Research Papers: Materials and Fabrication

Application of Weibull Stress Criterion to Brittle Fracture Assessment of Heat-Affected Zone-Notched Welds With Residual Stress

[+] Author and Article Information
Yusuke Seko

Tokyo Gas Co., Ltd.,
Yokohama, Japan
e-mail: y.seko@tokyo-gas.co.jp

Yasuhito Imai

Tokyo Gas Co., Ltd.,
Yokohama, Japan
e-mail: yasu-imai@tokyo-gas.co.jp

Masaki Mitsuya

Tokyo Gas Co., Ltd.,
Tokyo, Japan
e-mail: mitsuya@tokyo-gas.co.jp

Noritake Oguchi

Tokyo Gas Co., Ltd.,
Tokyo, Japan
e-mail: yuri-o@tokyo-gas.co.jp

Fumiyoshi Minami

Osaka University,
Osaka, Japan
e-mail: minami@mapse.eng.osaka-u.ac.jp

Contributed by the Pressure Vessel and Piping Division of ASME for publication in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received April 8, 2015; final manuscript received September 15, 2015; published online October 15, 2015. Assoc. Editor: Haofeng Chen.

J. Pressure Vessel Technol 138(2), 021404 (Oct 15, 2015) (8 pages) Paper No: PVT-15-1058; doi: 10.1115/1.4031662 History: Received April 08, 2015; Revised September 15, 2015

A constraint loss correction procedure using the Weibull stress criterion is specified in ISO 27306. However, this standard is applicable only to structural steel components with defects, not to welded joints. Therefore, we propose a method for estimating the brittle fracture limit of a weld with a notch in the heat-affected zone (HAZ) and residual stress based on the Weibull stress criterion. Three-point bending (3PB) tests and wide-plate (WP) tension tests of HAZ-notched welds made of 780-MPa class high-strength steel were conducted at −40 °C. The minimum critical crack tip opening displacement (CTOD) of the WP specimen fracturing at the coarse-grained region of the HAZ (CGHAZ) was approximately four times that of the 3PB specimen. Then, the effects of specimen geometry, residual stress, crack-front shape, and HAZ microstructure classification on the Weibull stress were investigated by using a finite element analysis (FEA). The results of these analyses showed that the specimen geometry, the welding residual stress, and HAZ microstructure affect the Weibull stress of HAZ-notched welds as crack driving force. Based on above results, the CTOD–Weibull stress curves for 3PB and WP specimens fracturing at CGHAZ were calculated by using an FEA. It was confirmed that the brittle fracture limit of an HAZ-notched weld with residual stress could be predicted from the Weibull stress criterion because predicted critical CTOD of WP specimens obtained by Weibull stress included experimental critical CTOD of WP specimens.

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Fig. 1

Cross section of welded joint

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Fig. 2

Nominal stress–strain curves of base and weld metals

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Fig. 3

Distribution of transverse residual stress measured by released-strain method

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Fig. 4

Geometry of test specimens: (a) 3PB specimen and (b) WP specimen

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Fig. 5

Fracture surfaces of (a) 3PB specimen and (b) WP tension specimen

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Fig. 6

Critical CTOD of 3PB and WP specimens at brittle fracture initiation

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Fig. 7

Relationship between critical CTOD value and total CGHAZ size for HAZ-notched specimen

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Fig. 8

FE model of (a) 3PB and (b) WP specimens

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Fig. 9

Microstructure distribution for FEA

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Fig. 10

True stress–true plastic strain curves of materials used for FEA

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Fig. 11

Crack opening stress distribution at CTOD = 0.019, 0.043, and 0.085 mm

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Fig. 12

Effect of specimen geometry on the Weibull stress

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Fig. 13

Results of introducing residual stress: (a) welding plate model after generating welding residual stress and (b) distribution of transverse residual stress

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Fig. 14

Effect of residual stress on Weibull stress for 3PB and WP specimens

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Fig. 20

Relationship between CTOD and Weibull stress for 3PB and WP specimens fracturing at CGHAZ

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Fig. 19

Effects of microstructure distribution on Weibull stress for 3PB and WP specimens

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Fig. 18

Microstructure distribution B

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Fig. 17

Effects of crack-front shape on Weibull stress for 3PB specimens

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Fig. 16

Crack-front shape of each model

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Fig. 15

Effects of compressive residual stress generated by fatigue loading on Weibull stress for 3PB and WP specimens



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