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Fracture Analysis and Corrosion Fatigue (1 of 4) 01-70
Fracture Analysis and Corrosion Fatigue (1 of 4) 01-70
September 1983
ANNUAL REPORT
Prepared for
U.S. Department o f Transportation
September 1983
ANNUAL REPORT
Prepared f o r
U.S. Department of Transportation
1. Report N o .
Governmcnt Acccssion N O .
3.
Recipient's Catolog
NO.
5. Roport Dote
September 1983
6 . Performing Organization Code
7-
Author's)
DTRS 56 82-C-00014
13.
12.--
and Address
Department of Transportation
Research and Special Programs Administration
Office o f University Research
Washington, D.C.
U.S.
15.
Annual ReDort
October 1982-September 198:
14:Sponsoring
Agency Code
Supplemontary Not..
16. Abstract
In this report the completed p a r t of the research project on the fracture analysis
and corrosion f a t i g u e i n pipelines i s presented. The report consists o f two parts.
The f i r s t p a r t describes the theoretical work on the flaw evaluation as i t relates t o
weld defects in pipelines. The experimental work on the corrosion fatigue i n pipeline steels i s discussed i n the second part. The fracture mechanics methodology i s
used throughout the investigation. First, the possible weld defects have been reviewed and classified from a viewpoint of their importance in a fracture initiation
and propagation process. Then a group of flaw-flaw and flaw-free surface interaction
problems have been identified and investigated. Three groups of defects which are
identified are pores and solid inclusions with smooth boundaries, pores, notches, and
solid inclusions w i t h sharp corners, and cracks and planar inclusions. The results
for the following interaction problems have been presented: the interaction between
a crack and a solid inclusion o r a pore, between cracks and boundaries, between
multiple cracks, between f l a t inclusions and cracks, and planar cracks of f i n i t e size.
In the second p a r t of the report a f t e r briefly discussing the mechanisms of corrosion
fatigue, the electrochemical measurement techniques for determining the kinetics of
passivation o r surface reaction of clean surfaces are described. The completed p a r t
of the studies on the kinetics of corrosion fatigue crack propagation i n X70 linepipe
IU n L ,
Fracture Mechanics, P i pel i nes , 18. Distribution Statement This document i s available
F1 aw Interaction , We1 d Defects , Cracks , In t o the U.S. public t h r o u g h the National
clusions, Fatigue Crack Propagation, Cor- Technical Information Service , Springfield ,
rosion Fatigue, Chemical Reactions, EnVirginia
22161
vironmental Effects
Key
Unclassified
Unclassified
21.
No. of P a g e r
22.
Price
TABLE OF CONTENTS
Page
SCOPE OF THE PROJECT
GENERAL IN FORMATI ON
PART I
TYPES OF FLAWS
2.1 Pores and S o l i d Inclusions
2 . 2 Pores, Notches and Solid Inclusions with
Sharp Corners
2.3 Cracks and F l a t Inclusions
4
4
6
10
10
37
45
45
45
52
64
70
73
75
PART I 1
MECHANISMS OF CORROSION FATIGUE IN PIPELINES
77
INTRODUCTION
77
2.
78
3.
PROGRESS TO DATE
3.1 Electrochemical Measurement Techniques
3 . 2 Fatigue Crack Growth
79
80
81
iii
Table o f Contents
cont.
Page
4.
PLANNED RESEARCH
82
5.
83
APPENDIX A
Introduction
I n t e g r a l Equations o f the Problem
Stress Singularities
Crack-Inclusion I n t e r s e c t i o n
The Results
References
1
1
1
8
11
25
APPENDIX B
Introduction
On the Formulation o f the Problem
The Results for a Single Crack
References
iv
1
1
4
14
vi
PART I
THE FLAW INTERACTION STUDIES
In this part of the report various kinds of flaws which may be
found in pipelines, particularly i n g i r t h welds are classified and the
problem of interaction between the s t r e s s fields o f typical flaws are
considered. The emphasis i n the study i s on the application of fracture
mechanics techniques t o the problem o f flaw evaluation.
1.
INTRODUCTION
and gross bending in offshore piping due t o buoyancy and other hydroe l a s t i c effects. I t should be added that the "stress transients" may
also play a major role i n the subcritical crack propagation and particularly i n the final phase of the fracture process, i f one takes place.
These stresses are generally caused by the pressure waves resulting from
changes in flow rate due t o partial ly o r ful ly closing of the valves.
In the case of pipes carrying liquids such as petroleum pipelines t h i s
i s known as the "water hammer" effect due t o which the peak pressure
may be as h i g h as multiples of the then operating pressure in the pipe.
In the natural gas pipelines, this increase i n the peak pressure may
be somewhat more moderate. Nevertheless, in either case, such sudden
surges o f pressure are probably responsible i n most cases for the final
stage of the net ligament failure in the pipe wall resulting in leaks o r
i n a catastrophic fai 1 ure.
A detailed description and classification of weld discontinuities
(including "flaws" which are considered t o be undesirable) a n d a c r i t i c a l
review of the l i t e r a t u r e as we71 as very extensive references on the subj e c t up t o 1976 may be found in [I].
The problem o f interaction between
two (planar) cracks and some empirical rules t o define a single equivalent crack are discussed i n 121. The procedures dealing w i t h the subc r i t i c a l crack propagation by u s i n g the tools of linear e l a s t i c fracture
mechanics (LEFM) i s highly standardized and may be found, for example,
in [3] o r [4]. Similarly, the process of b r i t t l e or quasi-brittle fracture is relatively well-understood and i s easily dealt with techniques
based on LEFM and the concept of fracture toughness. The process which
i s not well-understood and not standardized, however, i s the ductile
fracture. The Appendix i n the API Standard 1104 concerning the fracture
mechanics applications i s based on the c r i t i c a l crack t i p opening displacement concept, whereas the J-integral seems t o be more widely used
i n pressure vessel technology. The description, some applications of
and extensive references on the crack opening displacement approach t o
fracture may be found i n [5]-[7].
Application o f a general fracture
instability concept based on the crack opening displacement t o shells and
plates w i t h a part-through crack i s described in [8].
-3-
TYPES OF FLAWS
'max
K = -A,
'ij
k
-- -r~
-6-
-0.2 I
0
x /R
Figure 2 . T h e s t r e s s d i s t r i b u t i o n i n a p l a t e with a c i r c u l a r
e l a s t i c i n c l u s i o n ( p 2 = 23p, , K~ = 1 . 6 , K~ = 1 . 8 ) .
- 7-
where k and x are constants representing the strength and the power of
the stress singularity and r i s a (small) distance from the notch t i p .
Generally, E q . ( 2 ) is valid for values o f the material angle e > IT
( F i g . 1 bl , b2, b3). Even t h o u g h the term ''stress intensity factor'' i s
commonly used i n relation w i t h crack problems for which A = 0.5, i n
the more general problem leading t o an expression such as ( 2 ) k i s also
called the "stress intensity factor".
In the case of notches w i t h a material angle IT < e < 2n the power
of singularity A i s dependent on e only and may be obtained from (see,
for example, [9] where the general problem o f bimaterial wedge under
variety of boundary conditions are discussed)
cos[2(~-1)e] - 1 + (X-1)2(1-cos2e) =
o .
(3)
-8-
3w4
WEDGE ANGLE
Fig. 3
-9-
2lT
3.
where the kernels k i j are known functions and have a Cauchy type singul a r i t y . The known i n p u t functions p1 and p2 are given by
-1 0-
G e o m e t r y s h o w i n g t h e d i s l o c a t i o n s b, a n d b y , a n d t h e
Figure 4 .
crack L i n t h e neighborhood o f t h e i n c l u s i o n 2.
-11-
g j ( t ) = Gj(t)/J(t-t2)(tl-t), ( j = l , 2 )
(7)
where G1 and G p are unknown bounded functions. After solving the integral equations the Modes I and I1 stress intensity factors a t the crack
tips tl and t2 may be defined by and obtained from the following expressi ons :
k 2 ( t l ) = lim
owt(t,c) =
t-tt 1
k 1 ( t 2 ) = lim
t+t2
k 2 ( t 2 ) = lim
t+t2
-"1
lim +Q
g l (V
t) ,
lCKl t+tl
fi(t2-t)
aw(t,c) = "1
lim -4
l f K 1 t t2
h(t,-t)
awt(t,c) =
g2(t) ,
(8a-d)
In the absence of a crack the stress components on a line perpendicul a r t o the loading direction are shown i n Fig. 2 for an e l a s t i c inclusion.
Similar results for a circular hole ( i . e . , for p2=0) are shown in Fig. 5.
The stress intensity factors calculated a t the crack tips t l and t2
are shown in Figures 6-13. The results shown i n the figures are normalized with respect t o u o 6 where a. i s the tensile stress acting on the
plane away from and perpendicular t o the crack and a i s the half crack
length. Thus, the normalized stress intensity factors k i j shown i n the
-1 2-
C /R
ro
\\L1.5
I
0.8
I
X/R
Figure 5 .
hole.
The s t r e s s d i s t r i b u t i o n i n a p l a t e with a c i r c u l a r
-1 3-
2.0
I .o
-1
I
f
I .o
0.5
-0.2
2
IO
c/o
Fig ure 7. T h e stress intensity f a c t o r s f o r a symmetrically
located " tangential crack" perpendicular to t h e l o a d ( b = 0,
R = 2a).
-15-
2
"0
-----
-0.5
0
k2,
0 - - - - -
-----
c/a
Figure 8 . Stress i n t e n s i t y f a c t o r s f o r a c r a c k perpendicular
t o the e x t e r n a l load ( R = 2 a , b = 3 a ) .
-16-
2.5
2.0
I .5
I .o
0.5
-0.5
-2.4
//
o 1
0
R /a
Figure11. S t r e s s i n t e n s i t y f a c t o r s f o r a crack in the matrix
containing a n e l a s t i c i n c l u s i o n ( p 2 = 23p1, c = R, b- a = 0 . 2 R ,
a=constant).
-19-
I .o
0.5
b/a
Figure 1 2 . S t r e s s i n t e n s i t y f a c t o r s for a crack in the matrix
containing a c i r c u l a r hole (v2 = 0 , c = 2 . 2 a , R = 2 a ) .
-20-
0.2
1-0.2
6
b /a
Figure 13. S t r e s s i n t e n s i t y f a c t o r s f o r a crack in the matrix
c o n t a i n i n g an e l a s t i c i n c l u s i o n ( p 2 = 2 3 v 1 , c = 2 . 2 a , R = 2 a ) .
-21 -
JL!Go 6
( i , j = 1,2)
(9)
where k i ( t . ) are given i n ( 8 ) . Figures show the results for only two
3
cases, namely a circular hole ( i . e . , p2=0) and a s t i f f e r e l a s t i c inclusion w i t h e l a s t i c constants
(i,j=x,y)
(O<B<~)
(ii)
a (x-a)'olyy(x90)
X-ta
-23-
G
0
Figure 14.
Inclusion-crack geometry.
-24-
The f i r s t special problem ( i ) w i t h a2=b2 corresponds t o the limiting case of the problem considered in Fig, 6. In the problem of a crack
terminating a t the bimaterial interface such a s the cases ( i ) and ( i i )
mentioned above, the power of the stress singularity ( a o r 6 ) i s
highly dependent on the stiffness ratio p2/pl and i s relatively insensiand K ~ ) . For the crack geometry
tive t o the Poisson's r a t i o s ( o r
a2=b2, a l = a , b l > a , Fig. 14, Table 1 shows the effect o f p$p1 on 6 .
I t may be seen t h a t for ( p z / p l ) < 7 the power 6 i s greater than 0.5, meaning t h a t i f the stiffness o f the inclusion i s less t h a n t h a t o f the
matrix, then the stress singularity i s stronger than the corresponding
homogeneous case. Similarly, i f u2>pl then 6<0.5. This i s the reason
for the asymptotic trends observed in Fig. 6 for the stress intensity
factor k(a) as b 4 + a . Table 1 also gives the corresponding stress intens i t y factors calculated from (12).
For this problem, t o give some idea about the nature and the relative magnitude of the crack surface displacement, Fig. 15 shows some
calculated results. Here v(x,O) i s the crack surface displacement i n
y direction.
Figures 16 and 17 show the stress intensity factors for a crack
located i n the inclusion. The limiting values of the stress intensity
factors shown in these figures f o r the crack length 2c2 approaching zero
are obtained from uniformly loaded "infinite" plane solution w i t h the
applied stress s t a t e away from the crack region given by the uncracked
-25-
Table 1.
T h e e f f e c t o f m o d u l u s r a t i o on t h e
stress intensity factors for a crack
terminating a t the interface ( a l = a ,
b , / a = 2 , ~1 = 2 = 1 . 8 , C 1 = ( b l - a ) / 2 ) .
ko
f3
OoCl
0
2.808
0.05
0.81730
1.615
1.053
1/3
0.62049
1.229
0.5836
1.0
0.5
1 .ooo
1 .ooo
3.0
0.40074
0.8610
1.299
10.0
0.33277
0.7969
1.389
23.0
0.30959
0.7796
1.375
100
0.29387
0.7691
1.345
300
0.28883
0.7667
1.348
-26 -
!
1
v(x, 0 )
vo
0
1
1.5
x/ a
-27-
7.275
0.5
c2 /a
7.0
-28-
2.0
--
2.0
t!
tl
F i g u r e 17. S t r e s s i n t e n s i t y f a c t o r s f o r a c r a c k l o c a t e d
i n t h e i n c l u s i o n ( K ~= K * = 1 . 8 ,
one t i p f i x e d a t
a2 =-0.9a
or
a2 = -0.75a,
-29-
b2 v a r i a b l e ,
c2 = (b2-a2)/2).
a
Ol xy (X,O)
= 0
UZxy
(x,o) = 0
lirn
c24
k
a o q
Fig. 16 shows the results for a symmetrically located crack. The results
for an eccentric crack a r e shown i n Fig. 17 (see Fig. 14 for n o t a t i o n ) .
Some typical results for the case i n which b o t h the inclusion and
the matrix o r base material contain a crack are shown i n Fig. 18.
The stress intensity factor for a completely cracked inclusion
( i . e . , for a2=-a, b2=a, a l = b , ) i s given in Table 2. The stress intens i t y factor k(a) given i n this table i s defined by (13) where 01 i s the
power of stress singularity.
The stress intensity factors for a crack crossing the interface are
given by figures 19 and 20. I n these figures x=a2 and x=b, are conventional crack t i p s f o r which the stress s t a t e has square-root singularity
( i . e . , a'=~'=0.5). For the p o i n t of the intersection of the crack w i t h
the boundary (x=a) the normal and shear cleavage components of the stress
intensity factor kxx and k are defined by (14) and (15). The asymptotic
XY
trends of the stress intensity factors observed in these figures as a
crack t i p approaches the boundary x=a'are again due t o the change i n the
-30-
Table 2 .
=1.8
c1
Stress int-ensity f a c t o r f o r
a completely cracked inclusion.
ko
c1
~ .8 K,1 = l . 8 , ~ L, = 2 .2
k(a)
a
aOa
c1
K1 - K 2 = 2 . 2
k(a)
c1
k(a)
a
GOa
0.33845 1.010
0 . 6 3.45025 1 . 0 1 4
0.44466 1.068
1 . o 3.5
0.5
2.0
1 .o
1.o
-31 -
+-
kof
(E)
yQ xx 2
or
and
- /
/
/
r
1.5
2.o
d/.
2.5
- 34-
4
\
0.5
1.0
d/a
1.5
0.3
0.2
05
1.0
a/c
1.5
e
Fig. 22, Angular variation of ue8 around a crack t i p touching t h e
interface.
-38-
-39-
k ( - a ) p o 6 = k3(-a) = lim d
x+-a
m olyz(x,c)
(29)
Figure 27 shows the results f o r the radial crack in a medium containing an inclusion o r a hole. Similar results for an arbitrarily
located crack are shown i n Figures 28 and 29. Figure 30 gives some comparative results showing the influence o f the crack length-to-radius
ratio on the stress intensity factors where m i s the modulus r a t i o
m = u2/p1 and k ( i a ) = k3(7a)/pon. For m = 1 we have a homogeneous
plane w i t h a crack o f length 2a for which k3(ia) = p o 6 . Consequently
giving the s t r a i g h t line shown i n the figure. For m=O, m=l and m=23.3
the slopes o f k ( i a ) vs.
curves as ( a / R ) 4 are 1.47, 1 and 0.57,
respectively. The results for m=O and rn>O are obtained from the solution
of an "infinite" plane w i t h a central crack subjected t o the crack surface tractions 0 (x,O) which are equal and opposite t o the corresponding
YZ
stresses given i n figures 25 and 26 a t x=b=1.5R.
The singular behavior of the stresses terminating a t and crossing
the boundary is discussed i n [16] and [17].
-40
@
0
x/R
T~~
i n a matrix w i t h a
ci rcul a r hole.
Y
2.0 t
I .o
0
0
x/ R
Fig. 26.
l.2pr&
I .o
/
I ,
0.6
1.0
1
-
b /R
-42-
I .4
I .2
I .o
0.8
0.6
/R
1.1
I .o
0.9
1
-I
b/a
-43-
2.0
1.0
0
0
0.4
0.8
I .2
1.6
fiR
-44-
4.
r4
r4
where r y $are the polar coordinates a t the crack t i p , the crack being
along 4 = IT. Note that as the distance 28 between the cracks decreases
kl also decreases and k2 becomes more significant. The angle e shown
in this table i s an (approximate) direction of a probable crack growth
which i s obtained from a simple assumption t h a t along this radial line
a t the crack t i p the cleavage stress u g e ( r , e ) i s maximum [12], where
r<cH-d. Here e>O indicates that the cracks would grow away from each
other.
4.2
The stress intensity factors and the angle o f probable crack growth
direction i n a plate containing two paral7e7 and equal surface cracks
under uniform tension o r pure bending are shown in Figures 32-35. In this
problem we have a = b , c=O and dcH. The figures also show the Mode I
-45 -
11:
8
n
X
>
a
y
b
-
Figure 3.
-46-
Table 3 .
0.05
0.5
1 .o
1.5
2.0
5.0
10.0
20.0
0.7797
0.8512
0.9052
0.9395
0.9953
1.0053
1.0060
-0.1175
-0.061 6
-0.0308
-0.01 63
-0.0001
-0.00001
0.0000
16.430
8.194
3.887
1.992
0.157
0.014
0.000
0.1
0.5
1 .o
1.5
2.0
5.0
10.0
20.0
0.7992
0.8749
0.9310
0.9660
7.0219
1.0247
1.0248
-0.1199
-0.0624
-0.0307
-0.0162
-0.0001
-0.00001
0.0000
16.363
8.076
3.774
7.920
0.106
0.003
0.000
0.5
1.o
1.5
2.0
5.0
10.0
0.8846
0.9749
1.0437
1.0839
1.1096
7.1097
-0.2570
-0.0656
-0.0330
-0.0155
-0.0001
0.0000
15.578
7.634
3.648
1.641
0.019
0.000
0.2
-47-
I.6
=0
00.4~
0
Figure 32.
0.2
0.4
B/H
0.6
0.8
II.o
-48-
io"
=O
!OO
8
0"
I
0.2
0.4
0.6
B/ H
Figure 33.
-49 -
I
0.8
1.0
1.6
40"
1.2
30"
1.056
0.8
20"
0.4
IO"
-0.4
I
0.2
I
0.4
I
0.6
0.8
I.o
B/ H
F i g u r e 34.
-50-
Figure 35.
-51 -
The stress intensity factor k ( d ) for the outer cracks approaches zero
as B -+ 4H (for which the moment i s zero).
4.3 Cracks Parallel t o the Boundary
The basic geometry for the plate containing a crack parallel t o
the boundary is shown by the insert i n Fig. 42. The problem considered
in this section also takes into account the material orthotropy. Thus,
the material constants shown i n Fig. 42 a r e related t o the e l a s t i c
constants of an orthotropic plate as follows:
-52-
I .6
I .36a
I .2
0.a
0.4
b = d = O.2H
- 0.40
0.2
0.4
0.6
0.8
I .o
BIH
._ _
Figure 26.
-53-
b = d = 0.5H
' 3
=0
H'
r-
' =o
-I
I
0.2
0.4
0.6
B/H
Figure 37.
-54-
I
0.8
b=d=0.2H
r
I
F i g u r e 38,
Stress i n t e n s i t y f a c t o r s i n an i n f i n i t e s t r i p c o n t a i n i n g
three edge cracks under bending, d=b=0.2H, a,=6M/H2.
-55-
2.0
b = d = 0.5H
I .5
I .498
nM
E
%
1.0
Lb_,
0.5
c
W
-0.5
B/H
Figure 39.
-56-
b=d
=0
I
1
-I
0.2
0.4
0.6
0.8
I .o
b/ H
Figure 40.
-57-
I .6
b = d =0.2H
-0.40
1
B/H
Figure 41.
S t r e s s i n t e n s i t y f a c t o r s i n an i n f i n i t e s t r i p containing
edge cracks and subjected t o three p o i n t bending, om 6M/H2 = 24P/H.
-58-
64 =
E11/E22
2G12
-sa
(34)
2E12
-- 1
G,2 12
* * e
-59-
14-
I
I
I
I
12-
Orthotropic
--- - I sotropic
I
I
K=
1.2895
8=1.1I75
=I
8 =I
K
0.5
HI/H
Figure 42. The effect of the crack location on the s t r e s s intensity factors for uniform surface pressure.
6
K
1 =
H = 0.75a,
-60-
Orthotropic
- - - - Isotropic
= 1.2895
8 = I . I 175
K = I
K
8=I
I .8
\
I .6
- \
I .2
-\
H
- = 0.75
klA
= -k18
\
\'
0.a
\ '
0.4
0
Figure 43. Same as figure 2 for uniform shear applied to the
crack surface.
-61-
4
__-
Figure44.
I
IO
H /a
= 1.
-62-
$"'
I
31
H /a
Figure 45. Same as f i g u r e 4 f o r uniform shear applied t o crack
surface
-63-
IO