings
used to connect bars together, often using threaded ends on the bars. This
course looks at welded joints.
Welding can be used for both load and non-load bearing joints. A non-load
bearing joint normally only keeps the reinforcing components in their correct
place during fabrication, transportation and concreting and are often referred
to as tack welds. Welds which may be classified as non-load bearing in
terms of their action in the design of the structure may be subject to
significant loads during handling and transport of the assembly to site, in
such cases the welds should be treated as load bearing welded joints.
5.8.4 Properties
Reinforcing bars are available for a wide range of chemical compositions
and mechanical properties. The type of bar to be used will be detailed in the
relevant construction code for the structure being built.
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Note: the joints shown are applicable for welding processes 111, 114, 135
and 136.
Butt welds are used to join two bars together, end to end, only necessary for
load bearing joints and a range of groove designs are available to use.
Single V groove
Double V groove
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Backing strips may be used when making a butt weld. Figure 5.17 shows a
single V groove butt weld with a backing strip (applicable only to bars over
12mm). The backing strip should be tack welded to the bar on the inside.
Figure 5.17 Full penetration butt weld with permanent backing strip.
Lap joints join two bars together by staggering the ends and then welding
them together and can be used for both load and non-load bearing joints.
For load bearing joints a double sided weld is also possible with a minimum
weld length of 2.5d. The weld dimensions given in Figure 18 are valid for
load bearing joints. The minimum throat thickness, a, should be ≥ 0.3d.
Strap joints use short pieces of reinforcing bar as straps to join two pieces of
bar together. Strapping provides a strong joint so is only necessary for load
bearing joints. It requires no groove preparation unlike a butt joint but
requires extra material (straps) and more welding is required. A double
sided weld is possible with a minimum weld length of 2.5d. Where the
mechanical properties of the strap and bar are equal, the combined area of
the two straps shall be equal to or greater than the cross-sectional area of
the bars to be joined. The minimum throat thickness, a, should be ≥ 0.3d.
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Straps
The cross or cruciform joint is used when two bars are joined perpendicular
to each other, one on top of the other and are suitable for both load and
non-load bearing joints. Non-load bearing joints are usually single sided but
for load bearing joints double sided welds should be used when possible. To
avoid cracks the minimum throat thickness, a, should be ≥ 0.3dmin and the
length of the weld, l, should be ≥ 0.5dmin. If more than one transverse bar is
used on the same side of the longitudinal bar, the spacing of the transverse
bars should be at least three times the nominal diameter of the transverse
bar. When welding bars of different diameters, dmin/dmax should be ≥ 0.4.
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Table 5.3 Common range of bar diameters for non-load bearing welded joints
depending on the welding process.
Welding
Type of joint Bar diameters, mm
process
21
Cross joint 4-20
23
24 5-50
Butt joint
25 5-25
Butt joint 6-50
42
Joint to other steel component 6-50
47 Butt joint 6 to 50
Butt joint without backing ≥16
Butt joint with permanent
111 ≥12
backing
114 Lap joint 6 to 32
135 Strap joint 6 to 50
136 Cross joint 6 to 50
Joint to other steel component 6 to 50
A butt joint is classed as a direct loading joint as the bars are axially aligned;
lap and strap joints are indirect loading joints as the forces are transmitted
with eccentricity. Eccentric loading causes the joint to flex hence bending
stresses are set up. Attention needs to be paid to the steel-concrete bond
strength at these joints to ensure the concrete does not split when the joint
flexes.
5.10.2 Preheating
Preheating is the process applied to raise the temperature of the parent
steel before welding, used to slow the cooling rate of the weld and the base
material, resulting in softer weld metal and HAZ microstructures with a
greater resistance to fabrication hydrogen cracking. The slower cooling rate
encourages hydrogen diffusion from the weld area by extending the time
over which the temperature is elevated to where hydrogen diffusion rates
are significantly higher than at ambient temperature. The reduction in
hydrogen reduces the risk of cracking.
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The minimum preheat temperatures for reinforcing steel welded joints are
dependent on the type of joint, the carbon equivalent value of the steel, the
diameter of the bar or combined diameter of the joint, the hydrogen content
of the weld metal and for some joints the arc energy. The following data is
taken from BS 7123:1989.
Table 5.4 Minimum preheat temperatures for butt and cross joints.
Nominal bar size, mm
Carbon
equivalent, % ≤ 25 > 25-40 > 40
Non- Non- Non-
Hydrogen Hydrogen Hydrogen
hydrogen hydrogen hydrogen
controlled controlled controlled
controlled controlled controlled
consumable consumable consumable
consumable consumable consumable
0.42 or less 0°C 50°C 0°C 75°C 50°C 100°C
> 0.42 to 0.51 50°C 100°C 75°C * 100°C *
* Hydrogen controlled consumables to be used
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5.12 Summary
At the end of this section you should be able to calculate the static stress in
beams under axial loading, bending moments and torsion. You are expected
to explain the way that reinforcing steel bars improve the load bearing ability
of concrete and give joint designs for welding reinforcing bars together.
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Revision questions
1 What formula do you use to calculate the second moment of area for a
rectangular section beam?
3 Show designs with improved section modulus compared to solid round or square
bars.
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Section 6
The main standards for the design construction of boilers and pressure
vessels in the UK and in Europe are PD 5500 and the BS EN 13445 series.
BS EN 13445 is harmonised with the Pressure Equipment Directive (PED),
so that compliance with BS EN 13445 can be used to demonstrate
compliance with the PED. In other parts of the world, the ASME Boiler and
Pressure Vessel Code (ASME= American Society of Mechanical Engineers)
is most widely used. These design codes specify maximum allowable
stress, the minimum design temperature (MDT) and list permitted materials,
mechanical properties and design features that can be used in the design of
pressure vessels. These are all to ensure that the pressure vessel designs
conservatively meet the service requirements and ensure the safety of the
vessel over its lifetime.
Shell(s)
Main body of the vessel, it is most often cylindrical but some pressure
vessels might use conical or spherical shells.
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Heads
A head is present at each end to complete the basic shape and produce a
closed container. They are most often dished but can also be flat.
Nozzles
A number of openings for filling, inspection or drainage.
Saddle supports
Saddle supports hold the pressure vessel in place.
Nameplate
Nameplates indicate the main working parameters of the pressure vessel
including work pressure and temperature. Details also included may be the
manufacturing company, year of manufacture, the relevant code according
which the pressure vessel has been designed and manufactured and the
inspection body stamp.
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The shell of a pressure vessel can range in thickness from only a few
millimetres for an LPG gas bottle to several hundred millimetres for
industrial pressure vessels. The minimum design thickness is dependent on
the shape of vessel, the internal pressure, the diameter of the vessel and
the material strength. A spherical shell requires a much smaller wall
thickness than a cylindrical shell for the same diameter, internal pressure
and construction material. If a pressure vessel is to contain corrosive fluids
there may be an additional corrosion allowance given on the required wall
thickness, although the design stresses are calculated without the corrosion
allowance.
The hoop stress within a pressurised cylinder is twice that of the axial
stress, so there is a higher potential that the failure of a pressure vessel will
occur along the longitudinal welds. In order to prevent cracks propagating
along the entire length of a vessel, longitudinal welds are normally offset. In
the ASME Boiler and Vessel Code, Section VIII, Division 1, vessels made of
two or more strakes shall have the centres of the welded longitudinal joints
of adjacent courses staggered or separated by a distance of at least five
times the thickness of the thicker plate. In PD 5500, the longitudinal seams
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a b c
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The junction of the torus with a cylinder gives rise to bending stresses., but
torispherical dished heads are often preferred to semi-elliptical ones since
the depth of drawing is less and so they are cheaper to manufacture. Also
the small axial dimension is of advantage when the longitudinal size of the
pressure vessel is a critical factor. However, the thickness required for a
torispherical dished head is larger than the thickness of the corresponding
cylindrical shell.
The weld preparation used at the shell to head joint can be designed to
account for any misalignment which may occur between the head and the
shell (Figure 6.5a). The simplest of these is a ’K’ bevel as seen in Figure
6.5b).
a b
The main advantage of this type of preparation is that only one side of the
joint needs to be machined to a specific geometry. The disadvantage
however is that access to both the internal and external surfaces is required
in order to complete the weld. Also, the misalignment can cause local
bending stresses in the shell. Alternative joint designs suitable for single-
sided access for shells to heads welds are shown in Figure 6.6.
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a b
Figure 6.6 Alternative self-jigging single-sided access joint designs for shell to
head welds.
Both these designs shown in Figure 6.6 have the advantage of requiring no
jigs during fit-up since both are self-jigging. They both also allow for use of
high heat input welding processes to deposit the weld root as backing is
provided, require access from one side only and have no danger of burn
through. The disadvantages of such weld preparations are that they are
difficult to inspect and have poor resistance to fatigue. In addition, Figure
6.6a) results in a high level of residual stresses and is hard to apply to thin
walled components. Figure 6.6b) on the other hand can only be applied to
thin walled components.
Set-on nozzles have the benefits of being cheaper to forge since they are
shorter, requiring less weld metal leading to less distortion; groove
preparation is easy and can be used with full or partial penetration welds.
Disadvantages of set-on nozzles however include the limitation for access
from one side only and welding in the 2G/2B position and thus requirement
for a skilled welder. With set-on nozzles, the through thickness stress from
welding can lead to lamellar tearing and it can be difficult to apply UT on
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small diameters. Set-on nozzles are generally used when the nozzle
diameter is small (typically under two inches) and/or when the vessel has a
large diameter or thick wall. When using set-on nozzles, it is often
necessary to use compensating plates or other reinforcement.
Figure 6.9 Drilled out round bar to aid penetration of small diameter nozzles.
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Reinforcement can be used either on the shell, on the nozzle or both. Figure
6.10 shows two types of reinforcement.
A b
Parent metal.
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Hole drilled.
6.6 Flanges
Flanges connected to the nozzles attach other pieces of plant to the
pressure vessel via a network of piping. The flange faces are held together
using bolts, which enables them to be disconnected and reconnected when
needed. A gasket, made of softer material sits between the flange faces and
deforms under load to produce a tight seal in the joint.
Most flanges are designed to a particular code (such as ASME B31.3) and
will have standard dimensions and a given pressure rating. This is to utilise
their interchageability and flexibility to attach to other pieces of pipework and
equipment.
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Figure 6.12 Flanges, showing the design principle and a flange attached to a
pressure vessel nozzle.
The welded joint efficiency is defined as the ratio of joint strength to parent
material strength. It varies from 100%-45% according to the standard and to
the level to which the integrity is assured, such as the extent of NDT
(whether 100%, spot inspection or none), joint design (whether full
penetration, using backing bar, lap joint, etc). The efficiency factor is often
applied to the design stress to reduce the level to which the welded joints
will be loaded if there is any uncertainty in their integrity. The weld joint
efficiency factors employed by certain pressure vessel codes are given
below.
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Considering a section of length, L, the total vertical force due to the internal
pressure acting on half the cylinder Fy equal to:
Fy' 2 P r L [6-1]
The internal force in the vessel wall needed to balance this force for
equilibrium, F’y, which is supplied by the resulting hoop stress, is equal to:
Fx' 2 L t y [6-2]
Thus we can set these to forces equal to one another to find a value for the
hoop stress σy.
2
L
t
2
P
r
L
y
[6-3]
y
. [6-4]
The axial force exerted on the shell, Fx, as a results of the internal pressure,
p, can be calculated by the following equation.
Fx p π r 2 [6-5]
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where r is the radius of the pressure vessel. The cross sectional area of the
vessel shell wall, A, is approximately equal to:
A 2 r t [6-6]
Thus the resulting opposing axial force within the shell, F’x, as a result of the
axial stress, x, is equal to:
F' x x 2 r t [6-7]
x 2rt P r 2 [6-8]
Pr
x [6-9]
2t
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The force F acting over the cross section due to the internal pressure is
equal to:
F p r 2 , [6-10]
The cross sectional area A of the vessel wall is equal to the circumference
multiplied by the wall thickness:
A 2 r t , [6-11]
And the reaction force due to the internal membrane stress is equal to:
F 2 r t . [6-12]
Setting these two forces equal to one another allows us to evaluate the
stress resulting from the internal pressure p:
2 r t p r 2 [6-13]
pr
. [6-14]
2t
A sphere thus provides ideal closure to a cylinder since the stresses are
less than those in other shapes which would have an associated hoop
stress. In practice however, the high degree of mechanical forming
necessary together with the necessity to change the set of die-former for
each different diameter makes it impractical except for very high-pressure
vessels.
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Pressure vessels are widely used in various industry sectors such as Oil
and Gas, Petrochemical, Power Generation, etc. Generally speaking, a
pressure vessel is a container designed to hold liquids or gases and store
them at a different pressure to that surrounding the structure without
changing volume.
Fired pressure vessels are vessels that include power boilers and other
vessels that are designed to accept heat. This category of component would
include coal/gas and oil fired boilers as well as boilers that are heated by a
waste heat gas stream or a hot oil system. Electrically heated steam
generators are also considered to be fired. Steam boilers are used to
generate steam by boiling water; often the steam is required for
petrochemical process plant.
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Fractional distillation columns are used to separate crude oil into its
many components and can be as tall as 60 meters or more. The heating
within the vessels is incremental, operating at about 400°C at the bottom,
decreasing the as you move up the vessel. This means that the weight of
the vessel rests upon the area most susceptible to creep, hence making it
prone to deformation. This is exacerbated by the pressure exerted by the
vessels contents. In order to provide the best resistance to creep possible,
the vessels are usually made from high strength, low alloy steel such as Cr-
Mo steel.
Unfired pressure vessels are not in direct contact with a heating flame.
These would include equipment such as pressurized tanks storing air,
nitrogen ammonia or natural gas.
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Materials
Improper selection of materials for given service loading and temperature
may result in overload or fracture. If there are defects in the materials such
as inclusions, these could cause lamellar tearing after welding.
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Design
Incorrect design data or inaccurate or incorrect design methods will not
result in the correct design to meet the required service conditions. This may
not have been identified in time is there was inadequate shop testing.
Fabrication
Poor quality control during fabrication, or improper or insufficient welder and
welding procedure qualification can result in defective welds being present,
giving a risk of fatigue, or fracture. Inadequate post weld heat treatment can
leave high residual stresses or excessive hardness in the welds. If forming
methods are inadequate, then the fit-up during welding can be poor and
additional defects, distortion or bending stresses can result.
Service
It can be common for failures to occur as a result of a change of service
condition by the user without proper revalidation. Inexperience operations
and maintenance personnel can mean that safety devices can be
overlooked and failures be more likely. Sometimes the upset conditions
during operation exceed those anticipated during design, which can cause
failures.
Figure 6.20 The John Thompson pressure vessel after failure during hydrotest.
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The basic premise behind a pressure vessel code is that equipment should
meet its requirements in all respects, ie full code compliance. This is not
always strictly adhered to, with the result that some equipment may be
specified as being code intent. This means it may comply with the code in
some areas, eg design stresses, but not in others, such as the requirements
for NDT and defect acceptance criteria. Equipment built to such code intent
cannot be officially code stamped though.
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6.12.1 EN 13445
Latest Edition 2009
Design covered by Part 3
Corrosion There is some clear guidance, including a minimum corrosion
allowance of 1mm (Section 5)
Design methods Design-by-rule (Section5)
Design-by-analysis (Annexes B and C)
Experimental techniques (very little guidance)
Weld joint coefficient Depend on the extent of NDE, similar to ASME VIII Div 1
Notes EN 13445 was developed as a harmonised standard for use
with the Pressure Equipment Directive (PED) and is intended
to cover the essential safety requirements (ESRs) of the PED.
Use of this standard is not mandatory in the PED, but vessels,
designed, manufactured and tested in accordance with this
standard have an automatic presumption of conformity with
the ESRs of the PED.
6.12.2 PD 5500
Latest Edition 2009
Design covered by Section 3
Construction categories Three construction categories (Section 3.4)
Joint efficiencies -
Joint types Type A and B with different NDT requirements (Section 5.6.4)
Design features Figures E.1 to E.6 show typical (rather than mandatory) weld
details
Notes The technical content claims to satisfy the essential safety
requirements of the PED
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6.13 References
The following references are recommended for further reading:
6.14 Summary
At the end of this module you should be confident to explain the design of
different weld details for welding pressure vessels and describe their
particular advantages. You should be able to interpret different pressure
vessel codes and calculate axial and hoop stresses in a cylindrical pressure
vessel. You should be able to design structural details such as nozzles,
dished heads or flanges for a pressure vessel and explain the advantages of
your chosen design.
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Revision Question
1 You are designing a 3 metre diameter cylindrical pressure vessel which will be
supported horizontally. The vessel requires a manway access as well as
connections to 2inch diameter pipework for both the incoming and outflowing
process fluids. The vessel shell is made from 30mm thick steel plate. Sketch your
pressure vessel, showing the structural details and the weld joint preparations
you intend to use, explaining the reasons for your choices.
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Section 7
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Figure 7.3 Effect of higher stress or larger number of cycles on the predicted
fatigue failure (above the S-N curve).
Figure 7.4 S-N curve plotted on logarithmic axes, showing a linear relation in the
high cycle regime.
The position of the S-N curve is affected by stress concentrations and other
features. A simple notch will reduce the S-N curve (Figure 7.5). Welded
structures have intrinsic sharp stress concentrations at the intrusions at weld
toes and show much lower fatigue resistance than plain or notched material
(Figure 7.6). Welded structures effectively do not have any initiation period
for fatigue and will propagate fatigue from the weld toes if exposed to
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One of the most serious consequences of the fact that the fatigue lives of
welded joints are dominated by crack growth concerns the influence of
material strength. Although the fatigue strength of un-notched material
usually increases with tensile strength, the level of increase decreases if the
material contains a notch until there is no increase at all for welded material
(Figure 7.7). This is because rate of fatigue crack growth is not dependent
on material strength and hence welded low and high strength materials give
the same fatigue life. The benefit of material strength comes in the crack
initiation stage, which is effectively absent in the welded material. For a
structure under fatigue loading, using higher strength material, whereby a
thinner section can be used under higher stress, is a real mistake. Not only
does the higher stress level result in fewer cycles to failure, the thinner
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section takes less time to fatigue crack though. A thicker member under
lower stress will have a better fatigue life.
Figure 7.7 The change in S-N curve with steel strength for parent material,
notched metal and welds.
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K defines the magnitude of the crack tip singularity (stresses near tip are
proportional to 1/√r and K) and it defines the crack tip conditions under
linear elastic conditions: if K is known, stresses, strains and displacements
can be determined. If a material fails locally at some critical combination of
stresses and strains, this corresponds to a critical value of K, which is a
measure of fracture toughness.
The stress intensity factor varies with time in the same way that the stress
varies with time, Figure 7.9.
Fracture
Relationship between
da/dN and K
increasing R
determined
experimentally
Log (da/dN)
m
da
1 Paris law : = A (K)m
dN
increasing R
Figure 7.10 Relationship between crack extension per cycle and stress intensity
factor ranges.
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Where A and m are material constants. This is known as the Paris equation.
There is no influence of mean stress on crack growth rate in this central
region.
At low values of K, the rate of crack extension per cycle reduces rapidly
and effectively becomes zero. There is therefore a threshold stress intensity
factor range (K0) below which fatigue crack growth does not occur. This
threshold occurs at lower values of K as the mean stress is increased.
The Paris equation can be used to establish the rate at which a crack of a
given length will grow when subjected to a specific stress range. Simple
mathematical techniques based on integrating the Paris equation are
available to determine the number of cycles required for a crack to grow
from a given size to a greater limiting size. This approach forms the basis for
fitness-for-purpose assessment of cracks or planar weld flaws subjected to
fatigue loading.
For a given situation, all the terms on the left hand side of the equation are
approximately constant, so that the integration predicts a linear S-N curve of
the form ∆σmN = constant, where the slope m is the same as that in the
Paris law. This partly explains why most of the S-N curves for welded joints
are parallel with a slope corresponding to m = 3, the value which most
fatigue crack growth data approximately conform to.
The flexibility of the fracture mechanics approach is such that any of the four
main variables, ai, amax, ∆s and N can be calculated if the other three are
known. For example, if N is unknown it is possible to calculate the life of a
known flaw under specified loading or inspection periods based on
detectable crack amax. If flaw size ai is unknown you can estimate the
tolerable flaw size to satisfy the required S-N curve; if amax is unknown you
can estimate the required toughness to avoid unstable fracture from fatigue
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a b
Figure 7.11 Fatigue fractures as seen under the scanning electron microscope; a
fatigue striations in an aluminium alloy; b intergranular fracture in a hard HAZ in
steel.
a b
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The graphs in Figure 7.13 summarise the mean + 2SD 2-stage crack growth
laws recommended in BS 7910, all for R ≥ 0.5. Other curves are provided
for R < 0.5. In addition, conservative single Paris laws are provided for
convenience. Special attention is paid to environmental influences and the
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Free corrosion produces around 3-fold increase in da/dN compared with air;
use of cathodic protection (correct or over-protection) restores in-air
behaviour up to K = 144 N/mm3/2 (315 N/mm3/2 for R < 0.5), but da/dN
increases at higher values. Cathodic over-protection (-1100 mV) is
particularly detrimental at high K and K max due to the generation of
hydrogen. The majority of the raw data were generated to reproduce North
Sea conditions, approx. 6-10oC and a cycling frequency of 1/6 Hz. Crack
growth rates could be higher at higher temperatures and lower frequencies
and vice versa.
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Figure 7.15 Objective of cycle counting to convert a variable amplitude stress cycle
into blocks of common stress range.
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Figure 7.16 Sections of constant and variable amplitude loading illustrating the
problem of cycle counting.
For the variable amplitude sequence there are many other options to divide
the cycles and each different cycle count if used in a design calculation will
give a different result. There is no ‘correct’ way of counting cycles in variable
sequences but there are several standard methods which can be used. Two
methods (rainflow and reservoir) are extensively used as they give similar
results and produce the most severe count from the fatigue point of view.
The rainflow method gets its name from the analogy with the flow of
raindrops down a pagoda roof. The first step is to redraw the stress as a
sawtooth pattern with the magnitudes of the peaks and troughs unaltered.
To simplify the peaks and troughs have been labelled with letters. The
stress sequence is reproduced with time as the vertical axis and the starting
point at the top, Figure 7.17. As a convention the trace will begin and end at
the highest peak in two successive occurrences.
The waveform is broken into a series of paths which raindrops can follow,
the beginning and end of each path defining the extremities of a half cycle.
Raindrops can flow both from right to left and from left to right and a path or
a combination of paths must cover the top of every roof.
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The count will extend from the first occurrence of the highest peak J to the
corresponding peak J’ the second occurrence of the same event. The
raindrop starts at J and is allowed to run down until a peak or trough is
reached, when the rain falls vertically until it reaches another roof, the
process is repeated until one of the two conditions is satisfied:
1 For rain falling down a roof, the path cannot cross paths with rain which
is falling from above (examples in Figure 7.17 LM, E’F’ and G’H’)
2 For a raindrop starting at a trough and falling vertically from a peak the
flow stops if the drop passes opposite a trough which is more negative
than that at the start of the path under consideration (drops falling from L
for which trough N is more negative than K). Similarly for a drop starting
from a peak and falling vertically from a trough the flow stops if if the
drop passes opposite a peak which is more positive than the one at the
start (drops falling from G’, for which peak J’ is more positive than C’).
Each complete flow path (JKMN, KL, LM, C’D’F’G’ Figure 7.14) is
considered a half cycle and half cycles of equal stress range are combined
to give complete cycles. Small interruptions in the flow path such as KLM
result in complete cycles, ie KL combined with LM but a cut-off value in the
magnitude of the stress may be imposed for small interruptions.
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Reservoir counting involves counting whole cycles rather than half cycles for
the rainflow method, but produces the same result. The stress history is
taken to represent the cross section of a reservoir, which is drained
successively from each low point (trough) counting one cycle for each
draining operation. The magnitude of the corresponding cycle is equivalent
to the depth of the water drained. Figure 17 represents the same stress
sequence as in Figure 16, but counted using the reservoir method.
1 The reservoir is bounded by the two highest peaks (JJ’) and a line is
drawn representing the surface level.
2 Drain the reservoir from the lowest trough (N) and note the height of the
original water level (to N) which represents the range (260). This results
in water being trapped behind other peaks L, O, U and C’
3 Step two is repeated for the remaining bodies of water until all water is
drained, listing each cycle with each drainage operation
If there are two or more equal lowest points (such as P and R) it makes no
difference which one is used as the initial drainage point, the final answer
will not depend of the choice but will be the same whichever is chosen first.
Once the fatigue spectrum can be separated into sets of cycles with the
same stress range, Miners rule of linear cumulative damage is then used to
assess the contribution of each set to the total fatigue damage.
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n 2N
where:
n1 = number of cycles applied at stress range 1
N1 = number of cycles allowed at stress range 1
Σn/N_(i ) 1 at failure
where i = 1,2,3 etc, should be less than 1 at the end of the service life. Often
a safety factor is applied such that the allowable fatigue damage is limited to
less than 1.
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The fatigue stress spectrum The flaw type and The fatigue crack growth
collated into blocks of same geometry relationship
stress range.
The flaw type and the applied stress range contribute to the
determination of the stress intensity range K. This, in conjunction with the
fatigue crack growth relationship allows integration of the crack growth cycle
by cycle to determine final flaw size. This final flaw size can then be
evaluated in a fracture assessment.
The type and geometry of the flaw will have a significant effect on its fatigue
performance. The parameters to be considered include whether the flaw is
is a surface flaw or a buried defect, the flaw height, length and ligament
height (Figure 7.19). The plate thickness also needs to be known. In a
fatigue assessment, all flaws are assumed to be planar, which can be over-
conservative for volumetric defects such as slag inclusions. If a flaw is not
aligned perpendicular to the principal applied stress, then the flaw
dimension is taken as the resolved flaw dimension perpendicular to the
applied stress.
Figure 7.19 Fatigue flaw dimensions to use as inputs into a fatigue assessment.
BS 7910 includes procedures for dealing with groups of flaws. If flaws are
close to each other, they may interact (ie the stress intensity factor for the
flaw is increased by close proximity of other flaws). BS 7910 gives flaw
interaction rules, where pairs of flaws are considered. However, it is now
recognised that these are not applicable in a fatigue assessment. Multiple
fatigue cracks behave independently until they actually coalesce. Therefore,
the flaw interaction rules required in a fracture assessment are not applied
in a fatigue assessment.
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Figure 7.20 Flaw interaction rules for fracture are not applicable to fatigue
assessments.
The stresses used as input to a fatigue assessment are the primary and
secondary (excluding residual) stress ranges due to fluctuating components
of applied load, allowing for stress concentration factor kt due to any gross
structural discontinuity, if necessary.
kt (P + Q)
The applied stress intensity range is proportional to the stress range and the
size of the flaw, ΔK YΔσ √πa. There is also a significant influence of
geometrical factors which makes the calculation more complex:
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Figure 7.22 Incremental crack growth assessed using the Paris Law.
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If the conditions are such that fracture is a possibility before the fatigue
crack breaks through to the surface, then additional allowances must be
included on flaw size to account for dynamic snap-through effects.
Provided failure conditions are not reached during the required service life of
the component, the crack can be considered to be acceptable. The
calculations can also be used to define appropriate inspection strategies for
detecting and monitoring fatigue crack growth.
7.8 Summary
At the end of this module you should understand how to interpret an S-N
diagram and how the S-N curves are affected by factors such as joint design
or tensile strength. You should be able to explain how to carry out a fatigue
assessment on a variable amplitude stress spectrum, including methods for
cycle counting and Miner’s rule. You should also understand how fatigue
cracking is assessed using fracture mechanics methods to determine the
crack growth over a given number of cycles.
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Revision questions
1 Sketch a graph of S-N curves for plain material, notched material and welded
material.
5 What might be the failure criteria for an embedded flaw growing by fatigue?
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Section 8
Stresses in Welds
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8 Stresses in Welds
8.1 Why calculate weld stress?
Most products are made from more than one piece of material; most
products, therefore, need joints to hold the pieces together. The cost of
assembling and making joints is frequently the major part of the total
production cost. More products fail from inadequate joints than any other
cause. Many products contain hundreds or thousands of joints. The cost of
disassembly and repair of one failed joint can often exceed the cost of an
entire new replacement product.
Inadequate joint design costs the world economy hundreds of billions of $/£
each year.
1 Draw a diagram! Make sure you have a large sketch of the joint design
and the weld dimensions. Label the information you have, such as
component size, leg length or throat size, plate thickness, applied load
etc.
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2 Calculate the weld cross section area. Is the load carried by just one
weld, or are there two welds (eg in a lap joint or double sided fillet weld).
What is the design throat (not the actual throat)?
3 Convert the applied forces into a stress. What are the units of the forces
or loads you have been given? What units will you need for the
calculation? Is it an axial stresses or shear stress? Does more than one
stress need to be combined into an effective stress?
4 Compare the stress to the allowable value. What is the design stress?
Do you need to determine it from the parent metal yield strength?
If the parent materials are stressed close to their own mechanical limits, the
joint will need to be full strength, ie at least as strong as the weakest parent
member being joined. The static stress limit is never the material’s yield
strength, but is often ⅔ of the yield strength, so that there is a sufficient
margin in the design.
Conversely, if the members at the joint position are always stressed well
below their potential static strength, the joint can be designed to be partial
strength. A joint that is designed to be able to withstand ⅔ of the parent
metal yield strength, but which only ever experiences, say, a quarter of the
yield stress is over-engineered and there may be a case to use less
welding, less consumable and save unnecessary costs.
The most onerous mode of stressing on a joint is, generally, tension. This
will arise whenever the members joined are subjected to axial tension or
bending. The most common modes of failure are shown in Figures 8.1-8.3.
It is good practice to ensure that welded components fail in the parent
material rather than in weld metal, by using an over-matching weld metal.
Figure 8.1 Possible locations of failure in fillet weld under static loads.
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either:
Weld throat
or:
HAZ or parent
material
Weld throat
Figure 8.2 Possible locations of failure in butt weld under static loads. It is good
practice to ensure that welded components fail in the parent material rather than in
weld metal.
Weld throat
Weld throat
or:
HAZ or parent
material
Figure 8.3 Possible locations of failure in lap welds under static loads.
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8.3.3 Fatigue
Fatigue will only occur if there are a sufficient number of stress fluctuations
of a sufficient magnitude during the design life. Fatigue is covered in more
detail in the lectures on the dynamic loading of structures.
Toe
crack
Figure 8.4 Fatigue crack propagation from weld toes under cyclic loads.
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Toe
Z2
Toe
Root
Z1
leg length
The relative magnitude of shear and axial stresses in the weld is determined
by both the geometry of the component and the direction and position of
loading. Figure 6 shows the orientations of the axial and shear stresses in a
fillet weld. It is possible that two types of shear might exist in a fillet weld as
shown in Figure 8.6. The shear stresses and the axial stress are all shown
acting on the weld throat.
Figure 8.6 Definition of stresses on the weld throat of typical fillet welds.
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reaches a critical value. There are a number of methods to combine all the
stress components to calculate the effective stress. A simple, but
conservative, formula for when there is one axial stress and one shear
stress is given below.
2
e
f
f
e
c
t
i
v
e
Figure 8.7 Stresses occurring in a fillet weld under load according to the IIW
formula.
The value of these stresses can be calculated by resolving the load P onto
these three axes. The stresses are calculated by dividing these load
components to the weld’s cross section area. Let’s consider the load
component acting perpendicular to the throat as Ptension, the load component
acting along the throat as P and the load component acting along the
longitudinal axis of the weld as PII. If the weld throat is t and the weld length
is L, the stresses produced by these load components are:
Ptension P PII
II
Lt Lt Lt
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These stresses are further combined to give an equivalent stress using the
following formula:
In the above formula, is a coefficient that takes into account the type of
material. It has a value of 0.7 for carbon steels and 0.85 for high strength
low alloy steels. In order to avoid failure, this equivalent stress must not
exceed the allowable tensile stress all. Since this method is more refined
than the previous simple one and a higher applied load can be tolerated,
sometimes this method gives smaller weld sizes.
The method for calculating stresses in fillet welds is also applicable to fillet
welds in lap joints too.
Take this example of a fillet weld deposited using the correct leg length of
4mm (Figure 8a) and where the weld has been over-welded and a 6mm leg
length has been deposited (Figure 8.8b). What is the difference between the
cross section area (CSA) and hence the relative volume of weld metal, for
these two welds?
Figure8. 8 Over-welded fillet weld b containing more weld metal than necessary.
The welds are assumed to be mitre fillet welds, with no excess weld metal.
The cross section area of weld b is over double that of weld a. Twice as
much weld metal has been deposited than is needed, with only a 2mm
increase in leg length.
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The excess weld metal at the cap and root is ignored. For partial penetration welds,
the cross section area is reduced by the unfused ligament and is calculated using
the nominal throat of the partial penetration weld, or the depth of penetration below
the plate surface.
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The root is the position of furthest penetration into the joint. The position of
the root, eg which side of the joint and whether backing material is to be
used may affect the static and fatigue performance of the joint.
The preparation is the shape of the joint faces needed to ensure that the
necessary access for weld metal deposition is available. The fit-up is the
dimensional relationship between the two sides of the joint (eg root gap,
alignment, etc). The selection of preparation and fit-up dimensions, together
with their tolerances, will depend on the welding process and procedure
being used and have a considerable influence on the economy, quality and
distortion of the joint.
8.6 Summary
At the end of this module you should be confident to determine weld cross
section areas. You should understand the difference between axial and
shear stresses and between equivalent and design stresses. You should be
able to combine stresses (such as axial and shear stress) in calculations of
weld stresses.
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Revision Questions
1 What is the cross section area of a full penetration butt weld in a 4m wide plate of
12mm thick steel?
2 The plate has a yield strength of 320MPa. What will you assume the design
strength is?
3 Therefore, what is the maximum load that this weld can carry?
4 A single fillet weld attaches a plate of length 200mm onto a base plate. The
single fillet weld has a throat thickness of 6mm. If the designer wishes to change
the design to have two fillet welds, one on either side of the attachment plate,
what size leg length will they specify?
5 A 50kN load is carried by a 300mm long fillet weld in shear. If the steel has a
yield strength of 240MPa, what size does the fillet weld need to be?
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Section 9
Revision Session
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2 Describe four joints that could be used to weld 75mm thick steel.
5 Briefly describe eight joint configurations for thin sheet (<1.5mm thick)
and indicate their advantages and disadvantages.
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Section 10
10.2 Welds
A weld is a permanent union between materials caused by the application of
heat or pressure or both. A weld made between two faces that are
approximately parallel is known as a butt weld.
A weld made between two faces that are approximately at right angles to
each other is known as a fillet weld.
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For simplicity these diagrams show an arc welding process that deposits
filler weld metal in a single weld pass. Typical features of a butt weld are
shown in Figure 10.3. Typical features of a fillet weld are shown in Figure
10.4. The weld or weld metal refers to all the material that has melted and
re-solidified. The heat-affected zone is material that has not melted, but
whose microstructure has been changed as a result of the welding. The
fusion line is the interface between the weld metal and the heat affected
zone. The root is the bottom of the weld, or the narrowest part and the face
is the top, or the widest part. At the corners of the weld cross section where
the weld metal joins the parent metal are the weld toes. Weld toes are at
each corner of both the weld face and the weld root in a butt weld, but only
on the weld face in a fillet weld.
Figure 10.3 Typical features of a butt weld, shown schematically in a and in b for a
double-sided butt weld.
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The distance between the weld toes is called the weld width. When the
distance is between the toes at the weld cap, it is the weld cap width; the
distance between the toes at the root is the weld root width. The height of
the additional weld metal in the weld cap is called the excess weld metal.
This used to be called reinforcement which wrongly gives the impression
that increasing this dimension will strengthen the weld. If the excess weld
metal is too great it old serves to increase the stress concentration at the
weld toe. This extra weld metal at the weld root is called the excess root
penetration.
Figure 10.6 Definitions of excess weld metal, root penetration and weld width on a
butt weld.
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An alternative to a conventional lap joint is to weld the joint using plug or slot
welding. Slot and plug welds are shown in Figure 10.12 we can drastically
alter the typical lap joint. The hole for a slot weld should have a width at
least three times the plate thickness and not less than 25mm. In plate less
than 10mm thickness, a hole of equal width to the plate thickness can be
welded as a plug weld.
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a b
Figure 10.12 A slot welded lap joint b plug welded lap joint.
Corner joints can be fitted and welded in a number of ways. The unwelded
pieces can be assembled either with an open corner or closed together. The
weld can be placed on the external corner, the internal corner or both in a
double-sided weld.
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This is only valid for mitre fillet welds having similar leg lengths (see Figure
10.14), but is not valid for concave, convex or asymmetric welds. In concave
fillet welds the throat thickness will be much less than 0.7 times the length.
The leg length of a fillet weld is often approximately equal to the material
thickness. The actual throat size is the width between the fused weld root
and the segment linking the two weld toes, shown as the red line in Figure
10.15. Thanks to root penetration, the actual throat size of a fillet weld is
often larger than its design size, but because of the unpredictability of the
root penetration area, the design throat size must always be taken as the
stress parameters in design calculations.
Figure 10.14 Mitre fillet weld. Figure 10.15 Design throat of a fillet weld.
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Figure 10.17 Definition of design and actual throat in concave and convex fillet
welds.
The choice between mitre weld, concave and convex fillet weld needs to
take into account the weld toe blend. A concave fillet weld gives a smooth
blend profile and a low stress concentration at the fillet weld toe. Convex
fillet welds can have a higher stress concentration at the weld toe. If the
fluidity of the weld pool is not controlled, it is possible to obtain an
asymmetrical fillet weld where the weld pool has sagged into the joint
preparation and there is also a risk of undercut on the bottom weld toe (see
Figure 10.18). Having a smooth toe blend is important to give better fatigue
performance for fillet welds.
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Figure 10.19 Design throat (t1) and the actual throat (t2) for butt welds.
The weld toe blend is important for butt welds as well as fillet welds. Most
codes state that the weld toes shall blend smoothly. This statement is open
to individual interpretation however. The higher the toe blend angle the
greater the amount of stress concentration. The toe blend angle ideally
should be between 20-30o (Figure 10.20).
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10.6 Dilution
When filler and parent material do not have the same composition, the
resulting composition of the weld depends largely on the weld preparation
before welding. The degree of dilution results from the edge preparation and
process used; the percentage of dilution (D) is particularly important when
welding dissimilar materials and is expressed as the ratio between the
weight of parent material melted and the total weight of fused material
(multiplied by 100 to be expressed as a percentage), as shown by the
equation below.
Low dilutions are obtained with fillet welds and with butt welds with multiple
runs. However, considering a single pass, better dilution is obtained with
grooved welds; see Figure 10.25.
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Figure 10.25 Effect of weld preparation on dilution and weld metal composition (for
a single pass only).
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ISO 2553 and AWS A2.4 list all the main elementary symbols, some
examples are shown in Table 10.1.
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Flat PA
Horizontal PB
Horizontal
PC
vertical
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Welding
Symbol Abbreviation
position
Vertical up,
vertical PG/PF
down
Overhead PE
Horizontal
PD
overhead
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The design of the edge prep includes not only the bevel angle (or included
angle is both sides are bevelled), but also the square edges root face and
root gap. In a joint where both sides are bevelled, the prep is called a V or
vee preparation (Figure 10.22). V preps are usually used for plate of
thickness between 3-20mm. An alternative is a U prep (or J prep if only one
side has the edge prep) in which the edge is machined into the shape of a
U. This type of edge preparation is used in thicker plate, over 20mm thick,
where it uses less filler metal than a V prep joint. J or U edge preparations
also requires a bevel angle and root face and gap to be defined, but also
needs a root radius and land to be specified (Figure 10.23). Single sided
edge preparations are often used for thinner materials or when there is no
access to the root of the weld (such as pipelines). If there is access to both
sides of the material then a double-sided edge preparation is used,
especially for thicker materials. Single and double edge preps are shown in
Figure 10.24.
Included angle
Bevel angle
Root face
Gap
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Included angle
Root radius
Bevel
angle
Root
face
Gap
Land
Figure 10.24 Range of single and double sided bevel, vee, J and U preps.
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Figure 10.25 Bevel angle to allow electrode manipulation for sidewall fusion.
The root gap and root face are selected to ensure good root fusion
(Figure 10.26). This will depend on the welding process and the heat input.
If the root gap is too wide or the root face is too narrow then there is a risk of
burn through. If the root gap is too narrow or the root face is too deep the
there is a risk of lack of root penetration. A balance must be found and
designed for and this difference in weld root size is shown in Figure 10.27.
High heat input process require a larger root face, but less weld metal is
required, which reduces distortions and increases productivity. Typical
values for the root face are around 1.5-2.5mm and the root gap around 2-
4mm.
Figure 10.26 The importance of selecting the correct root face and root gap.
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a b
Figure 10.27 Root size for welding processes with different heat inputs, a low heat
input, b high heat input.
a b
a b
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Backing bar or backing strip is used to ensure consistent root fusion and
avoid burn through. However, if you choose to use permanent backing strip
(rather than a backing bar which is removed after welding), be aware that it
gives a built-in crevice which can make the joints susceptible to corrosion
(Figure 10.30). When using backing for aluminium welds, make sure any
chemical cleaning reagents have been removed before assembling the joint.
A backing strip will also give a lower fatigue life.
Outside of the design of the joint and weld, access to weld locations and the
order in which welds are made are just as important. Figure 10.31 shows
examples of the limitations of access in designing welded joints and gives
improved designs. It is important to ensure that it is indeed possible to make
welds as required by the drawing.
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Figure 10.31 Examples of improved weld designs where there is limited access.
10.11 Summary
At the end of this module you should be able to label the parts of a butt and
fillet weld and to label the parts of a vee and U edge preparation. You
should be able to recognise welding symbols and know what they mean.
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Definition
1-1
Course Objectives – DAC3
1-2
Aluminium Alloys
2-1
6XXX Series Alloys 7XXX Series Alloys
• Al-Mg-Si precipitation hardened alloys.
• Most widely used of HT alloy. • Al-Zn-Mg precipitation hardened alloys
• Reasonable strength.
• Good corrosion resistance. • Stronger grades • Weaker grades
– strongest of all aluminium – reasonable mechanical
• Excellent extrudability. alloys, UTS up to 550N/mm2 properties
• Can be welded but with softening in HAZ. – inferior corrosion resistance – HAZ softening less severe
– poor extrudability than 6XXX alloys
• Stronger grades • Weaker grades
– unsuitable for arc welding – corrosion resistance fair but
– have same YS as structural – used for low stress members
– used in aircraft engineering not as good as 6XXX alloys
steels but lower UTS and – good stiffness, used for
– reasonable extrudability
ductility architectural members
– used in non-aeronautical
– used for stressed members – fatigue applications (structure
welded constructions
of rail-cars)
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2-2
Properties of Aluminium Properties of Aluminium
• Lower strength at high temperature. • High fluidity of weld pool.
– some alloys lose strength when operated above 100°C
– smaller root gap required to avoid burn-through
– limited upper service temperature
• Limit stress. • High affinity for oxygen.
– Define a 0.2% proof strength as no clear yield point – Remove oxide film to avoid inclusions
• High coefficient of thermal expansion. – Chemical or mechanical cleaning
– twice as much as steel – Importance of gas shield and wider weld means
– high level of distortion when welding larger gas nozzles for TIG or MIG welding
• Tensile strength. – increased preparation angle
– pure Al has UTS 70~150 N/mm2
– alloying increases this to 650 N/mm2 UTS
– Ensure weld metal composition not at risk of hot cracks
Steel Aluminium
• Intermittent welds in stiffeners reduce distortion. • Consider weld placement - put welds in low stress
• Increase local weld cross section area to compensate areas such as close to the neutral axis.
for HAZ softening. • Orient welds parallel to the maximum stress.
2-3
Design of Weld Joints Design of Weld Joints
For self-adjusting joints, make use of aluminium’s
Consider elimination of welding extrudability
Definition of the
severity
severity and the
extend of the
softened HAZ
extent
2-4
Control the Interpass Temperature Extent of HAZ Softening
Extent of nominal HAZ - one inch rule:
Normal control Strict control
5XXX and 6XXX alloys To 100C To 50C
7XXX alloys To 80C To 40C
2-5
Overview
• The different ways a structure is loaded will affect
the ways it may fail.
• Under high static (over) load, failure is ductile. • Sudden changes in geometry cause localised
• Ductile fracture, or plastic collapse, occurs when areas of high stress.
yielding and deformation precedes failure. • Imagine flow lines which get close together at
• Fracture surface appears torn and fibrous. stress concentrations.
• The surface shows 45° shear lips or have • The stress concentration at a hole is 3, sharper
surfaces inclined at 45° to the load direction. notches concentrate the stress much more.
Stress
Concentration
3-1
Effect of High Temperature on Strength Creep
High
temperature
Measure
extension
• Load applied at a fast rate (impact) leads Charpy test Pellini test specimens
to an increase in tensile strength and a
drop in ductility.
Dynamic
Anvil
3-2
Effect of Low Temperature on Strength Charpy Transition Curve
Energy Test
• Low temperatures cause ferritic steel to increase (J) set 1
ductility. Test
• Drop in temperature causes rise in yield but same set 2
tensile strength, less plastic deformation.
σ σ σ Test
set 3
Temperature
ε ε ε Test Test Test (ºC)
Temperature drop temperature 3 temperature 2 temperature 1
Brittle
Temperature
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3-3
Preventing Fracture Example – Cryogenic Pressure Vessel
General approach by codes and standards: Materials require:
• Ensure adequate toughness (Charpy requirements). • Good impact toughness values at extremely
• Design to prevent high stress (no stress low temperatures.
concentrations).
• Good weldability and ductility.
• Stress relieve thick sections to reduce residual stress.
• Fabricate/inspect to minimise defects. • Low thermal conductivity in order to insulate
from atmospheric heat.
• Proof test.
• Cheap.
Examples:
Materials used:
BS PD 5500 (pressure vessels), BS 5400 (steel
bridges), BS 5950 (steel structures), ABS rules • Aluminium, austenitic stainless steel, 9% nickel
(fixed offshore structures), BS 4515 (pipelines) steel.
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3-4
Historical Background Applications of Fitness-for-Service Methods
3-5
Fracture Mechanics Stress Concentration Near Cracks
K
Y
a
Units of K
K Y a 1 N/mm3/2 = 0.0316 MPam
2a a a
KI a K I 1.12 a K I 0.637 a
Small through- Small through- Small penny-
thickness crack thickness edge shaped embedded Mode I Mode II Mode III
in large plate crack in large plate crack in large body (Opening) (In-plane shear) (Out-of-plane shear)
LEFM applies for brittle materials with small plastic zone • For ductile materials the energy to initiate
EPFM applies for ductile materials where the plastic zone crack propagation was significantly higher
is significant than predicted by LEFM.
CT elastic • This was explained by the role of the
plastic zone.
elastic-plastic
Y
• EPFM considers the elastic behaviour of
the material and the local plastic
crack deformation at the crack tip.
r
Plastic zone
3-6
Plastic Collapse Measures of Fracture Toughness
Plastic zone
F/2 F/2 F
Span = 4W
a a
B
W = B or 2B
W
B
F F
3-7
Measurements During Testing Calculating Fracture Toughness
K Y a
el pl
Vp
z
K 2 1 2 /(2 Y E ) r p W a Vp / r p W a a z
Load
a Up
bo rp(W-a)
W
Displacement J J el J pl
K 2 1 2 / E U p /(Bbo )
Load
Subscripts: c u m
• These include restrictions on the fatigue crack
size, position and shape, together with limitations
Toughness
Temperature
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2B B
• Weldments are critical in terms of fracture: B B
• Complex geometries.
• Complex microstructures.
Through-thickness Surface
notch (WP) notch (SM)
• Complex residual stress distributions.
• Specimen thickness = section thickness.
• Is the test intended to model an actual crack,
or to measure a lower-bound toughness?
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3-8
Notch Classification Notching into the HAZ
• Two notch methods are the Weld Positional • HAZ has narrow width & irregular shape.
(WP) and Specific Microstructure (SM) • HAZ has local variations in microstructure.
approaches. • Uncertain nature of fatigue pre-cracking makes HAZ
notching of a target microstructure difficult.
• SM testing requires post test metallography
to confirm whether the notch sampled the Notch plane
2c
• Level 1 • General • Corrosion
• Level 2 • Simplified • Buckling
Surface
a
• Leakage
• Level 3 • Yielding Actual flaw is
• Erosion
(Section 7) (Section 8) (Section 9) (Section 10) modelled as an p
Immediately • Assume yield magnitude • Value is taken as lowest from three similar
after welding
• Known values
specimens.
cold cold cold
• Additional testing recommended if results
After cooling
• Residual stress relaxation are too scattered:
if
contraction from:
allowed
– Mechanical loading
cold cold cold
– Heat treatment min < 0.5 ave or max > 2 ave
After cooling
with
contraction
resisted Kmin < 0.7 Kave or Kmax > 1.4 Kave
tension residual stress
compression
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3-9
Failure Assessment Diagram Axes Failure Assessment Diagram Axes
• The Y-axis of the FAD is termed Kr, the fracture • Kr is defined as:
ratio.
KI
– This axis represents proximity to failure of the flawed Kr
component by fracture K IC
where KI is the stress intensity or crack driving force
• The X-axis of the FAD is termed Lr, the stress and KIC is the material toughness
ratio.
– This represents the proximity to failure of the • Lr is defined as:
component by plastic collapse
Lr ref
y
• Failure assessment line shows the limit of safety σref is the reference stress or the net section stress
for failure from either mode. due to a flaw and σy is the yield stress (or flow stress)
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0.6
• Level 2 FAD reduced
conservatism. 0.4
1
Sr
• More analysis more costly.
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3-10
Assessment of Fatigue BS 7910 Fatigue Assessment Procedures
• Fatigue grows a crack from a sub-critical size • The parameters required to carry out a
until it is critical to cause failure. general fatigue assessment are:
• The rate the fatigue crack grows can be
estimated, and an initial tolerable flaw sizes
can be derived if the lifetime is known.
Flaw Type and Geometry
• For an ECA measure the fatigue crack growth Stress n1 cycles at 1
rate in parent material, weld metal or HAZ. range
Log (da/dN)
n2 cycles at 2
n3 cycles at 3
– Crack growth rates affected by environment e.g. etc...
seawater with CP compared to air
• Determine the fatigue threshold. Time Log ( K)
Applied Stresses Crack Growth Relationship
• The basis of the fatigue crack growth calculations • Lack of fusion was detected in a propane storage
is the relationship between K and the rate of crack sphere in Saudi Arabia during outage.
growth da/dN for the material under consideration. • Before the vessel could go back into service, its
fracture
defect tolerance had to be assessed to show that the
sphere would not fail by brittle fracture or plastic
Log (da/dN)
collapse.
m
Summary
3-11
Objectives
4-1
Classification of Welded Joints Classification of Welded Joints
Fatigue weld joint classification (BS 5400)
Fatigue weld joint classification (BS 5400)
• Class A: plain steel, all surfaces machined and • Class C: full or partial penetration butt or fillet welds,
polished. Uniform or smoothly varying cross- parallel to the direction of stress, made by
section. mechanised welding, with no stop/start. Butt welds
transverse to stress direction, machined flush and
• Class B: as-rolled free from defects.
steel, no flame cut
edges. Full penetration
butt welds free of
defects, parallel to the
direction of stress and
with faces dressed
smooth.
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• Class F: butt welds on backing strip, transverse to • Class F2: cruciform or T-joints made with partial
stress direction. Member carrying fillet or butt penetration butt or fillet welds. Butt welds between
welded attachments clear of edge. Cruciform or T- two rolled or built-up sections.
joints made with full penetration butt welds.
4-2
Classification of Welded Joints Classification of Welded Joints
Fatigue weld joint classification (BS 5400)
Fatigue weld joint classification (BS 5400)
• Class W: weld metal in load carrying fillet or partial
• Class G: members with attachments welded to penetration butt welds, regardless of direction of
their edges or close to the edges. stressing. Stress used in calculating the fatigue life
is the stress on the weld throat.
4-3
Fatigue Fracture Surface Fatigue Failure in Components
Depends on:
• Load direction
• Geometry
Beach marks
• Provide record of crack front
location at particular time
• Associated with differential Striations x1800
corrosion, sudden change in • Usually represent crack Large structures can be tested using representative
crack growth rate, rest increment per cycle
periods…
smaller-scale specimens
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t = plate thickness
r/t >0.25
r = groove radius r/d >4
300
Stress to minimise
range d = groove depth notch effect
2
N/mm 200
150
100
As-welded
Flush-ground weld
Flush ground, failed from flaw
Unbroken
50
4 5 6 7 8
10 10 10 10 10
Endurance, cycles
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4-4
Fatigue Improvement Techniques Burr Machined Weld Toe
45º
Direction
Minimum of travel
depth 0,8 mm
• improves fatigue life by 2 classes (30% on stress or 2.2 on life).
• slow careful application required.
• must penetrate recommended depth below any undercut or flaw.
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30-45º
Direction
• Quicker than burr machining. of travel
4-5
Weld Toe Burr Grinding TIG or Plasma Dressing
H/course/burr
600
500
Weld toe burr ground
with r/T > 0.25 & r/d > 4
400 Unbroken
Depth of grinding Stress
d = 0.5mm below undercut r 300
range
2
N/mm Butt welds
200
d
Stressed plate 150
T=13mm
Unwelded steel
Endurance, Cycles
• Very slow technique.
• Requires separate qualified procedure and
significant skill element.
• Delays subsequent weld inspection.
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4-6
Ultrasonic Impact Treatment Fatigue Performance of Welded Joints Improved by
Peening
log (stress range)
As- welded
Increase in
fatigue limit
400 600
Mild steel
R=0
500
300
400
Hammer peened Fatigue
Stress strength
range 200 Burr ground 300
N/mm2 at 2x106
cycles,
Shot peened 200
150 MPa
As welded Plasma dressed
100
TIG dressed weld
Toe ground weld
100 0
5 6 7 7
10 10 10 5x10 300 500 700 1000 1200
Endurance, cycles
Ultimate tensile strength of steel, MPa
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4-7
Fatigue cracking in brace D6 of Alexander L.
Mooring Buoy Failure
Kielland Platform
• Incomplete
Flotation
penetration and poor Chamber
weld bead shape.
• Fatigue crack
propagated into
Plane of
brac.e Failure
• No redundancy (loss
100m
of one brace led to
overloading of
others).
• Importance of
welded attachments.
Universal
Joint
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4-8
Mooring Buoy Failure Mooring Buoy Failure
Fatigue
Reasonable theory
Actual situation
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4-9
Tacoma Narrows Bridge, 1940 Tacoma Narrows Bridge, 1940
4-10
Objective
• Use design stress which is a fraction of • Ratio of yield stress (or UTS) to design
the yield strength of the parent material. stress is known as factor of safety (FoS).
5-1
Material Load Carrying Capacity Fillet Weld Features
• The simplest and cheapest type of welded design
• Weld metal overmatches parent metal.
• requires less preparation.
– Parent strength defines load carrying
• May be made in flat or horizontal positions by semi-
capacity skilled operators.
• High strength low alloy steels. • Possible problems with penetration into the parent
– Weld metal sometimes undermatches metal.
parent metal • Welds can be made with any number of passes
• Difficult to examine by NDT methods for subsurface
• Welded joints in aluminium. defects.
– The static strength may be reduced by the • Once you calculate the required size of fillet weld stick
heat of welding to it - the volume or weight of weld metal increases as
the square of leg length.
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• The weld metal must match the strength of parent Throat dimension: - the shortest distance between
metal. root and the chord between the toes or profile face
(whichever is less).
• Weld will fail across the throat.
• Excess weld metal is neglected (for calculation use throat throat
design throat instead actual throat).
• Assume adequate weld quality. 60º
• Neglect stress concentrations due to bead shape.
• The design stress is YS/2 (when it is not given in
the applicable standard).
Welds with faces meeting at more than 120° or
• Ignore residual stress.
less than 60° should NOT be used for load
carrying parts.
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5-2
Types of Forces Bending Moment
• A cantilever beam:
Compression
Force, F
Fy
– Compression
M
Fx
– Tension Tension
– Shear d
Shear
Bending M=Fxd Fx Fy M
M
y Iz
-σ
m
a
x
Before bending
m
a
x
Tension (+)
+σ
where:
M M
After bending
M = bending moment
Iz = moment of inertia towards axis Z
Compression (-) Neutral Axis -
Longitudinal stresses ymax = maximum distance between cross section’s
are zero CG and extreme fibre
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5-3
Ways to Improve Resistance to Bending Ways to Improve Resistance to Bending
h h
L L
b b
Bending moment? Bending moment M = Force x distance = P x L
Moment of inertia? Moment of inertia I = (b x h3)/12
Maximum distance? Maximum distance ymax= h/2
Bending stress? Bending stress σ = M x ymax/I
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bh 3 100 300 3 1. Calculate the leg length needed for the fillet welds shown
I 2.25 10 8 mm 4 300 Distribution of
12 12 longitudinal
above if the allowable stress in the fillets is 250MPa.
stresses
6 10 6 150 2. How would this change if the beam length was 0.75m?
max 4MPa 4MPa
2.25 10 8 I Tension
5-4
ANSWER 1 ANSWER 1
F
Throat, t = L/2
50mm Moment L, leg length
250 = (F2)/(L.w)
Applied moment = moment reacted in welds = 50 x F
So, L = (1.8x104 2)/(250.20)
F = 9x105/50 = 1.8x104N
= (2.54x104)/(5000)
= 5.1mm
Stress in fillet = F/(t.w)
Where:
t is the throat thickness and w is beam width (20mm)
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ANSWER 2 Torsion
Stress calculation (valid only for round shape transverse section
beams-bars or tubes):
Beam length makes no difference to required weld M tZ p
size because the applied loading is a bending
moment. That is, F is independent of beam length.
Mt - torsion moment τ
Zp - polar section modulus of τ
the transverse section
Note that: Mt
• Largest values of stress are obtained on the extreme fibres
while in centre of section, stress is 0.
• the stress have a continuous linear variation throughout entire
transverse section.
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D
M F F
2 M
force F:
2 D
2 π
M 2
DD
F F
π
t
D
t
D D
5-5
Reinforcing–Steel Welded Joints Purpose
Purpose Purpose
• A beam made only of concrete has little or • In concrete beams the steel bars are
no bending strength since cracking embedded in the tension fibres of the beam.
occurs in the extreme tension fibres in the
early stages of loading.
• Reinforcing bar is rolled with a ribbed die • Reinforcing bar is available in sizes
when manufactured to produce a ribbed ranging from 6mm up to 50mm diameter.
surface. • A whole assembly of reinforcing bars will
• Concrete shrinks around the bar when it sets usually be used.
to grip the reinforcement. • To join bars together there are several
methods:
– Welded joint
– Wire joint - wire wrapped around bars and
tightened
– Rebar coupler – mechanical fixing
5-6
Joints Properties
• Welding can be used for both load bearing • Reinforcing bars available for a wide range of
joints and non load bearing joints. chemical compositions and mechanical
properties.
• Non load bearing joints used to keep
components in place during fabrication, • Not all reinforcing bars are weldable -
transportation and concreting - tack welds. weldability is determined by the carbon
equivalent value and the limitations on the
• Joints may be subject to significant loads content of certain elements.
during handling and transportation –
should be treated as load bearing.
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5-7
Types of Joint Types of Joint
• Cross Joint: • Joints between reinforcing bar and other
– Load bearing and non load bearing steel components:
– Double sided weld used for load bearing
– Minimum throat thickness, a ≥ 0.3dmin – For load bearing functions, steel reinforcing
– Minimum weld length, l ≥ 0.5dmin bars are often joined to other steel
– When welding different diameters: dmin/dmax ≥ 0.4 components in a structure such as plates or
sections.
– The types of joint used include side lap weld
joints and transverse end plate joints.
5-8
Standards and Specifications
• AWS D1.1: Structural Welding Code.
• BS 5950: Structural use of steelwork in building.
• BS 8118: Structural use of aluminium.
• Eurocode 3 (BS EN 1993): Design of steel structures.
• Eurocode 9 (BS EN 1999): Design of aluminium
structures.
• BS 7608: Code of practice for fatigue design and
assessment of steel structures.
• BS 7910: Guide to methods for assessing the
acceptability of flaws in metallic structures.
• BS EN 22553: Welded, brazed and soldered joints.
Symbolic representation on drawings.
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5-9
Design Codes
• Design and build pressure vessels to an
established design code.
• In EU must be in accordance with PED.
Design of Pressure Equipment • Codes will define:
– Maximum allowable stress
– Minimum design temperature
TWI Training & Examinations Services – Materials and mechanical properties
EWE/IWE Diploma – Permitted design features
• PD 5500, EN 13445, ASME Boiler & PV
codes.
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• Design-by-rule: • Design-by-analysis:
– Virtually all codes use this approach – Use stress analysis to compare the stresses
– Relatively simple equations against specific criteria
• Advantages: – Use limit analysis to determine the load to
cause failure by gross plastic deformation
– Simple and consistent
– Safety factors applied to ensure constant level
• Disadvantages: of safety
– The rules are sometime open to interpretation.
– Difficult to apply when dealing with loadings and
geometries which are not covered by the standards
6-1
Shell Design Dished Head Design
offset
Crown
6-2
Set-on nozzle Set-Through Nozzle
• 1G/PA position much easier.
• Shorter nozzle is cheaper.
• Groove prep can be flame cut.
• Easy to make groove for full or partial
penetration. • No danger of lamellar tearing.
• Single side welding in 2G/PB position • Easy access to the back side of root,
means high welder skill is required. so full penetration is easier to
achieve.
• Through thickness stress means danger
of lamellar tearing. • For nozzles with small diameters no
need for reinforcement.
• Can be difficult to UT especially on
smaller diameters. • Nozzle body needs to be longer.
• Mainly used for small (<2inch diameter) • Greater weld volume means higher
nozzles, or thick wall or large diameter distortions.
vessels. • Can be hard to UT on smaller
• May require reinforcement. diameters, usually easy to inspect.
• Used for larger diameter nozzles, and
thinner walled small diameter vessels.
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Reinforcing ring/
Long neck
Compensating plate
nozzle
Parent material
Hole bored
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6-3
Corrosion Allowance Weld Joint Efficiency
• Corrosion occurring over the life of a • Most vessel codes assume that welded joints are
vessel is catered for by a corrosion not as strong as the parent material.
allowance.
• The design value depends on vessel duty • The welded joint efficiency is defined as the ratio
and the corrosiveness of its contents of joint strength/parent material strength.
• Example, EN 13445 requires minimum
1mm. • Varies from 100-45% according to the standard
applied, to the extent of NDT and joint design.
• Dimensions used in formula for thickness
calculation are for end of the vessel life, ie
when all the corrosion allowance has been • Reduces the maximum design stress for lower
integrity welds.
used.
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• EN 13445 Fy
t
– 100% NDT: 100% p
– No NDT: 70% p
2r
'
– Butt joint with backing strip, full RT: 90%
– Single full filet lap joint, no RT: 50% 1/2 Fy σy t
F y2
' t
exchangers.
x
are tighter
– Internal stiffeners are used
6-4
Types of Pressure Vessel Reasons for Failures in Pressure Vessels
• Boilers & distillation columns • Material: improper selection of materials, defects in
are fired pressure vessels. materials.
• Operate at high temperature. • Design: incorrect design data, inaccurate or
• Use creep-resistant steels. incorrect design methods, inadequate shop testing.
• Fabrication: poor quality control, improper or
insufficient welding; heat treatment and forming
• Storage vessels, eg for LPG
methods.
are unfired.
• Service: change of service condition by the user,
• Low temperature and
inexperience operations and maintenance
cryogenic vessels use nickel
personnel, upset conditions.
steel, stainless or aluminium.
6-5
Objectives
σ1
N N N1 N2 N
Endurance
Increase stress - more damage limit
Increase number of cycles - more damage Log N
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7-1
Effect of a Notch Fatigue of Welded Joints
Fatigue strength of welded joints << Parent Material
400
Log σ Without notch Stress 300
range, 200
N/mm2 100
With notch
50
Steel
350 N/mm2 yield
10
Log N 105 106 107 108 Cycles
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K Y a
crack tip singularity (stresses
Fatigue near tip are proportional to 1/√r
Stress range for life of 106
100
strength and strains, this corresponds to a
critical value of K, which is a
measure of fracture toughness.
Fracture
Stress intensity factor range = K Relationship between
= Kmax - Kmin da/dN and K
determined
increasing R
Stress ratio R = Kmin / Kmax
experimentally
d d
a N
Log (da/dN)
A
K
m
m
da
Kmax
Stress, s
7-2
Fracture Mechanics Analysis of Fatigue Crack
Integration of Crack Growth Law Growth
If we take the Paris law region and integrate….
Crack growth rate (Paris
d d
a N
w
h
e
r
e
K
Y
a
A
K
m
law)
da AK m
d
a a
dN
N
m
a
x
m
m
ai
where
K Y a
1 A
d
a a
a
o
r
m
a
x
m
m
af
ai
da
A1 Y a N m
m
NB: m is the slope of the calculated S-N curve
ai
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d
a a
a
N
m
a
x
m
Y
ai
Four unknowns… can solve if we know any three
• N for known flaw and loading.
• Tolerable flaw ai for a given and N.
• Required toughness ( a max ) to avoid fracture from
fatigue cracking.
• Allowable for known flaw and required life.
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How accurate are fracture mechanics calculations ? How accurate are fracture mechanics calculations ?
12
11
10
9
Crack 8
Actual
depth 7
mm 6
5
4 Predicted by
3 fracture mechanics
2
1
0
5 5 5
0 2x10 4x10 6x10
Endurance, cycles
7-3
Fatigue Crack Growth Laws in BS 7910 BS 7910 Recommended Fatigue Crack Growth
Laws for Steels in Marine Environments
da/dN,
mm/cycle
-2
10
-1100mV
• Free corrosion produces around 3-fold increase in da/dN
cathodic
protection
compared with air.
-3
10
• Use of cathodic protection (correct or over-protection) restores
10
-4 Simplified law for in-air behaviour up to K = 144 N/mm3/2 (315 N/mm3/2 for R < 0.5),
free corrosion -850mV
cathodic but da/dN increases at higher values.
protection
2-stage law
• Cathodic over-protection (-1100 mV) is particularly detrimental at
-5
10
for free
corrosion
high K and K max due to the generation of hydrogen.
-6
10
• Majority of the raw data were generated to reproduce North Sea
10
-7
With cathodic
conditions, approx. 6-10oC and a cycling frequency of 1/6 Hz.
protection
(-850 or -1100mV)
Crack growth rates could be higher at higher temperatures and
10
-8 lower frequencies, and vice versa.
10 20 50 100 200 500 1000 2000
-3/2
K Nmm
-4
10
Simplified law for
welded steels,
including
-5
10
austenitics
-6
10
-7
10
2-stage law for
welded steels
-8
10
10 20 50 100 200 500 1000 2000
-3/2
K Nmm
7-4
Analysis of Fatigue Loading Miner’s Linear Cumulative Damage Rule
n 2N
n N
log
i
1
.
.
.
N3 = infinity
3
= zero
n1 N1 n2 N2 n3
log N
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fracture
d d
a N
A
K
• Height, Length.
m
Flaw Type and Geometry • Ligament, Plate thickness….
2c
Log ( K)
Stress n1 cycles at 1
range n2 cycles at 2 K Crack Growth Relationship
a
n3 cycles at 3
2c
etc...
Integrated cycle by cycle B
to determine final flaw 2a
time size p
Applied Stresses ()
Fracture assessment
7-5
Flaw Interaction/Orientation In A Fatigue
Stresses Used in Fatigue Assessments
Assessment
Flaw projection (as in fracture assessment)
Stress linearisation Establish primary and secondary (excluding
residual) stress ranges due to fluctuating
Principal
Resolved components of applied load, allowing for
stress
flaw SCF kt due to any gross structural
discontinuity, if necessary
Stress
b
Flaw interaction - NOT required for fatigue
kt (P + Q)
Cracks behave independently until they actually m
coalesce s1 2c
Linearise through-thickness distribution (do
Actual stress not underestimate surface stresses) to
distribution deduce m and b.
s2
2a
SCF associated
SCF due to Log (da/dN) fracture
with gross
Bulging misalignment
structural
Correction
discontinuity
Factor Paris law
2ci+1
ai
2ci
K
a
M
fw
kt
M
M
kt
M
M
ai+1 m
︵ da/dN = A ( K)m
m
k
m
b
k
b
b
1
K Y a
7-6
Why Calculate Weld Stress?
8-1
Butt Weld Failure Modes Lap Weld Failure Modes
Single fillet weld – lap joint
either:
Weld throat
Weld throat
HAZ or parent
material
Weld throat
In-line butt weld – partial penetration
or:
Weld throat
HAZ or parent
material
• Fatigue cracks propagate from stress • Subject to both axial and shear stresses.
concentrations such as weld toes.
• Cyclic stresses, below the yield stress.
• Designer considers effect of cyclic
stresses as well as static stress.
Toe
crack
IIW Method for Fillet Weld Stress IIW Method for Fillet Weld Stress
P
3
||
2
2|
e
q
||
L
8-2
Over-Welding Fillet Welds Over-Welding Fillet Welds
It is important to keep the fillet weld leg length
limited to the correct calculated size (a) (b)
4mm 6mm
(a) (b)
4mm 6mm
4mm 6mm
(a) (b)
4mm 6mm
Area = 4 x 4 = 8mm2 Area = 6 x 6 = 18mm2
2 2
The c.s.a. of (b) is over double the area of (a)
How much larger is the CSA in (b) comparable to (a)?
Ignoring the excess weld metal being added
Copyright © TWI Ltd 2012 Copyright © TWI Ltd 2012
Weld Designers
8-3