A new monitoring system for piping systems in fossil fired power plants

A CEC-funded project has been performed to tackle the problem of producing an advanced Life Monitoring System (LMS) which would calculate the creep and fatigue damage experienced by high temperature pipework components. Four areas were identified where existing Life Monitoring System technology could be improved:

1. 1. the inclusion of creep relaxation

2. 2. the inclusion of external loads on components

3. 3. a more accurate method of calculating thermal stresses due to temperature transients

4. 4. the inclusion of high cycle fatigue terms.

The creep relaxation problem was solved using stress reduction factors in an analytical in-elastic stress calculation. The stress reduction factors were produced for a number of common geometries and materials by means of non-linear finite element analysis. External loads were catered for by producing influence coefficients from in-elastic analysis of the particular piping system and using them to calculate bending moments at critical positions on the pipework from load and displacement measurements made at the convenient points at the pipework. The thermal stress problem was solved by producing a completely new solution based on Green's Function and Fast Fourier transforms. This allowed the thermal stress in a complex component to be calculated from simple non-intrusive thermocouple measurements made on the outside of the component. The high-cycle fatigue problem was dealt with precalculating the fatigue damage associated with standard transients and adding this damage to cumulative total when a transient occurred.

The site testing provided good practical experience and showed up problems which would not otherwise have been detected.     

Growth Stresses in the Oxide Scales on TiAl Alloys at 800 and 900°C

In the oxidation of TiAl alloys, the role of scale-growth stresses formed during oxidation has, thus far, been unknown. In the present paper the oxide-growth stresses were investigated by the deflection-test method in monofacial oxidation (DTMO) accompanied by acoustic-emission measurements. On unmodified surfaces the growth stresses are compressive and reach levels of around –100 MPa. At the same time, significant acoustic emission occurs indicating that even under isothermal conditions, stresses are relieved by a scale-cracking mechanism. For oxide scales on TiAl surfaces, which had been ion implanted with chlorine before oxidation, a very thin protective alumina layer is formed which, however, develops growth stresses in the range of several GPa, accompanied by intensive acoustic emission. In all stress–time curves, a dynamic situation is observed. This consists of phases of stress relief by scale microcracking and phases of stresses increase due to crack healing and further oxide growth. As a result, the level of stress as a function of oxidation time, is characterized by an oscillating course.     

Life Calculations for Header – PGV-1000 Steam Generator Connector Weld Joints under NPP Service Conditions

The procedure for calculating the life of header – steam generator connector weld joints is proposed. It allows for running out the material plasticity reserve upon static cyclic elastoplastic loading as well as operating conditions, local stress concentrations, and residual stresses after welding.     

Thermomechanical Models of Irreversible Finite Deformation of Anisotropic Solids

The proposed models for irreversible finite deformation of initially anisotropic solids are based on the hypothesis of the parameters of state, for which the authors have chosen a universal parameter (temperature) and a strain component, which is analogous to volume strains in an isotropic body and represents thermal strains of an unconstrained (stress-free) anisotropic solid. The application of this hypothesis allows the strain tensor to be resolved into a reversible and irreversible components. For irreversible processes of finite deformation of hardenable materials, the authors have proposed a deformation-type model, which makes it possible to describe a change in the type of anisotropy of initially anisotropic materials in the course of deformation. For the flow-theory-type model, the limiting state function, as given in the space of irreversible strains, allows for the experimentally observed plastic flow of anisotropic crystals under the action of hydrostatic pressure only.     

Influence of Ni Interlayers on the Mechanical Properties of Ti6Al4V/(WC-Co) Friction Welds

Ni interlayers were introduced prior to dissimilar friction welding of Ti6Al4V base material to three cemented carbide substrates. The fracture strength of Ti6Al4V/(WC-6 wt% Co) welds were poor and were markedly improved when 20-µm thick Ni interlayers were introduced prior to dissimilar friction welding. These results were only produced when the (WC-6 wt% Co) cermet was electroplated prior to friction welding. When the Ti6Al4V alloy was electroplated prior to friction welding, fractured WC particles and cracking were observed in the (WC-Co) carbide substrate. The fracture strengths of Ti6Al4V/(WC-11 wt% Co) and Ti6Al4V/(WC-24 wt% Co) welds were not improved when 20-µm thick Ni interlayers were introduced prior to friction welding. During mechanical testing, the Ni layer retained at the dissimilar joint interface created a region of weakness.     

Schubspannungsbomben in Faserverbunden

Shear Bombs in Fibre Composites Despite an optimum external shape non‐load adapted internal fibre orientation can lead to the formation of shear cracks where crossing tension‐compression principal stress trajectories create localized shear peaks. Trees are subject to those failure because they cannot re‐arrange their fibres after wood formation. Bones can adjust their micro‐structure to changing load conditions and in this way can better control shear failure. The engineer working with fibre composites should be alert to avoid fibre arrangements not following the force flow. Localized shear zones may also form near notches similar to normal notch stresses, however they are not always situated at the contour line of the notch.     

Analysis of adhesive bonded composite lap joints with transverse stitching

The effect of transverse stitching on the stresses in the adhesive is investigated using an adhesive sandwich model with nonlinear adhesive properties and a transverse stitching model for adhesive bonded composite single-lap and double-lap joints. Numerical results indicate that, among all stitching parameters, thread pretension and stitch density have significant effect on the peel stresses in the adhesive; increase in the thread pretension and the stitch density leads to a decrease in peel stress in the adhesive, while an increase in other parameters generally results in a negligible reduction in peel stress. The effect of stitching was found to be negligible on the shear stresses in the adhesive. Thus it is concluded that stitching is effective for the joints where peel stresses are critical and ineffective for those where shear stresses are critical.     

Cohesive stresses and size effect in quasi-brittle materials

A novel approach to the derivation of Bažant’s size effect law is presented. Contrarily to the original Lagrangian derivation which hinged on energetic consideration, a Newtonian approach based on local stress intensity factors is presented. Through this approach, it is shown that Bažant’s size effect law is the first (and dominant) term in a series expansion for the nominal stress. Furthermore, analytical expressions forB are derived for selected specimen geometries.     

正交曲线坐标下三维代数应力通量模型

针对弯曲及不规则明渠的水动力及物质输运特性，本文建立了曲线坐标系下的三维代数应力通量数学模型，对平面上弯曲及不规则复杂边界情形，采用Poisson方程进行正交曲线坐标变换，各向异性的湍流代数应力通量模型被引用于本文的模拟计算中，以体现复杂边界条件引起的水动力及物质输运特性的变化。通过180度强弯曲明渠水槽及贵溪电厂不规则边界河段物理模型试验两个实例计算表明，实测值与计算吻合良好，效果令人满意。     

磨机大齿轮对缝处产生张口的初探

针对大中型磨机大齿轮对缝处在使用中会产生张口现象而降低其使用寿命的问题,从分析产生张口的原因入手,通过理论计算,提出设计的配合间隙,并指出在安装与使用中应注意的问题.