Reduction method for residual stress of welded joint using harmonic vibrational load

Welding is widely used for construction of many structures. Since welding is a process using locally given heat, residual stress is generated near the bead. Tensile residual stress degrades fatigue strength. Some reduction methods of residual stress have been presented and, for example, heat treatment and shot peening are practically used. However, those methods need special tools and are time consuming. In this paper, a new method for reduction of residual stress using harmonic vibrational load during welding is proposed. The proposed method is examined experimentally for some conditions. Two thin plates are supported on the supporting device and butt-welded using an automatic CO₂ gas shielded arc welding machine. Residual stress in the direction of the bead is measured by using a paralleled beam X-ray diffractometer with scintillation counter after removing quenched scale chemically. First, the welding of rolled steel for general structure for some excitation frequencies is examined. Specimens are welded along the groove on both sides. For all frequencies, tensile residual stress near the bead is significantly reduced. Second, welding of the specimen made of high tensile strength steel is examined. In this case, tensile residual stress near the bead is also reduced. Finally, the proposed method is examined by an analytical method. An analytical model which consists of mass and preloaded springs with elasto-plastic characteristic is used. Reduction of residual stress is demonstrated using this model.     

Electromagnetic and Structural Analysis on Vacuum Vessel for CFETR During Plasma Major Disruption

China Fusion Engineering Test Reactor (CFETR) is a superconducting magnet tokamak and its goal is to achieve the magnetic confinement fusion. The electromagnetic (EM) transients cause mechanical forces, which represent one of the most vital loads for tokamak vacuum vessel (VV). This paper is focused on calculational methods and results for the EM loads on the simplified but practical model of CFETR VV with respect to plasma major disruption scenarios as a reference of the design and analysis. Commercial finite element method software, ANSYS, was employed to evaluate the eddy current on the VV module with the 22.5 ° sector model for major conducting structure of the tokamak including double-walled VV, T-shape rib, and three ports. The plasma current is damping as exponential function 36 ms corresponding to the current simulating in ITER outputs, which are one of major sources of EM loads on VV components. As the results of calculating the eddy currents and EM forces, stress and deformation on CFETR VV can be obtained, which is useful for the structural design of VV.     

Effect of processing on properties of thin walled calandria tubes for pressurised heavy water reactor

Thin walled calandria tubes for pressurised heavy water reactors are manufactured either by seam welding of Zircaloy-4 sheets or by seamless route. In the present study, the effect of processing on the critical properties such as texture, microstructure, hydriding behaviour and residual stress for both the routes as well as the mechanical anisotropy developed due to seam welding are investigated. The properties of the seam welded tube in the fusion and adjoining region are markedly different from the base material and from the seamless tube. Residual stress measurements indicate that heat affected zone (HAZ) of seam welded tubes have longitudinal tensile residual stress and the seamless tubes have uniform compressive stress along the circumference. The phase transition in the presence of residual stresses due to thermal gradient is found to modify the texture in the HAZ. The hydride orientation and mechanical anisotropy in these regions are found to be dependent on the texture of the material.     

A study on nuclear analysis of the divertor region of the CFETR

This paper presents the nuclear analysis performance of the Chinese Fusion Engineering Test Reactor(CFETR)divertor region using the MCNP-5 Monte Carlo N-particles code in a 3D geometry model.We assessed the nuclear responses of the divertor region component systems and evaluated their shielding capability,which can support the development strategy of the physical and engineering design of the CFETR.Model specification based on the latest CAD model of the CFETR divertor has been integrated into the CFETR MCNP reference model with a major/minor radius R=7.2 m/a=2.2 m in the 22.5° model,and a fusion-power range of around 1-1.5 GW.The nuclear heating and radiation damage of the divertor system are enhanced compared to that of the ITER and the earlier CFETR design.The initial nuclear responses of the toroidal field coil and vacuum vessel systems showed that the shielding of the current divertor design is not sufficient and optimization work has been carried out.We also carried out calculations and analysis using a hypothetical operating scenario of over 14 years.An excellent improvement in the nuclear performance has been obtained by the improved additional shielding block in the divertor region when referring to the ITER design limit,which can support the design of the future update of the divertor region systems of the CFETR.     

反应堆压力容器内部大尺寸环形异种金属焊缝残余应力分布研究

获得反应堆压力容器内部大尺寸环形异种金属焊缝残余应力分布可为反应堆压力容器结构设计和制造工艺优化提供指导,通过设计和制造能够代表产品焊接结构形式的镍基合金和低合金钢异种金属焊接结构模拟件,采用轮廓法测试焊接结构模拟件内部纵向残余应力,采用有限元法模拟计算焊接结构模拟件横向和纵向残余应力,获得了整个异种金属焊接接头残余应力分布特征。结果表明:焊缝区域内部纵向残余应力为拉伸应力,峰值应力达到500 MPa左右,并且表层应力大于内部应力,峰值应力出现在距下表面3 mm和24 mm位置;横向残余应力在焊缝区域从上表面到下表面的分布为拉应力-压应力-拉应力,压缩横向残余应力峰值达到?300 MPa,出现在距下表面约18 mm位置。本文研究可为焊接结构设计提供理论指导。      

贯穿件J形坡口焊接残余应力分析

核电站反应堆压力容器(RPV)顶盖控制棒驱动机构(CRDM)管座J形坡口焊缝在一回路高温高压水环境下存在应力腐蚀开裂(SCC)的风险,而焊接残余应力是SCC的主要驱动力。使用二维轴对称模型有限元方法对CRDM中心管座J形坡口进行焊接残余应力分析。为了探索一种简单、高效和保守的方法,研究了热源简化、焊缝形状简化、屈服强度、相变和强化行为对焊接残余应力的影响。结果表明:双椭球热源与均匀热源得到的残余应力结果基本一致;焊缝形状由鱼鳞状简化为方块模型对焊接残余应力结果影响不大,但是与合并焊道的结果相差较大;采用低屈服强度得到的残余应力结果并不保守;在ANSYS软件中,固液相变对残余应力结果影响不大;等向强化模型的结果比随动强化模型的结果保守;在工程上,建议采用均匀热源、方块焊道模型和等向强化模型进行焊接模拟。     

Neutronics Analysis of Water-Cooled Ceramic Breeder Blanket for CFETR

In order to investigate the nuclear response to the water-cooled ceramic breeder blanket models for CFETR, a detailed 3D neutronics model with 22.5otorus sector was developed based on the integrated geometry of CFETR, including heterogeneous WCCB blanket models,shield, divertor, vacuum vessel, toroidal and poloidal magnets, and ports. Using the Monte Carlo N-Particle Transport Code MCNP5 and IAEA Fusion Evaluated Nuclear Data Library FENDL2.1,the neutronics analyses were performed. The neutron wall loading, tritium breeding ratio, the nuclear heating, neutron-induced atomic displacement damage, and gas production were determined.The results indicate that the global TBR of no less than 1.2 will be a big challenge for the watercooled ceramic breeder blanket for CFETR.     

RAMI Analysis Program Design and Research for CFETR (Chinese Fusion Engineering Testing Reactor) Tokamak Machine

Chinese Fusion Engineering Testing Reactor (CFETR) is a test reactor which shall be constructed by National Integration Design Group for Magnetic Confinement Fusion Reactor of China with an ambitious scientific and technological goal. The reactor has the equivalent scale compared with ITER, but has the complementary function to ITER. CFETR is a demonstration of long pulse or steady-state operation with duty cycle time not less than 0.3–0.5 and the full cycle of tritium self-sustained with TBR not less than 1.2. At the same time it will be exploring options for DEMO blanket and divertor with an easy changeable core by remote handling way. To be able to reach its scientific and technological objectives, as one of technical risks control methods, RAMI analysis need to be done during the hold lifetime of CFETR, from conception design to decommissioning. Base on stating of CFETR lifetime and preliminary operational programme, the RAMI analysis program and process are designed and discussed, it consists of five major steps: (1) functional analysis are performed, (2) calculating reliability block diagrams, (3) analyzing failure mode, effects and criticality analysis, (4) risk mitigation actions are taken to ensure every system is compatibility with RAMI objectives, (5) All the RAMI analysis are integrated as the final RAMI analysis reports to be reviewed in the system final design review. Along with the elements of the analysis the vacuum vessel (VV) system was performed to provide as examples, detailed showing how the CFETR RAMI analysis is carried out. CFETR RAMI analysis guidelines were designed and established, after constantly revised and improved these analysis criteria and programs will become the basis standards for CFETR RAMI analysis. Preliminary RAMI analysis of CFETR VV system was obtained, which will be updated with the VV system design progresses.     

Mechanical properties and microstructural investigations of TIG welded 40 mm and 60 mm thick SS 316L samples for fusion reactor vacuum vessel applications

The development of advanced fusion reactors like DEMO will have various challenges in materials and fabrication. The vacuum vessel is important part of the fusion reactor. The double walled design for vacuum vessel with thicker stainless steel material (40–60 mm) has been proposed in the advanced fusion reactors like ITER. Different welding techniques will have to be used for such vacuum vessel development. The required mechanical, structural and other properties of stainless steels have to be maintained in these joining processes of components of various shapes and sizes in the form of plates, ribs, shells, etc. The present paper reports characterization of welding joints of SS316L plates with higher thicknesses like 40 mm and 60 mm, prepared using multi-pass Tungsten Inert Gas (TIG) welding process. The weld quality has been evaluated with non-destructive tests by X-ray radiography and ultrasonic methods. The mechanical properties like tensile, bend tests, Vickers hardness and impact fracture tests have been carried out for the weld samples. Tensile property test results indicate sound weld joints with efficiencies over 100%. Hardening was observed in the weld zone in non-uniform manner. Macro and microstructure studies have been carried out for Base Metal (BM), Heat Affected Zone (HAZ) and Weld Zone (WZ). Scanning Electron Microscopy (SEM) analysis carried out for the impact fractured specimens show ductile fracture. The microstructural study and ferrite number data indicate the presence of high content of delta ferrite in the weld zone as compared to the delta ferrite in base metal.     

Reduction method for residual stress of welded joint using random vibration

Welded joints are used for construction of many structures. Residual stress is induced near the bead caused by locally given heat. Tensile residual stress on the surface may reduce fatigue strength. In this paper, a new method for reduction of residual stress using vibration during welding is proposed. As vibrational load, random vibration, white noise and filtered white noise are used. Two thin plates are butt-welded. Residual stress is measured with a paralleled beam X-ray diffractometer with scintillation counter after removing quenched scale chemically. It is concluded that tensile residual stress near the bead is reduced by using random vibration during welding.     

CFETR氦冷固态包层及其辅助系统动态氚输运分析

实现氚自持、建立完整的氚循环系统并保证氚安全是中国聚变工程实验堆(CFETR)的主要目标之一。在CFETR氦冷固态包层及其辅助系统设计过程中,需对系统级氚输运行为进行详细分析,包括氚滞留量、释放量、浓度的动态变化等。基于已建立的动态氚分析程序TriSim-Dynamic,在此基础上进行修改完善,利用该程序对CFETR氦冷固态包层及其辅助系统氚动态输运进行分析模拟,得到了冷却剂及提氚吹扫气中氚浓度、氚分压,管壁及结构材料中氚盘存量,氚通过包层结构材料和辅助系统管壁向真空室、水冷系统及建筑的渗透通量动态变化,并将其稳态值与已进行基准校核的稳态氚分析程序TriSim-SA及理论解析解进行比较,以初步验证分析结果的准确性,数据结果也对CFETR氚安全分析提供了一定的参考。     

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.     

Numerical simulation of creep damage for low alloy steel welded joint considering as-welding residual stress

A model to calculate the welding temperature and residual stress was built using finite element code ABAQUS, and a subroutine of creep damage was also developed. Based on the coupling of welding residual stress and creep damage, the welding residual stress and creep damage of a tube made of Cr5Mo steel were simulated. This method can obtain the distributions of complex residual stress, creep damage and stress relaxation, which provide a reference for discussing the effect of residual stress on creep damage. The results show that the welding residual stress is very large at initial stage, then it is relaxed in a short time at high temperature. The distribution of creep and damage is mainly decided by the as-welding residual stress. Welding residual stress has a great effect on the creep and damage, which provides a reference for the design and life prediction of high temperature component.     

焊后热处理对16MND5钢焊接组织结构与残余应力的影响

16MND5钢广泛应用于核岛承压容器构件,其焊接接头不可避免地会引入高的残余应力,而焊后热处理可有效消减焊接残余应力以克服应力腐蚀裂纹的影响。本工作利用轮廓法和中子衍射技术研究了焊后热处理对16MND5钢焊接残余应力的影响。结果表明,轮廓法与中子衍射测试结果在趋势和数值上取得了较好的一致性,焊后热处理使焊接态的残余应力峰值从约420 MPa降低至约210 MPa。同时,利用金相法和SEM研究了焊后热处理对焊缝区域组织结构的影响。结果表明,焊后热处理主要表现为贝氏体和少量自回火马氏体的焊缝中心组织转变为回火贝氏体和回火马氏体,热处理后的焊缝区晶粒明显长大。     

Control of welding residual stress for ensuring integrity against fatigue and stress–corrosion cracking

The availability of several techniques for residual stress control is discussed in this paper. The effectiveness of these techniques in protecting from fatigue and stress–corrosion cracking is verified by numerical analysis and actual experiment. In-process control during welding for residual stress reduction is easier to apply than using post-weld treatment. As an example, control of the welding pass sequence for multi-pass welding is applied to cruciform joints and butt-joints with an X-shaped groove. However, residual stress improvement is confirmed for post-weld processes. Water jet peening is useful for obtaining a compressive residual stress on the surface, and the tolerance against both fatigue and stress–corrosion cracking is verified. Because cladding with a corrosion-resistant material is also effective for preventing stress–corrosion cracking from a metallurgical perspective, the residual stress at the interface of the base metal is carefully considered. The residual stress of the base metal near the clad edge is confirmed to be within the tolerance of crack generation. Controlling methods both during and after welding processes are found to be effective for ensuring the integrity of welded components.     

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.     

Predicting welding residual stresses in a dissimilar metal girth welded pipe using 3D finite element model with a simplified heat source

Dissimilar metal welds are commonly used in nuclear power plants to connect low alloy steel components and austenitic stainless steel piping systems. The integrity assessment and life estimation for such welded structures require consideration of residual stresses induced by manufacturing processes. Because the fabrication process of dissimilar metal weld joints is considerably complex, it is very difficult to accurately predict residual stresses. In this study, both numerical simulation technology and experimental method were used to investigate welding residual stress distribution in a dissimilar metal pipe joint with a medium diameter, which were performed by a multi-pass welding process. Firstly, an experimental mock-up was fabricated to measure the residual stress distributions on the inside and the outside surfaces. Then, a time-effective 3-D finite element model was developed to simulate welding residual stresses through using a simplified moving heat source. The simplified heat source method could complete the thermo-mechanical analysis in an acceptable time, and the simulation results generally matched the measured data near the weld zone. Through comparing the simulation results and the experimental measurements, we can infer that besides the multi-pass welding process other key manufacturing processes such as cladding, buttering and heat treatment should also be taken into account to accurately predict residual stresses in the whole range of the dissimilar metal pipe.     

Prediction of residual stress in the welding zone of dissimilar metals using data-based models and uncertainty analysis

Since welding residual stress is one of the major factors in the generation of primary water stress-corrosion cracking (PWSCC), it is essential to examine the welding residual stress to prevent PWSCC. Therefore, several artificial intelligence methods have been developed and studied to predict these residual stresses. In this study, three data-based models, support vector regression (SVR), fuzzy neural network (FNN), and their combined (FNN + SVR) models were used to predict the residual stress for dissimilar metal welding under a variety of welding conditions. By using a subtractive clustering (SC) method, informative data that demonstrate the characteristic behavior of the system were selected to train the models from the numerical data obtained from finite element analysis under a range of welding conditions. The FNN model was optimized using a genetic algorithm. The statistical and analytical uncertainty analysis methods of the models were applied, and their uncertainties were evaluated using 60 sampled training and optimization data sets, as well as a fixed test data set.     

Stress corrosion cracking countermeasure observed on Ni-based alloy welds of BWR core support structure

The effect of hydrostatic test on the residual stress re-distribution was simulated by experiment to confirm the residual stress behavior of the cone-shaped shroud support to reactor pressure vessel (RPV) weld, where a number of cracks due to stress corrosion cracking (SCC) were observed on the inner side only. Test specimen with tensile residual stress was loaded and unloaded with axial plus bending load, which simulates the hydrostatic test load, and the strain change was measured during the test to observe the residual stress behavior. The results verify that the residual stresses of the shroud support to the RPV weld were reduced and the stresses on inner and outer sides were reversed by the hydrostatic test. As the SCC countermeasure, the shot peening (SP) technology was applied. Residual stress reduction by SP on the complicated configuration, and improvement of SCC resistance and endurance of the compressive residual stress were experimentally confirmed. Then, SP treatment procedures on the actual structure were confirmed and a field application technique was established.     

Decay Heat Removal by Natural Circulation of Vacuum Vessel Coolant for ITER

The decay heat-driven temperature transients of the in-vessel components following a postulated loss of all in-vessel cooling have been calculated. The resulting time-dependent heat load to the vacuum vessel is due to radiation from the backplate and convection of postulated steam between backplate and vacuum vessel. It is shown, that even for a failure of all in-vessel cooling and total loss of power, the ITER design can rely on passive decay heat removal by natural circulation in one of the two existing cooling loops of the vacuum vessel. A mathematical model describes the transient operating conditions and shows that the temperature established by natural circulation does not exceed 200°C at the maximum shut down heat load to the vacuum vessel. Therefore, no additional emergency cooling system is required if the existing heat exchanger is designed for natural circulation and a bypass is used during normal operation to maintain operation temperature.