Key Engineering Materials Vol. 795

Abstract: Neutron diffraction and finite element method were combined to analyze the through-thickness residual stresses in the thick weld plate considering back chipping. Large residual stresses were generated near the surface. Furthermore, the effect of back chipping width, the heat input of the back weld after back chipping, interpass temperature and plate thickness on the residual stresses were conducted by finite element method. The results showed that larger back chipping width could be helpful to decrease the risk of stress corrosion crack. With the decrease of heat input, the stress variation becomes more obvious. The interpass temperature has an obvious effect on the longitudinal residual stresses but little effect on the transverse residual stresses. Nevertheless, the plate thickness has little influence on the residual stress distribution law. Based on the finite element method results, a formula focused on the 10-40 mm thick plates was fitted to calculate residual stresses with the change of depth through thickness, which was verified by neutron diffraction measurement.

Abstract: The burst strength is the key parameter to the design of glass-fibre reinforced composite (GFRC) pipes with good performance and security. In this paper, the burst strength and the optimized winding angle of the GFRC pipes are derived by the theoretical analysis, experiment and simulation considering the progressive damage. The effects of the winding angle on the burst strength and failure modes are fully discussed. The results show that, the burst strengths obtained by the proposed theoretical formulas and simulation agree well with the experiment results. There is a critical winding angle for the GFRC pipes demarcating the burst modes of axial burst or circular burst. With the increase of the diameter, the critical winding angle decreases, but never less than 55^° . With the increase of the winding angle, the burst strength firstly increases, and then decreases. The winding angle of the GFRC pipes should be optimized between 55^° and 60^° to derive the best burst strength.

Abstract: One conventional domed slotted rupture disc, which was fabricated with Inconel 600 alloy, was used in reaction kettle. It was burst after only 2000 times of operational circles. The burst causes were investigated. Morphologies of the fracture were observed by scanning electron microscope and the relatively chemical compositions were analyzed by energy dispersive spectrometer. Meanwhile, metallographic microstructures were also observed and analyzed for the material of the failure of the rupture disc. The results show that the bursting of the rupture disc was caused by fatigue fracture.

Abstract: Reinforced s-shaped bellows, which can withstand high pressure, is a kind of typical reinforced metal bellows. The reinforced s-shaped bellows mainly uses the hydroforming process, and the forming process is a severe plastic deformation process. The hydroforming process and its effects on the fatigue life of reinforced s-shaped bellows were discussed in the present study. Different levels of plastic strain and wall thickness thinning were detected in the hydroforming process. The maximum plastic strain can reached 32%, while the maximum wall thickness thinning ratio is 20%, which occurs on the wave peak. Mechanical characteristics of reinforced s-shaped bellows were discussed considering the effects of hydroforming process. The maximum stress appears on the upper and lower ends, which is the weak part of the structure. Fatigue life of the reinforced s-shaped bellows was analyzed based on the modified Manson-Coffin method. Mechanical properties of related materials, which can be more accurate consideration the effects of hydroforming process, were tested under the pre-plastic deformation. Fatigue life analysis of reinforced s-shaped bellows was carried out and the effects of hydroforming process were discussed. The hydroforming process will lead to a decline in fatigue life, which needs to be considered well in the structural design and analysis. Keywords: Reinforced s-shaped bellows, Hydroforming process, Fatigue life, Mechanical characteristics.

Abstract: The durability airworthiness verification of turbine blade is one key issue in the process of certifying a type certificate for the aircraft engine. This paper summarizes the limiting factors for turbine blade durability and proposes a compliance method to evaluate the durability life of turbine blade. The typical standards of blade durability were selected and evolution history of the regulations was traced. The regulation contents and differences between CCAR-33 and CS-E were analyzed. A series of compliance methods in airworthiness verification process were discussed in detail. Furthermore, an experimental compliance methodology was proposed to estimate the durability life of turbine blade, considering the damage of creep and fatigue. The novel methodology was verified using the scanning electron microscope (SEM) analysis. These efforts are of great benefit to support the process of obtaining the final type certificate.

Abstract: The creep rupture behavior of weld joint of modified 9Cr-1Mo martensitic heat-resistant steel is investigated by conducting creep tests. The creep strain-time curves of 838K under different stress levels are obtained. The effects of different stress conditions on the creep rupture lifetime are analyzed. Based on the creep test data, the relationship between minimum creep rate and stress, creep rupture time is analyzed. The test results show that the creep rupture occurred in the fine-grained heat-affected zone. The microstructure evolution during creep process is studied by metallographic analysis and fracture analysis.

Abstract: A large number of inclusion defects were found during the metal supervision process of 15Cr1Mo1V steel main steam pipeline of the Russian-made thermal power unit. In this paper, the tracking supervision research of 15Cr1Mo1V steel pipe elbow with inclusion defects is carried out. The variation law of strength, toughness, metallographic structure and creep rupture strength with inclusion defects at different operating time is studied. Type and composition of inclusions are analysed and creep fatigue crack evaluation of the most serious inclusion defects discovered is performed. The results show that with the increase of service time, the room temperature and high temperature strength of the material gradually decreased, the impact toughness deteriorated, the ductile-brittle transition temperature increased and greater than room temperature, the metallurgical organization aging grade rose from 3 to 4, creep rupture strength decreased, creep aging was increasingly serious, and creep residual life reduced. The main inclusions are plastic MnS、SiO₂ and severe inclusion levels up to 3. Longitudinal inclusions are mostly long-chain features, and the ends are sharp but no sharp cracks are found at the sharp ends; the transverse inclusions are granular. Creep fatigue crack evaluation show that there was no obvious growth of material inclusion defects with the increase of service time, it is necessary to strengthen the supervision and inspection of brittle inclusions in the follow-up operation.

Abstract: The research work in this paper is focused on studying the failure behavior of an integral π-shaped laminated composite structure subjected to a bending load. A progressive damage model based on the 3D Tsai-Wu failure criterion and a developed gradual degradation model was employed to simulate and assess the load-carrying capacity, the onset and propagation of damage, and the failure mechanisms. For this unique π-shaped composite structure, disbonding was found to be the dominant damage mode under bending load, and the approximate maximum load could be maintained for a brief time during the final failure due to the gradual loss nature of the load-carrying capacity. The extent of damage was found to be more serious on the side of Rib II compared to the other side.

Abstract: When the reactor pressure vessel (RPV) is subjected to pressurized thermal shock (PTS), the cooling water injected by the emergency core cooling system (ECCS) will generate a large temperature difference in the wall thickness of the pressure vessel. On the other hand, the fracture toughness of the RPV material decreases a lot under long-term neutron irradiation. Under this condition, the PTS transient may cause a rapid growth of defects in the inner surface of the vessel, resulting in failure of the pressure vessel. In this paper, the fracture mechanics analysis method of RPV under pressurized thermal shock is studied. The thermal analysis and structural analysis of the pressure vessel are performed by finite element method. The stress intensity factor and fracture toughness are obtained through calculation. At the same time, the influence factors of fracture mechanics analysis of RPV under PTS condition are analyzed. The effects of different crack size, crack type, load transient, and neutron irradiation flux on the PTS fracture mechanics analysis results are evaluated. Results show that the larger the ratio of length to depth for axial inner surface cracks, the easier RPV crack grows. Under small break condition, the circumferential cracks are safer than axial cracks. The longer the operating time, the more severe the embrittlement of RPV materials, which will lead to the failure of RPV more easily. For the two typical PTS transients studied in this paper, the re-pressurization condition is safer than the small break condition. The results can provide basis for structural integrity assessment of RPV under PTS condition.

Abstract: Failure analysis of the hot clamped outlet pigtail tubes connected with hydrogen reformer tube in refineries has been carried out. In this paper, hot clamp induced cracking on Incoloy 800HT outlet pigtail tube of a reformer unit is studied by microscopic observation and mechanical properties testing. Metallurgical evaluation and chemical composition analysis have been performed on both hot clamped cracking tube and no cracking one. Results indicated that the most important parameter affecting the high temperature brittleness of pigtails are the Ni/Cr value, surface grain size and impurity atoms grain boundary segregation.