Fatigue crack growth under continuous radiation

This paper examines the possibility that a drastic reduction of the rate of propagation of a fatigue crack can occur if a sample undergoing failure is simultaneously irradiated with high energy particles. For an effect to exist it is necessary that the rate of irradiation damage and the frequency of the cyclic stress are such that appreciable irradiation hardening occurs within the plastic crack tip zone during each stress cycle. The analysis is based on a fatigue crack growth theory of one of the authors (JW) that considers the true stress intensity factor at a fatigue crack tip. Although in a post-irradiation fatigue experiment appreciable irradiation hardening will not necessarily produce a decrease in the fatigue crack growth rate, a decrease in the fatigue crack growth rate should always occur in material with a Paris law exponent larger than two if the irradiation takes place continuously during a fatigue test that is carried out at temperatures at which annealing processes are relatively slow.     

Prediction of residual stress distributions due to surface machining and welding and crack growth simulation under residual stress distribution

In nuclear power plants, stress corrosion cracking (SCC) has been observed near the weld zone of the core shroud and primary loop recirculation (PLR) pipes made of low-carbon austenitic stainless steel Type 316L. The joining process of pipes usually includes surface machining and welding. Both processes induce residual stresses, and residual stresses are thus important factors in the occurrence and propagation of SCC. In this study, the finite element method (FEM) was used to estimate residual stress distributions generated by butt welding and surface machining. The thermoelastic-plastic analysis was performed for the welding simulation, and the thermo-mechanical coupled analysis based on the Johnson-Cook material model was performed for the surface machining simulation. In addition, a crack growth analysis based on the stress intensity factor (SIF) calculation was performed using the calculated residual stress distributions that are generated by welding and surface machining. The surface machining analysis showed that tensile residual stress due to surface machining only exists approximately 0.2 mm from the machined surface, and the surface residual stress increases with cutting speed. The crack growth analysis showed that the crack depth is affected by both surface machining and welding, and the crack length is more affected by surface machining than by welding.     

Fatigue cracks in Eurofer 97 steel: Part I. Nucleation and small crack growth kinetics

Fatigue crack nucleation and growth were studied in the Eurofer 97 ferritic-martensitic steel at room temperature. Cylindrical specimens with a shallow notch and no artificial crack starters were used. The constant strain amplitude cycling was adopted. First fatigue cracks nucleate at about 5% of the fatigue life along the surface slip bands. If a crack overcome the barrier of the first high angle boundary, its growth is regular and an exponential growth law is observed. This law may be used for the residual fatigue life prediction based on the small crack growth kinetics.     

Fatigue crack growth behavior of weld heat-affected zone of type 304 stainless steel in high temperature water

The fatigue crack growth behavior of the weld heat-affected zone (HAZ) of type 304 stainless steel in high temperature water which simulates the boiling-water reactor environment was investigated to clarify the effects of welding residual stress, cyclic frequency f and thermal aging on crack growth rate. A lower crack growth rate of the HAZ than of the base metal was observed in both the high temperature water and the ambient air caused by the compressive residual stress. The crack closure point was measured in the high temperature water. The effect of the welding residual stress on the crack growth rate of the HAZ can be evaluated separately from the environmental effect through the crack closure behavior. The high temperature water increased the crack growth rate at a cyclic frequency of 0.0167 Hz but did not affect it much at 3 and 5 Hz. The crack growth behavior of the thermally aged HAZ at 400 °C for 1800 h was almost the same as that of the unaged material tested at 0.0167 and 5 Hz in the high temperature water.     

Fatigue cracks in Eurofer 97 steel: Part II. Comparison of small and long fatigue crack growth

The fatigue crack growth rate in the Eurofer 97 steel at room temperature was measured by two different methodologies. Small crack growth data were obtained using cylindrical specimens with a shallow notch and no artificial crack starters. The growth of semicircular cracks of length between 10-2000 μm was followed in symmetrical cycling with constant strain amplitude (R_ε = −1). Long crack data were measured using standard CT specimen and ASTM methodology, i.e. R = 0.1. The growth of cracks having the length in the range of 10-30 mm was measured. It is shown that the crack growth rates of both types of cracks are in a very good agreement if J-integral representation is used and usual assumptions of the crack closure effects are taken into account.     

Sustained load crack growth in A533B-1 steel under neutron irradiation in a water environment

A study of the combined effects of radiation, water and temperature on sustained load crack growth behavior of reactor pressure vessel steel A533B-1 is reported. To complete this study wedge opening loading (WOL) T-type fracture toughness specimens were prepared from a sample of A533B-1 steel which had a copper content of 0.13%. The crack length change was measured after 939 hr of irradiation in a water environment. An electrical potential method was successfully used to measure the crack length of rusted radioactive specimens. Sustained load crack growth occurred at initial stress intensity factor K_Ii as low as . The value of stress corrosion cracking threshold factor K_Iscc after neutron irradiation in a water environment appears to be in the range of . The results of neutron irradiation in a water environment are to apparently increase the susceptibility of A533B-1 steel to stress corrosion cracking and hydrogen embrittlement.     

Simulation of stress corrosion crack growth in steam generator tubes

Assuming a small axial surface crack inside a steam generate (S/G) tube, stress corrosion crack growth is simulated by using finite element method. Pressure difference and residual stresses induced from the roll expansion are considered as applied forces and Scott's crack growth equation based on the stress intensity factor is used. Stress intensity factor distribution along crack front, variation of crack shape and crack growth rate are obtained during the crack growth. From the results, it is noted that for the given residual stress distribution, variation curve of the crack aspect ratio during the crack growth is uniquely determined. In addition, the curve shows nearly constant crack aspect ratio during the initial crack growth stage. When adjacently growing two small cracks are coalesced to form a longer crack, the growth rate of crack depth is increasing but that of crack length is decreasing, and the crack aspect ratio is converging to the original variation curve during the subsequent crack growth.     

Stable and unstable crack growth in type 304 stainless steel plate

Experimental and theoretical results on stable as well as unstable fractures for Type 304 stainless steel plates with a central crack subjected to tension force are given.In the experiment using a testing machine with a special spring for high compliance, the transition points from the stable to the unstable crack growth are observed and comparisons are made between the test results and the finite element solutions.A round robin calculation for the elastic-plastic stable crack growth using one of the specimens mentioned above is also given.     

Creep crack growth assessment by means of a crack tip/far field concept

A method has been developed to assess crack initiation and crack growth behaviour in the creep range. The proposed method is based on a two-criteria-diagram, which covers the crack tip/far field situation. The approach is similar to the application of the elastic stress concentration factor K, in the creep rupture range.     

Methods to characterize crack growth under elastic-plastic conditions

This paper discusses different methods of analysis to characterize crack growth under elastic-plastic conditions. Limits to the applicability of experimental resistance curve data are identified for both the deformation and modified J approaches, i.e. J_D and J_M, respectively. The limit of the J_M-R curve is shown to be consistent with an early analysis by Rice et al. Five methods of extrapolation allowing to extend the R-curves to large amounts of crack extension are presented and discussed in detail. The whole methodology is used to analyze experimental data obtained from seven welds, i.e. 61W-67W, in both the irradiated and unirradiated condition, with specimens of different size. The data from the small 0.5T CT specimens are extrapolated using the different methods and compared with those from the bigger 4T CT geometries. It is shown that the J_M-R curves from the small specimens and adequate extrapolation methods can indeed be used to simulate the behavior of the larger pieces.     

Mechanism of irradiation assisted stress corrosion crack initiation in thermally sensitized 304 stainless steel

Thermally sensitized 304 stainless steels, irradiated up to 1.2 × 10²¹ n/cm² (E > 1 MeV), were slow-strain-rate-tensile tested in 290 °C water containing 0.2 ppm dissolved oxygen (DO), followed by scanning and transmission electron microscopic examinations, to study mechanism of irradiation-assisted-stress-corrosion-crack (IASCC) initiation. Intergranular (IG) cracking behaviors changed at a border fluence (around 1 × 10²⁰ n/cm²), above which deformation twinning were predominant and deformation localization occurred earlier with increasing fluence. The crack initiation sites tended to link to the deformation bands, indicating that the crack initiation may be brought about by the deformation bands interacted with grain boundaries. Thus the border fluence is equivalent to the IASCC threshold fluence for the sensitized material, although the terminology of IASCC is originally given to the non-sensitized materials without microstructural definition. The IASCC threshold fluence was found to change with irradiation conditions. Changes in IASCC susceptibility and IASCC threshold fluence with fluence and DO were further discussed.     

Modes of long crack growth under non-stationary temperature fields

The exploitation practice of structures under thermal loads evidences that the final length of a quasistatic crack can be considerably greater than the thermal tension zone, sometimes causing that the structure approaches complete fracture. This occurs in one or several cycles of a gradual crack growth due to the evolution of thermal field in time resulting in that fracture zone follows the moving tension zone. By the extreme example of quasistationary thermal stress field the set of quasistatic crack growth modes and their peculiarities for the case of moving thermal stresses are described here. These are modes developing both in the direction of the thermal stress field propagation and in the opposite direction. The critical condition of each mode is described, and the crack growth rates are estimated. The rational crack growth evaluation procedure is also proposed. The theoretical conclusions are supported by the experiment, which demonstrates the growth of long thermal cracks.     

Effect of geometric conditions on residual stress of brazed stainless steel plate-fin structure

Plate-fin heat exchanger (PFHE) is the delegate of the miniaturization of heat exchanging equipment. As the core of PFHE, plate-fin structure is fabricated by vacuum brazing. Owing to the material mismatching between filler metal and base metal, residual stresses can arise during the brazing process and decrease the structure strength greatly. Therefore, estimating the magnitude and distribution of residual stress and discussing its influence factors for the early design and fabrication of plate-fin structure are deemed necessary. This paper presented a finite element analysis (FEA) of brazed residual stresses for a counter-flow stainless steel plate-fin structure. The effects of geometric conditions including brazing gap, plate thickness, fin thickness, fin pitch, fin height and fin layers on residual stress were investigated. This work provides a reference for design and decreasing residual stress for stainless steel plate-fin structure.     

Probabilistic assessment of creep crack growth rate for Gr. 91 steel

This paper focuses on a probabilistic assessment of creep crack growth rate (CCGR) for Gr. 91 steel which is regarded as one of major structural materials of Gen-IV reactors. A series of creep creak growth (CCG) data was obtained from the CCG tests under various applied loads at 600 °C. Using the experimental CCG data, four methods such as a least square fitting method (LSFM), mean value method (MVM), probabilistic distribution method (PDM), and the Monte Carlo method (MCM) were used to determine the parameters B and q for a power law equation between CCGR and C^* integral. The commonly used LSFM revealed a considerable difference in the CCGR lines compared with the MVM and PDM. The PDM was found to be more useful than the LSFM, because it can assess the CCGR lines from the probabilistic viewpoints. It was verified that the two parameters B and q followed a lognormal distribution well. From the lognormal distribution, a number of random variables for the B and q parameters were successfully generated by the Monte Carlo Simulation (MCS) technique. The CCGR lines for the 10% and 90% probabilities were predicted by the PDM and MCM, and the MCM result was compared with the PDM one.     

The frequency effect on the fatigue crack growth rate of 304 stainless steel

Under cyclic loading condition, the fatigue crack growth (FCG) rate governed by stress intensity factor and stress ratio is well known; Walker’s equation, Forman’s equation and Elber’s equation are typical formulae to describe the fatigue crack growth rate. However, the loading frequency effect on the fatigue crack growth rate has yet to be explored. Recently, studies have focused on the loading frequency effect on some visco-elastic materials, and have provided a clearer understanding of the frequency effect on the fatigue crack growth rate. In a physical sense, knowledge about the loading frequency effect on the fatigue crack growth rate for 304 stainless steel is still lacking. James conducted a lot of experiments, and through data analysis, he concluded an evaluation equation which is based upon the experimental illustration. In this study, the physical properties of the material are used to illustrate the modification of fatigue crack growth rate, and a new formula which is based upon the modified Forman’s equation, is provided.     

Experimental investigation on ductile stable crack growth emanating from wire-cut notch in AISI 4340 steel

An experimental investigation on the stable crack growth (SCG) behaviour in AISI 4340 using CT type specimen with a sharp slit (0.05 mm) under mode I and mixed modes (I and II) loading is presented. The slit was made in the specimen through wire cutting technique. Different combinations of loading angle and ratio of original crack length to specimen width (a₀/W) are examined. Data concerned with direction of initial crack extension, load–load line displacement (L–LLD) diagrams, initiation and maximum loads, range of stable crack growth, crack tip blunting, crack front geometry, fracture surfaces and their scanning electron micrographs are obtained. A noticeable blunting effect is observed prior to crack initiation. Although the crack initiates from a straight front, a considerable front tunnelling effect occurs as the crack extends. Under mixed mode, the crack extension takes place initially almost along a straight path, inclined with the main crack. The loading angle and initial crack length affect the initiation (P_i) and maximum (P_max) loads significantly, but the ratio between P_max and P_i remains almost constant. The direction of initial stable crack extension due to mixed mode loading is determined throughout an elastic finite element analysis. There is a good agreement between the experimental and predicted results.     

Cyclic crack growth evaluation of a 20MnMoNi55 piping steel in high-oxygen reactor water

Samples of a low alloy steel piping material taken from the full scale corrosion fatigue test loop of the Heissdampfreaktor (HDR) plant have been tested at 240°C in high oxygen reactor water. The small-scale specimens (CT25) were exposed to a similar loading spectrum to that which has been used in the full-scale corrosion fatigue tests at the HDR-plant. During the autoclave tests cyclic crack growth rates were determined. Fracture surface investigations were performed not only for the laboratory test specimens but also for the fracture surface of a sample taken from the HDR test loop piping after the full scale test. In this paper the autoclave testing results and fracture surface observations are presented and compared to those obtained in the HDR piping tests.     

Environmentally assisted crack growth in a low alloy boiler steel in high temperature water containing oxygen

The crack growth behaviour of the higher strength steel 17 MnMoV 6 4 in deionized high temperature water containing oxygen was investigated with respect to static loading. The tests were performed in an autoclave testing facility at an oxygen content of 8 ppm, a pressure of 70 bar and a temperature of 240°C under quasi-stagnant flow conditions. The stress intensities at the beginning of the tests were 17, 20, 27, 34, 40 and 58 MPa√m. In contrast to the higher loaded specimens no evidence of environmentally assisted cracking was found at stress intensities of 17 and 20 MPa√m.The maximum crack growth rate in the range where only environmetally assisted cracking occured amounted to about 4 x 10^-5 mm/s. The critical stress intensity K_IJ for the onset of stable ductile crack growth in air is 100 MPa√m. On the basis of fractographic studies the crack development found can be ascribed to the “Strain Induced Corrosion Cracking (SICC)” mechanism. This mechanism, used as a working hypothesis, gives a satisfactory explanation for the occurence of stress corrosion cracking of unalloyed and low alloyed steels in high temperature water. SICC is particularly characterized by aggravated corrosive attack occuring as soon as the magnetite/haematite protective layer has been locally disturbed. The stress concentration then just becomes so great that in the region of the resulting crack tips, yield/creep deformation within the critical range of strain rates occurs.     

Numerical simulation of residual stresses induced by laser beam welding in a SUS316 stainless steel pipe with considering initial residual stress influences

With the development of computer hardware and software, numerical simulation technology has been widely used to predict welding temperature field, residual stresses and distortion. However, till now the influences of initial stresses induced by the manufacturing process before welding on the welding-induced residual stresses are rarely investigated experimentally and numerically. In the present work, we have developed a computational approach based on thermal elastic plastic FEM to clarify how the initial stresses due to heat treatment affect the welding-induced residual stresses in an austenitic stainless steel pipe. A heat treatment process, which is similar to solution heat treatment, is employed to produce initial stresses in the pipe before welding. After the heat treatment, the laser beam welding is used to perform a girth weld in the middle of the pipe. Through comparing the residual stress distributions after heat treatment and laser beam welding, we have investigated the influence of the initial residual stresses on the welding-induced residual stresses. The numerical results suggest that the initial residual stresses prior to welding have significant effects on the residual stresses after welding in the pipe model.