Measurement of Residual Stress in a Welded Branch Connection and Effects on Fracture Behaviour

Abstract

The branch analysed in this paper was not post weld heat treated, resulting in significant residual stresses. Assessment codes assume these to be at, or close to, yield. An integrity assessment of a welded branch connection was carried out using these high assumed residual stresses.The weld then had residual stresses determined by neutron diffraction, performed using ANSTO's residual stress diffractometer, Kowari. The maximum measured residual stress (290 MPa or 60% of yield) was much lower than the yield value assumed by assessment codes. Reanalysing with the actual residual stresses almost doubled the critical crack size, increasing the safety of the connection.