Determination of the elastic-plastic fracture mechanics Z-factor for alloy 182 weld metal flaws

One of the ways that the ASME Section XI code incorporates elastic-plastic fracture mechanics (EPFM) in the Section XI Appendix C flaw evaluation procedures for circumferential cracks is through a parameter called Z-factor. This parameter allows the simpler limit-load (or Net-Section-Collapse) solutions to be used with a multiplier from EPFM analyses. This paper shows how 3-D finite element (FE) analyses were employed to investigate the sensitivity of the crack-driving force as a function of crack location (i.e., crack in the center of weld, or closer to the stainless or low alloy steel sides) in an Alloy 182 dissimilar metal weld (DMW), and how an appropriate (or equivalent) stress-strain curve was determined for use in the J-estimation schemes. The J-estimation schemes are then used to cover a wider range of variables, i.e., pipe diameters, cracks lengths, and also incorporate crack growth by ductile tearing. The Z-factor equations as a function of pipe diameter were calculated using the LBB.ENG2 J-estimation scheme along with the most conservative equivalent stress-strain curve from the FE analyses. The proposed Z-factor approach was then validated against an Alloy 182 DMW full-scale pipe test that had a circumferential through-wall crack in the fusion line. The predicted EPFM maximum load showed excellent agreement with the experimental result. Furthermore, it was shown that the proposed Z-factor equation is not sensitive to the location of the crack.