Papers by Author: Kamran M. Nikbin

Abstract: In a study to investigate the effect of residual stress relaxation on Creep Crack Growth (CCG) a novel fracture mechanics specimen has been designed. Compact Tension, C(T), specimens are fabricated from blocks with Electron Beam (EB) welds such that residual stresses induced during welding are retained in the specimen. Finite element analyses of EB welding and machining processes have been developed to predict the stresses in such C(T) specimens which will drive crack growth in future CCG studies. The residual stresses and strains in these samples have been quantified using the neutron diffraction measurement technique at various stages of the fabrication process and have been used to validate numerical simulations of the fabrication processes.

Abstract: Life assessment of Type 316H stainless steel (SS) is of great concern to industry due to the widespread use of this material in power plant components that often operate at a temperature of around 550 °C. An important issue to be understood and considered in the life assessment of 316H components is the creep deformation and crack growth behaviour of this material in short term and long term operation times. Due to the limited long term test data available in the literature (i.e. [1, ), a new technique have been recently developed to estimate uniaxial creep ductility trends and subsequently creep crack growth (CCG) behaviour of the material at low load levels [. In this new method the creep ductility trends have been estimated as a function of the applied stress normalised by the temperature dependent 0.2% proof stress of the material, σ/σ_0.2, to include the plasticity effects on the creep deformation behaviour of the material. These trends have been implemented in finite (FE) simulations to predict the CCG behaviour of 316H in intermediate and long term tests at 550 °C and provisional results are presented in [.

Abstract: Neutron diffractometer Engin-X at ISIS was used use in this study to investigate the residual stresses in a section of a multi-pass girth welded thick pipe, of nominal thickness 62 mm, which was made of a ferritic-martensitic steel denoted type P92. Measurements in such large component sections are rare, and have driven the neutron diffraction method to the edge of its capabilities. Significant stresses of over 150 MPa have been found in this pipe section, though post weld heat treatment has been performed. The influences of these welding residual stresses in components at operating temperatures are discussed in terms of their relaxation and high temperature fracture behaviour.

Abstract: This paper considers the prediction of the effects of tensile and compressive residual stress in fracture mechanics specimens by the application of a mechanical pre-load. This is considered in the context of a ‘C’ shape specimen which is mechanically pre-tensioned or pre-compressed to produce, respectively, a compressive or tensile residual stress in the region where the crack is introduced. Finite-element analysis is performed to simulate the pre-loading and the subsequent fracture loading of the cracked specimens. The finite-element predictions are compared with experimental data including residual stress measurements using neutron diffraction. A discussion is presented on modelling and material issues pertaining to the use of mechanical pre-loading as a means for introducing residual stress.

Abstract: Advanced steels are designed and produced to be used in engineering applications in which thermo-mechanical fatigue could be a main factor in causing failure in components operating at elevated temperatures. In this paper thermo-mechanical fatigue properties of these steels are studied under the influence of creep and fatigue damage evolution. Development of different models and simulation techniques are reviewed to predict material behaviour. Numerical simulations are carried out to predict experimental tests on parent material notched bar specimens. Numerical predictions are introduced in advance of experimental test to assess the experimental test procedure. This is usually done to enhance the experimental result integrity and expectations. A local ductile damage development methodology is employed using the kinematic hardening criterion and compared to previously used strain hardening material property. The modelling on notched bar geometries is extended to geometries with cracks in which a local damage criterion will be used to predict virtual crack extension in compact tension specimens.

Abstract: Modelling of Creep Crack Growth (CCG) using analytical and numerical methods is relevant to life assessment procedures of components operating at elevated temperatures. This paper compares an analytical crack prediction and a numerical based virtual CCG technique used in fracture mechanics components with sample experimental results. Two approaches are presented. First the well developed strain exhaustion model called the NSW and the modified NSW-MOD models which predict plane stress/strain bound crack initiation and growth rates for engineering alloys and the second a damage-based approach used to numerically predict the crack propagation rate in Finite Element models of fracture mechanics specimens. The results from both methods are correlated against an independently determined C* parameter. As an example the NSW and the extended NSW-MOD strain exhaustion models are applied to compare to the experimental data and FE predictions for two steels at Carbon-Manganese steel tested at 360 oC and a weld 316H stainless steel at 550 oC. For values of C* within the limits of the present creep crack growth data presented the plane strain crack growth rate predicted from the numerical analysis is found to be less conservative than the plane strain NSW model but more conservative than plane strain NSW-MOD model.

Abstract: This paper considers the measurement of residual stresses induced by mechanical loading in a weld Type 347 stainless steel. The work is based in part on an ongoing Round Robin collaborative effort by the Versailles Agreement on Materials and Standards, Technical Working Area 31, (VAMAS TWA 31) working on ‘Crack Growth of Components Containing Residual Stresses’. The specific objective of the work at Imperial College London and HMI, Berlin is to examine how residual stresses and prior straining and subsequent relaxation at high temperature contribute to creep crack initiation and growth for steels relevant to power plant applications. Tensile residual stresses have been introduced in the weld by pre-compression and neutron diffraction measurements have been carried out before and after stress relaxation at 650 oC. Significant relaxation of the residual stresses has been observed, in agreement with earlier work on a stainless steel. Preliminary results suggest that the strains local to the crack drop by over 60% after 1000 h relaxation at 650 oC for the weld steel. The results have been compared with finite element studies of elastic-plastic pre-compression and stress relaxation due to creep.