Numerical analysis of the dissimilar welded joint used in

offshore equipment
D.N.L. Alves1, M.C. Rodrigues1, J.G. Almeida1
1
Universidade Federal da Paraiba, Department of Mechanical Engineering, João Pessoa,
Brazil
e-mail: celocr@ct.ufpb.br

Abstract: Experimental work presented significant deviations from the test crack in relation to
the fatigue pre - crack plane, towards the soft material present in dissimilar welded joints. This
work analyzes a dissimilar welded joint used in the union of flanges to pipes present in the
offshore oil production. The weld joint sample (SE (B)) shows a crack located 1 mm from the
AISI 8630M-INCONEL 625 interface, which causes high triaxiality in the material. The
deviation of the crack in dissimilar welded joints may be related to the stress and strain fields
generated in the crack tip vicinity. Numerical results show the behavior of the stress fields and
strain fields generated from the imposed loads. Critical stress zone were observed, evidenced
by numerical analysis. A preferential plastic flow was also observed, which the literature claims
to be a harbinger of the crack growth path. Numerical analysis presented significant accuracy
in relation to the plastic flow and the crack developed during the experimental tests performed.
Keywords: crack, stress fields, strain fields, numerical analysis, fracture mechanics.

Introduction
Studies carried out in recent years have sought to understand the response of materials to the
presence of cracks in dissimilar welded joints, but not sufficient to unmask the phenomenon of
the effects of a heterogeneous welded joint. [1] analyzed the effects of forces acting on a
dissimilar welded joint in local stresses in perfectly plastic materials, have identified factors
influencing local stresses. During an evaluation of the mechanical effect of the presence of
dissimilarity mechanics weld (DMW) on the stresses fields and crack driving forces, [2]
introduced such phenomena to the procedures used in determining fracture toughness (J Integral
and CTOD tests). Due mainly to the construction process, the welded joints present great
complexity mechanical and microstructural making them the main points susceptible to failures
in the component of the structure. Thus, the essential importance of an evaluation of structural
integrity in these joints in order to ensure safe operation.

Methodology and Computational Procedure

Analyse the behavior of a dissimilar welded joint through Finite Element Method using the
ANSYS 17, with fatigue crack located one millimeter from the Fusion Line towards the Base
Metal, and compare with the experimental results obtained by [3]. The case study was
characterized in a sample of a dissimilar welded joint in CTOD test. The sample consists of
three different materials: ASTM A-36 steel, Inconel 625 and AISI 8630M steel, Figure 1. Table
1 presents the stress values of each material.
 (a) (b)
Figure 1: (a) CTOD test; (b) Sample.

Table 1 – Stress values.

Materials Yield Stress [MPa] Rupture stress [MPa]
ASTM A-36 steel 250 400
Inconel 625 356.11 647.10
AISI 8630M steel 536.33 723.69

The numerical analysis was performed from the CAD model of the sample, where all the
physical and mathematical conditions of the CTOD test were addressed. The generated mesh
presented 39135 elements and 172919 nodes with hexahedral element SOLID186: 3D structural
solid with 20 nodes and freedom degree: UX, UY, UZ, Figure 2.

(a) (b)
Figure 2: (a) CAD model; (b) Mesh.

Results and Discussion

The Figure 3 presents the von Mises stresses distribution where can observe the criticality due
to presence of a crack in a solid (a) without cracking and (b) with cracking.

(a) (b)
Figure 3: The von Mises stresses; (a) without crack; (b) with crack.
The difference in geometry influences the behavior of the stress fields in the material, the
difference between the stress generated in the region tip crack, 553.2 MPa, and the stress in the
same region without crack, 41.08 MPa, which in this case was exceeded about thirteen times
its value, 543.6 MPa. The behavior of the von Mises stress is observed, where higher stresses
are generated in the 8630M steel (right) in the plane stress state due to the dissimilarity.

(a) (b)

Figure 4: (a) The von Mises Stress; (b) Equivalent plastic strain.

The high triaxiality region can be identified in the Figure 4(a). The crack tip region has stress
of 723.53 MPa, a value very close to the rupture stress of AISI 8630M steel, 723.69 MPa. This
triaxiality is punctual, that is, neighboring regions present stresses well below the material yield
stress, remaining in the elastic mode. From Figure 4(b) the crack deviation analysis was
performed in the plastic strain.

Figure 5: Crack deviation calculation.

A crack behavior was observed, Figure5, with a deviation for the material of lower mechanical
resistance ASTM A-36 steel, the crack propagation is preceded by a preferential flow of plastic
deformation as a way of cracking. By [3], the crack deviation for the softer material was 71° in
relation to the fatigue pre - crack plane.

Conclusions

The behavior of the deformation field may indicate the path of a crack already present in a
material during its growth. For the crack situation presented in a DWJ, it is evidenced the
preference of the plastic deformation flow, in the material direction of lower mechanical
resistance, that is, with lower yield stress, due to the constraints generated by the dissimilarities
in the specimens, which hinder the course of plastic deformation towards the most resistant
material.

Acknowledgments
Petroleum National Agency, PRH-54, Queiroz Galvão and Federal University of Paraiba
supported this work.

References

[1] Y.J. Kim, K.H. Schwalbe, Numerical Analyses of Strength Mis-match Effect on Local
Stresses for Ideally Plastic Materials. Engineering Fracture Mechanics, v. 71, p. 1197 – 1219,
(2004). ISSN 00137944.
[2] G. H. B. Donato, Efeitos de Heterogeneidades Mecânicas sobre Forças Motrizes de Trinca
em Juntas Soldadas: Determinação Experimental de Tenacidade e Extensão de Metodologias
de Avaliação de Criticidade de Defeitos. 2008. 248 p. Tese (Engenharia Naval e Oceânica) —
Escola Politécnica da Universidade de São Paulo.
[3] J.G. de Almeida, Análise da Influência do Hidrogênio na Tenacidade Quase Estática
de Junta Soldadas de Aço ARBL. 2014. 230 p. Tese (Engenharia Mecânica) — UFPB.

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