Non-idealized Through-wall Cracks Research Articles

Surface to Through-Wall Crack Transition Model for Circumferential Cracks in Pipes

Abstract In this paper, finite element (FE) analyses were performed to update and also extend the applicable ranges of the existing KI and crack-opening displacement (COD) solutions for nonidealized through-wall cracks (TWCs). Then, a surface to TWC transition model was proposed based on these solutions. The proposed model provides a criterion which determines when the final surface crack (SC) should transition to a TWC. It also provides a criterion to determine the two crack lengths (at the inner diameter (ID) and outer diameter (OD) surfaces) of the initial nonidealized TWC. Furthermore, crack growth of nonidealized TWCs can be simulated by using the proposed method. Finally, the proposed model was verified by demonstrating that it can well predict the surface to through-wall transition behavior when compared to the natural crack growth simulations.

On elastic-plastic and creep fracture mechanics parameters estimates of non-idealized axial through-wall crack in pressurized pipe

The present paper provides engineering estimates for plastic J-integral and crack opening displacement (COD) of a non-idealized axial through-wall crack (TWC) in pipes based on detailed 3-dimensional finite element (FE) analyses. The behaviors of plastic J-integral and COD of a non-idealized axial TWC in typical pressurized pipes in nuclear power plants were systematically investigated. The FE model and analysis procedure employed in this study were verified by comparing the present FE results with the limited existing solutions for pipes with an idealized axial TWC. Based on the FE results, the new plastic influence functions, h1 and h2, which include the effect of a non-idealized TWC on plastic J-integral and COD, are provided as tabular solutions. By employing the plastic influence functions, plastic J-integral and COD of a non-idealized axial TWC along crack front can be directly predicted based on GE/EPRI method. In the present paper, plastic J-integral and COD estimates based on the reference stress concept have also been suggested. Finally, the estimated results were compared with elastic-plastic FE results by using actual stress-strain data and Ramberg-Osgood constants for TP 316 stainless steel. In addition, the engineering estimates proposed in this study were extended to estimating the creep fracture mechanics parameters at elevated temperature. Based on Norton and RCC-MRx creep models, C*-integral and creep COD rate values predicted from the present engineering solutions were validated by comparing with creep FE results. The results provided in this paper demonstrate that the present estimates can be applied to calculating plastic J-integral and COD, C*-integral, and creep COD rate of a non-idealized axial TWC.

Nonidealized Surface to Through-Wall Crack Transition Model for Axial Cracks in Cylinders

Recent studies have shown that a subcritical surface crack, due to primary water stress corrosion cracking (PWSCC), can transition to a through-wall crack (TWC) with significant differences between the inner diameter (ID) and outer diameter (OD) crack lengths. This behavior has been observed for both circumferential and axial cracks. Recently, a surface to TWC transition model has been developed for circumferential cracks using existing K and COD (crack opening displacement) solutions for nonidealized circumferential TWCs. In this paper, a similar crack transition model (CTM) was developed for axial cracks. As a first step, a study was conducted to define the appropriate crack front shape for nonidealized axial TWCs. Then, elastic finite element analyses were carried out to develop K and COD solutions using these crack front shapes. The newly developed solutions were utilized for the CTM. The present CTM includes a criterion for transitioning the final surface crack to the initial nonidealized TWC. This criterion determines when the transition should occur (based on surface crack depth) and determines the two crack lengths (at ID and OD surfaces) of the initial nonidealized TWC. Furthermore, nonidealized TWC growth calculation can be conducted using the proposed model. Example results (crack length and COD) obtained from the proposed model were compared to those obtained from the natural crack growth simulations. Results presented in this paper demonstrated the applicability of the proposed model for simulating axial crack transition.

Engineering estimates of crack opening displacement for non-idealized circumferential through-wall cracks in pipe

The present paper provides the engineering estimates of non-linear crack opening displacement (COD) for a circumferential non-idealized through-wall crack in a pipe based on both the GE/EPRI and the enhanced reference stress methods. For the GE/EPRI-type solution, the h2 values are newly calibrated based on the elastic–plastic finite element analyses. Also, elastic COD and the reference load solutions are proposed. Then, the proposed engineering estimates are validated against the FE results using actual tensile data of SA312 Type 316 stainless steel. From these comparisons, it is revealed that the enhanced reference stress method provides the best and overall satisfactory results.

Korean Consortium's preliminary research for enhancing a probabilistic fracture mechanics code, PRO-LOCA

The Battelle developed a probabilistic fracture mechanics code called PRO-LOCA, which can be used as a tool for evaluating the pipe break frequency. It is being further developed through the international co-operative research program, PARTRIDGE. KINS, KHNP-CRI, and KEPCO-E&C are participating in the PARTIRDGE program by composing a Korean Consortium. The members of Korean Consortium performed benchmark analyses using the beta version of PRO-LOCA 4.0 to evaluate the effect of variables such as simulation methods, crack features, loading conditions, and inspection models on the failure probabilities. The benchmark analyses showed that the PRO-LOCA can provide a trend consistent with the expected crack growth and pipe failure behavior. Especially, the availability of the stress intensity factor and crack opening displacement for non-idealized through-wall cracks was proven from this study. This new solution for non-idealized through-wall cracks had been developed by the Korean Consortium and it was newly included in PRO-LOCA 4.0. However, further improvement is needed to address the problems such as the instability of adaptive sampling method and the unexpected trend of failure probabilities at the early stage of crack growth.

Finite element limit loads for non-idealized through-wall cracks in thick-walled pipe

The present paper provides plastic limit loads for non-idealized through-wall cracks in thick-walled pipe. These solutions are based on detailed 3-dimensional finite element (FE) analyses which can be used for structural integrity assessment of nuclear piping. To cover a practical range of interest, the geometric variables and loading conditions affecting the plastic limit loads of thick-walled pipe with non-idealized through-wall cracks were systematically varied. In terms of crack orientation, both circumferential and axial through-wall cracks were considered. As for loading conditions, axial tension, global bending, and internal pressure were considered for circumferential cracks, whereas only internal pressure was considered for axial cracks. Furthermore, the values of geometric factor representing shape characteristics of non-idealized through-wall cracks were also systematically varied. In order to provide confidence in the present FE analyses results, plastic limit loads of un-cracked, thick-walled pipe resulting from the present FE analyses were compared with the theoretical solutions. Finally, correction factors to the idealized through-wall crack solutions were developed to determine the plastic limit loads of non-idealized through-wall cracks in thick-walled pipe.