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Research Papers: Materials and Fabrication

Biaxial Residual Stress Mapping for a Dissimilar Metal Welded Nozzle

[+] Author and Article Information
Michael R. Hill

Department of Mechanical and
Aerospace Engineering,
University of California,
One Shields Avenue,
Davis, CA 95616
e-mail: mrhill@ucdavis.edu

Mitchell D. Olson

Department of Mechanical and
Aerospace Engineering,
University of California,
One Shields Avenue,
Davis, CA 95616

Adrian T. DeWald

Hill Engineering, LLC
3035 Prospect Park,
Rancho Cordova, CA 95670

1Corresponding author.

Contributed by the Pressure Vessel and Piping Division of ASME for publication in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received September 30, 2014; final manuscript received August 19, 2015; published online September 18, 2015. Assoc. Editor: Xian-Kui Zhu.

J. Pressure Vessel Technol 138(1), 011404 (Sep 18, 2015) (9 pages) Paper No: PVT-14-1154; doi: 10.1115/1.4031504 History: Received September 30, 2014; Revised August 19, 2015

This paper describes a sequence of residual stress measurements made to determine a two-dimensional map of biaxial residual stress in a nozzle mockup having two welds, one a dissimilar metal (DM) weld and the other a stainless steel (SS) weld. The mockup is cylindrical, designed to represent a pressurizer surge nozzle of a nuclear pressurized water reactor (PWR), and was fabricated as part of a weld residual stress measurement and finite-element (FE) modeling round-robin exercise. The mockup has a nickel alloy DM weld joining an SS safe end to a low-alloy steel cylinder and stiffening ring, as well as an SS weld joining the safe end to a section of SS pipe. The biaxial mapping experiments follow an approach described earlier, in PVP2012-78885 and PVP2013-97246, and comprise a series of experimental steps and a computation to determine a two dimensional map of biaxial (axial and hoop) residual stress near the SS and DM welds. Specifically, the biaxial stresses are a combination of a contour measurement of hoop stress in the cylinder, slitting measurements of axial stress in thin slices removed from the cylinder wall, and a computation that determines the axial stress induced by measured hoop stress. At the DM weld, hoop stress is tensile near the OD (240 MPa) and compressive at the ID (−320 MPa), and axial stress is tensile near the OD (370 MPa) and compressive near the midthickness (−230 MPa) and ID (−250 MPa). At the SS weld, hoop stress is tensile near the OD (330 MPa) and compressive near the ID (−210 MPa), and axial stress is tensile at the OD (220 MPa) and compressive near midthickness (−225 MPa) and ID (−30 MPa). The measured stresses are found to be consistent with earlier work in similar configurations.

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References

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Figures

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Fig. 1

(a) Dimensions of the nozzle mockup (dashed lines indicate axial sectioning cuts and plane of interest is between the dashed lines) and (b) photo of its original configuration before sectioning. Dimensions are in millimeters.

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Fig. 2

(a) Materials and properties and (b) slitting measurement locations (each line is a single slitting measurement)

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Fig. 3

Experimental step diagram. The initial configuration (A) is sectioned to the B configuration and the stress release σi is found with the strain measurements and a FE calculation. Configuration B is cut in half to configuration C and the stress release σii is found with the contour method. A slice (configuration D) is then removed from configuration C. The stress release σiii is not directly found, but could be found as σiii= σB(θ) − σii.

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Fig. 4

Diagram of cut planes. The opening cut is at 60 deg, the two sectioning cuts are at 240 deg and 345 deg, the contour cut is at 292.5 deg, and the slice cuts are at approximately 295 deg, 297.5 deg, and 300 deg.

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Fig. 5

Stress decomposition diagram; total stress is a sum of stress in a thin slice and the effect of hoop stress

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Fig. 6

DM weld hoop (left) and axial (right) stress: (a) release due to sectioning, (b) σB(θ) (same as contour for hoop stress), (c) slice stress, (d) total residual stress, and (e) FE weld model output from Ref. [27]

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Fig. 7

Line plot showing contributions to axial stress at the weld center for (a) DM weld and (b) SS weld along the radial direction from ID to OD

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Fig. 8

SS weld hoop (left) and axial (right) stress: (a) release due to sectioning, (b) σB(θ) (same as contour for hoop stress), (c) slice stress, (d) total residual stress, and (e) FE weld model output from Ref. [27]

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Fig. 9

Axial stress uncertainty (95% confidence interval) contour plots for (a) DM weld and (b) SS weld

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Fig. 10

Stress versus through-wall position at the center of the DM weld, comparing measurement results with FE model outputs: (a) hoop and (b) axial stress

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Fig. 11

(a) Axial stress results from slitting from slices 1, 3 and (b) combined uncertainty from the root sum square of the two uncertainty estimates calculated in slitting data analysis and half the range of the two measured stresses

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