Fracture behaviours of fracture toughness testing specimens with metallurgical heterogeneity along crack front

Safe use of welded structures is dependent on fracture mechanics properties of welded joints. In present research, high strength low alloyed HSLA steel in a quenched and tempered condition, corresponding to the grade HT 80, was used. The fluxo cored arc welding process (FCAW), with CO₂ as shielding gas, was used and two different tubular wires were selected. The aim of this paper is to analyse fracture behaviour of undermatched welded joints, and also to determine relevant parameters which contribute to higher critical values of fracture toughness. Towards this end three differently undermatched welded joints were analysed using results of testing the composite notched specimens with through thickness crack front positioned partly in the weld metal, partly in heat affected zone (HAZ) and partly in base material (BM).The presence of different microstructures along the pre‐crack fatigue front has an important effect on the critical crack tip opening displacement (CTOD). This value is the relevant parameter for safe service of welded structure. In the case of specimens with through thickness notch partly in the weld metal, partly in the heat affected zone and partly in the base material, i.e. using the composite notched specimen, fracture behaviour strongly depends on a partition of ductile base material, size and distribution of mismatching factor along vicinity of crack front. If local brittle zones occur in the process zone, ductile base metal can not prevent pop‐in instability, but it can reduce it to an insignificant level while the fracture toughness parameter is higher and the weakest link concept can not be applied.     

Effects of Size and Slenderness on Ductility of Fracturing Structures

The ductility of an elastic structure with a growing crack may be defined as the ratio of the additional load-point displacement that is caused by the crack at the moment of loss of stability under displacement control to the elastic displacement at no crack at the moment of peak load. The stability loss at displacement control is known to occur when the load-deflection curve of the whole structural system with the loading device (characterized by a spring) reaches a snapback point. Based on the known stress intensity factor as a function of crack length, the well-known method of linear elastic fracture mechanics is used to calculate the load-deflection curve and determine the states of snapback and maximum loads. An example of a notched three-point bend beam with a growing crack is analyzed numerically. The ductility is determined and its dependence of the structure size, slenderness, and stiffness of the loading device is clarified. The family of the curves of ductility versus structure size at various loading device stiffnesses is found to exhibit at a certain critical stiffness a transition from bounded single-valued functions of D to unbounded two-valued functions of D. The method of solution is general and is applicable to cracked structures of any shape. The flexibility (force) method can be adapted to extend the ductility analysis to structural assemblages provided that the stress intensity factor of the cracked structural part considered alone is known. This study leads to an improved understanding of ductility, which should be useful mainly for design against dynamic loads.     

加热炉烟囱开裂失效分析

通过分析母材材质及力学性能、环焊缝接头的金相组织及其力学性能、宏观断口特点,找到了加热炉烟囱开裂的主要失效原因是在主体环焊缝附近存在夹层金属,夹层金属与母材之间存在严重的末焊透。     

Evaluation on Fatigue Performance and Fracture Mechanism of Laser Welded TWIP Steel Joint Based on Evolution of Microstructure and Micromechanical Properties

The fatigue performance and fracture mechanism of laser welded twinning induced plasticity(TWIP)steel joint were investigated experimentally based on the evolution of microstructure and micromechanical properties.The optical microscopy was used to analyze the evolution of microstructure.The variation of composition and phase structure of fusion zone were detected by energy dispersive X-ray and X-ray diffraction spectrometers.The micromechanical behaviors of the various zones were characterized using nanoindentation.The static tensile test and high cycle fatigue test were performed to evaluate the mechanical properties of welded joint and base metal.The microstructures,tensile properties and fatigue strength of base metal as well as welded metal were analyzed.The fatigue fracture surfaces of base metal and welded joint were observed by means of scanning electron microscopy,in order to identify fatigue crack initiation sites and propagation mechanisms.Moreover,the fatigue fracture characteristics and mechanisms for the laser welded TWIP steel joints were analyzed.     

Q345B热轧带钢冷弯开裂成因分析

针对热连轧厂生产的Q345B冷弯型钢用钢带在生产矩形管过程中出现的焊缝开裂、热影响区压扁开裂和弯曲弧开裂问题,通过对Q345B带钢成分、组织、夹杂物、气体、硫偏析等检验、分析以及对焊接工艺研究,得出焊接工艺不合理是造成焊缝开裂和热影响区压扁开裂的主要原因;原料中夹杂物多、带钢中存在的孔洞(或微裂纹)是造成弯曲弧开裂的主要原因。通过改进焊接工艺、减少钢中硫含量和提高钙处理效果等提高了矩形管合格率。     

Machining of reproducible flaws corresponding to fatigue cracks for fracture mechanics tests of components and welded joints

In connection with the analysis and the development of failure concepts in fracture mechanics for quasistatic loaded components and elastic-plastic behaviour of the material, tests are also carried out with welded and/or complex shaped specimens or structures. Thereby the difficulty arises of generating reproducible flaws in the form of fatigue precracks in definite positions in the components, respectively in the welded joint. It is reported exemplarily about experiments on different CT25 and CCT specimens and on a pressure vessel which contained a fatigue pre-crack, a 0.2 mm saw cut or notches with notch root radius ≤ ≥ 0.1 mm as flaws. The comparison of the results with regard to J-integral at initiation of stable crack, J_i, and J_R curves shows that under certain conditions the 0.2 mm saw cut (notch root radius ≤ ≤ 0.02 mm) is a useful alternative, if reproducible generation of a fatigue pre-crack will not be successful or too expensive. The tests were carried out on StE 460 and on a welded joint of this steel at 25 ± 2°C.     

Research status of corrosion environment failure and safety assessment of pipeline welded joint

Pipeline transportation is an economical,safe,and efficient transportation method for transporting oil,natural gas,mineral slurry,and other fluids.Welding is the most critical construction process in pipeline engineering and is crucial in the safe operation and service of an entire pipeline system.Theoretically,the girth welded joint is the weakest link in a pipeline system.The unevenness of the structure and performance of the joint caused by welding frequently results in the failure of the welded joint before the failure of the base material of the pipe body,causing the pipeline to leak or even break.For steel pipes used in an acidic corrosive medium environment,the integration of the corrosive medium and mechanical load will accelerate the failure of the welded joint.This article reviews the failure modes of pipeline welded joints in acidic corrosive media,including stress corrosion cracking,hydrogen-induced cracking,and corrosion fracture,and corrosion fatigue considering the diffusion and accumulation of H+at the crack tip.It also reviews service pipelines in acidic corrosive media.The general processing technology of pipe joint engineering critical assessment(ECA)is investigated to provide a reference for the future development of technology in this field.     

SS400超细晶粒钢及其焊接接头的疲劳裂纹扩展速率

SS400钢是一种细晶强化的新一代钢铁材料．焊接对其疲劳性能的影响是人们关注的问题。笔者参照美国材料试验学会标准ASTME647—83的规定．采用紧凑拉伸CT试件对SS400钢及其焊接接头CT试件的疲劳裂纹扩展速率进行了测试。发现：母材的疲劳裂纹扩展存在两个不同速率的阶段,焊缝及热影响区的疲劳裂纹扩展速率均低于母材;热影响区的疲劳裂纹扩展速率介于焊缝与母材之间;焊接接头组织和性能的变化并未导致SS400钢疲劳性能的降低。     

Experimental and Computational Investigation of Structural Integrity of Dissimilar Metal Weld Between Ferritic and Austenitic Steel

The structural integrity of dissimilar metal welded (DMW) joint consisting of low-alloy steel and 304LN austenitic stainless steel was examined by evaluating mechanical properties and metallurgical characteristics. INCONEL 82 and 182 were used as buttering and filler materials, respectively. Experimental findings were substantiated through thermomechanical simulation of the weld. During simulation, the effect of thermal state and stress distribution was pondered based on the real-time nuclear power plant environment. The simulation results were co-related with mechanical and microstructural characteristics. Material properties were varied significantly at different fusion boundaries across the weld line and associated with complex microstructure. During in-situ deformation testing in a scanning electron microscope, failure occurred through the buttering material. This indicated that microstructure and material properties synergistically contributed to altering the strength of DMW joints. Simulation results also depicted that the stress was maximum within the buttering material and made its weakest zone across the welded joint during service exposure. Various factors for the failure of dissimilar metal weld were analyzed. It was found that the use of IN 82 alloy as the buttering material provided a significant improvement in the joint strength and became a promising material for the fabrication of DMW joint.     

K and J-Integral Variations Due to Residual Stresses in Welded Plates

Due to residual stress in a material, stress intensity factors (SIF) and also J-integral values are not constant and become path dependent parameters. Modified relations are used for calculations to take into account the effects of residual stresses. These relations give path independence values for the J-integrals in spite of existing the residual stresses. Effects of residual stresses due to welding on variations of SIF and J-integral are studied. Results have a good agreement with theoretical values obtained by weight function method. Through and surface cracks are considered on welded plate and distributions of J-integral on the crack front are obtained. Effects of lengths, depths and orientation angles of cracks are investigated due to applying only residual stress and also combination of residual and applied stresses. Redistributions of residual stress are determined for welded plates with through cracks and compared with experimental results in literature.     

水电站16Mn钢焊接压力管道断裂原因

对水电站１６Ｍｎ钢焊接压力管道纵向断裂和开裂的两节管节进行了断裂失效分析，并按ＧＢ１５９１－８８《低合金结构钢》标准复验钢板的化学成分和力学性能；采用焊接热模拟技术评价焊接热影响区的缺口敏感性，冲击韧性及热应变化脆化倾向；通过斜Ｙ坡口焊接裂纹试验，实物焊接接头的力学性能检验等方法，评价了钢板的质量和焊接工艺。     

Leak-before-break analysis of Prototype Fast Breeder Reactor main vessel

In Prototype Fast Breeder Reactor, the core is immersed in a sodium pool contained within the main vessel (MV). There is an argon cover gas space over the sodium. Top Shield supports the control plug which houses important components such as Control and Safety Rod Driving Mechanism. A core support structure welded to the bottom of MV carries the Grid plate which in turn supports the fuel subassemblies. MV is a cylindrical shell with a bottom dished end and supported at the top. Double ended guillotine rupture of MV will lead to downward movement of the core, which is in effect equivalent to withdrawal of control and safety rod and thus causing a series safety concern. It is essential to demonstrate Leak Before Break (LBB) argument for MV. LBB argument is justified if leak detection is ensured with adequate margin on critical crack length corresponding to failure by tearing instability. The material of construction of MV is SS316 LN. Towards assuring the justification of LBB argument, an isolated 5 mm deep X 200 mm long semi elliptical flaw is taken as the initial flaw and analysed under fatigue loading. A through wall crack in the argon space can be detected by sampling the nitrogen in the annular space between MV and safety vessel surrounding it. Accordingly the detectable crack length is arrived at. The critical crack length is obtained considering stable tearing. More details of the analysis and justification of LBB argument as per RCC-MR Appendix A16 are presented in the paper.     

Prediction of type IV cracking behaviour of 2.25Cr-1Mo steel weld joint based on finite element analysis

Creep tests were carried out on 2.25Cr-1Mo ferritic steel base metal and its fusion welded joint at 823 K over a stress range of 100–240 MPa. The weld joint possessed lower creep rupture strength than the base metal and the reduction was more at lower applied stresses. The failure occurred in the intercritical region of heat-affected zone (HAZ) of the joint, commonly known as Type IV cracking. Type IV cracking in the joint was manifested as pronounced localization of creep deformation in the soft intercritical region of HAZ coupled with preferential creep cavitation. The creep cavitation in intercritical HAZ was found to initiate at the central region of the creep specimen and propagate outwards to the surface. To explain the above observations, the stress and strain distributions across the weld joint during creep exposure were estimated by using finite element analysis. For this purpose creep tests were also carried out on the deposited weld metal and simulated HAZ structures (viz. coarse-grain structure, fine-grain structure, and intercritically annealed structure) of the joint. Creep rupture strength of different constituents of joint were in the increasing order of intercritical HAZ, fine-grain HAZ, base metal, weld metal and coarse-grain HAZ. Localized preferential creep straining in the intercritical HAZ of weld joint as observed experimentally was supported by the finite element analysis. Estimated higher principal stress at the interior regions of intercritical HAZ explained the pronounced creep cavitation at these regions leading to Type IV failure of the joint.     

防护型车用超高强钢的焊接性及焊接工艺

常规工艺大都采用奥氏体、铁素体不锈钢焊丝焊接来避免出现焊接裂纹等缺陷,然而采用这类焊丝焊接的接头抗拉强度和硬度会大幅降低,使得车辆的防护性能也随之降低甚至失效。为了使超高强钢焊接接头的强度和硬度达到较高的使用要求,针对超高强钢(抗拉强度1 500MPa以上)的焊接性及焊接工艺进行了研究。通过理论分析,选取了与母材组织匹配的超低碳马氏体不锈钢焊材,制定了与之匹配的工艺方法及参数,使得焊接后接头与母材组织均为马氏体组织,且有效消除了焊接裂纹等缺陷,从而实现了焊接接头抗拉强度达到母材抗拉强度的70%以上,硬度与母材硬度相当的目标。在试验过程中,采用最经济的MAG焊焊接方法和较容易控制的预热温度,较为经济地满足了工业化生产应用。     

CO2 Corrosion and Grooving Corrosion Behavior of the ERW Joint of the Q125 Grade Tube Steel

In order to investigate the CO2 corrosion behavior and the grooving corrosion susceptibility of electric resistance welded tubes of the Q125 grade,the high temperature and high pressure autoclave was employed to conduct CO2 corrosion experiments for the welded joint.The mechanisms of grooving corrosion and the factors influencing grooving corrosion susceptibility were identified by electrochemical measurement,microstructure observation,residual stress examination,micro-region composition and orientation analysis.The CO2 corrosion results show that the corrosion resistance of the base material is the best,followed by heataffected zone and the welded seam is the worst.The grooving corrosion occurred in the welded seam,and the grooving corrosion susceptibility of welded seam is relativity high.The dominated reason for the grooving corrosion of the electric resistance welded joint is the notable inclusions consisting of Mn S as the main content in the welded seam.The proportion of high-angle grain boundaries in the welding zone is higher than that of base metal and the heat affected zone,which plays an important role in the corrosion behavior of the welded seam.     

含钪Al-Zn-Mg-Zr合金薄板材MIG焊接接头的组织与性能

采用新型Al-Mg-Sc-Zr焊丝对含钪Al-Zn-Mg-Zr合金薄板材进行MIG焊,借助显微硬度及拉伸性能测试、OM,SEM,TEM等检测手段对焊接接头的微观组织和性能进行研究。结果表明:焊缝区为典型的铸态组织;热影响区靠近焊缝一侧呈现大量细小等轴晶组织,靠近基材区为纤维状组织和少量再结晶组织;基材区为纤维状组织。焊接接头的显微硬度以焊缝为中心呈近似对称,且中心处硬度值最低;抗拉强度为481 MPa,屈服强度为320MPa,伸长率为10.1%,焊接系数约0.83。同时,焊丝和基材中微量的Sc和Zr元素在合金中形成大量细小且与基体共格的Al3(Sc,Zr)粒子,能显著细化晶粒组织,有效抑制再结晶发生,大大改善焊缝区的力学性能。     

Characteristics of Welding Crack Defects and Failure Mode in Resistance Spot Welding of DP780 Steel

The mechanical properties of welded joints in resistance spot welding of DP780 steel were tested,and three dif-ferent types of welding cracks in welded joints were investigated by optical microscopy,scanning electron microscopy and electron back-scattered diffraction.Finally,the failure mode of the welded joints in shear tensile test was dis-cussed.It is found the shear tensile strength of welded joints can be greatly improved by adding preheating current or tempering current.The surface crack in welded joint is intergranular fracture,while the inner crack in welded joint is transgranular fracture,and the surface crack on the edge of the electrode imprint can be improved by adding prehea-ting current or tempering current.The traditional failure mode criterion advised by American Welding Society is no longer suitable for DP780 spot welds and the critical nugget size suggested by Pouranvari is overestimated.     

钛合金TC4制压力容器筒体外压失稳的有限元分析

钛合金TC4材料具有良好的综合力学性能,被用于压力容器产品。对于承受外压的TC4制压力容器除须满足强度要求外,还应满足稳定性要求。由于目前没有TC4材料外压应力系数B曲线,因此常规设计方法不能计算。可通过有限元法,采用非线性屈曲分析,逐步增加外压载荷,求解出相应的变形量,从而求解出其临界失稳点。     

Numerical Studies of Estimation of Fracture Parameters for Mismatched Welded Joints with HAZ Cracks

An idealized tri-material assumption is established to describe the constitutive relationship of mismatched welded joints by considering the influence of heat affected zone(HAZ).The fracture parameters Jand C*are estimated for mismatched welded joints with HAZ cracks by finite element analysis with ABAQUS.A middle crack tension(M(T))specimen is utilized in the analysis for different material properties and geometries of the weldment.The influence of mechanical property and geometry on the fracture parameters Jand C*of the specimen is discussed for the welded joints with HAZ crack.The results suggest that the HAZ property is a significant factor in the estimation of Jand C*for the mismatched welded joint with HAZ crack.