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Proceedings of the ASME 2016 Pressure Vessels and Piping Conference

PVP2016
July 17-21, 2016, Vancouver, British Columbia, Canada

PVP2016-63917

EVALUATION OF FATIGUE CRACK GROWTH CURVES IN EXISTING CODES


AND A PROPOSED MODIFICATION BASED ON EXPERIMENTAL DATA OF
CR-NI-MO-V STEEL WELDED JOINTS

Yan-Nan Du, Ming-Liang Zhu, Fu-Zhen Xuan, and


Shan-Tung Tu
Key Laboratory of Pressure Systems and Safety, MOE,
School of Mechanical and Power Engineering,
East China University of Science and Technology,
Shanghai 200237,
China

to the safety and reliability of engineering components [4].


ABSTRACT There are currently several codes for fatigue assessment
A comparison of currently available codes for assessment around the world, such as the ASME SEC. XI [5], FKM
of fatigue crack growth, including ASME (America Society of guideline [6], BS 7910 [7], WES 2805 [8] and JSME [9].
Mechanical Engineers) SEC. XI, FKM (Forchungskuratorium Each code provides the upper and lower bounds of FCG
Maschinenbau) guideline, WES (Japan Welding Engineering curves that are inclusive to many influencing factors, i.e.,
Society) 2805, BS7910 and JSME (The Japan Society of material strength level, residual stress, R and environment.
Mechanical Engineers), was carried out by paying attention to Hojo et al. [10] reported the differences among the assessment
the suitability of application and the easiness to obtain the curves, while the effect of long-term aging treatment on FCG
parameters, based on fatigue crack growth data of was not considered. Unlike the Paris regime where the linear

factor range, 'K, is often used, the FCG curve in the


Cr-Ni-Mo-V steel welded joints. Results showed that fatigue relationship between FCG rate, da/dN, with stress intensity
crack growth curves provided by the FKM or WES were good
choice when few inputs were at hand while the curves in the near-threshold regime is non-linear, and it is difficult to select
BS7910, JSME and ASME were recommended for precise the assessment curves among existing codes with sufficient
estimation. It was indicated that the assessment of welded accuracy due to less-verified assumptions and simplicities.
joints solely by fatigue crack growth behavior at base metal The assessment of FCG behavior in the near-threshold
part and the assessment of fatigue crack growth for the aged regime is of great significance to damage tolerant design of
condition by as-received one both resulted in materials in the perspective of structural integrity. Many
non-conservativeness, albeit dependent on the range of stress researchers [11-13] studied the prediction of FCG, largely in
ratios, R. A new bilinear form of fatigue crack growth model the Paris regime. However, the prediction of FCG in the
independent of R was developed based on transition point near-threshold regime is affected by many factors [12, 14-16].
occurred in the near-threshold regime. This constituted the As reported by Lal [17], a bi-linear method describing FCG
bilinear approach to fatigue assessment, and thus contributed curve is advisable to predict FCG curves. In our previous
to the optimization of fatigue assessment in the near-threshold work, the transitional behavior of FCG in welded joint has
regime. been investigated [18]. It is useful to develop new bi-linear
methods to improve the predictive accuracy and the range of
INTRODUCTION R that the model can cover. In case of welded joints, questions
that need to be answered include: (1) at what degree of
Nowadays, the life requirement of some key components, conservativeness if assessing the welds based on base metal
such as the advanced steam turbine, has been extended from (BM)? (2) What is the case for long-term aging process? (3)
40 to 60 years [1]. Fatigue resistance, especially the Are there better approaches that contribute to more accurate
performance of fatigue crack growth (FCG), is a key issue in assessment of welded joint?
material development and life design of components of power Therefore, in the present work, the effects of long-term
plants [2]. In order to predict and evaluate the structure life aging treatment and welded joint location on applicability of

FCG curve, fatigue threshold, 'Kth, and stress ratio, R [3].


well, it is important to further study relationship between the fatigue assessment curves are discussed. A new bilinear form
of model independent of R for FCG in the near-threshold
Moreover, the degradation behavior of materials and regime was developed based on transitional behavior in the
structures after long-term service is of immense significance

1 Copyright © 2016 by ASME


near-threshold regime. This constitutes the bilinear approach applicability in different da/dN is obviously different. Though
to fatigue assessment, and thus contributes to optimization of the equations ensure the safety of BM in some da/dN, the
fatigue assessment in the near-threshold regime. same position in WM and HAZ is still at risk.
Long-Term Aged Welded Joints
COMPARISON OF FCG MODELS IN DIFFERENT One of the challenges for design practice is the selection
CODES, STANDARDS, AND GUIDELINES of materials whose mechanical properties have the reasonable
safety margin and good long-term stability. An understanding
Materials of steam turbine rotor are mostly ferritic steels.
of degradation of mechanical behavior of materials is critical
The FCG models are listed in Table 1. Here the unit of FCG
to safety and reliability of structures under long-term service,
rate is mm/cycle and the stress intensity factor range is in
as demonstrated by Chung [20]. The FCG data after long-term
MPa˜m0.5. The effect of R is considered by BS7910, ASME
aging treatment comes from our published work [19], where
and JSME; and the near-threshold regime is taken into
experiments were conducted using the 30Cr2Ni2MoV welded
consideration by most models, except JSME. The range of R
hours at 300qC). The values of \ at R of 0.3 in different da/dN
joint in the as-received and aged conditions (aging for 3000
is simplified as two parts in BS7910, though the description of
the near-threshold FCG regime is better.
are listed in Table 4. Equations except BS7910 are suitable for
Fatigue assessment curves in different codes, standards,
30Cr2Ni2MoV in BM before and after the long-term aging
and guidelines are plotted in Fig. 1. The difference of the
treatment. It is observed that if the assessment could ensure
equations in the Paris regime affects the results slightly, while
the safety of BM at low R in the as-received condition, the
the one in the near-threshold regime is large. If the users have
Table 5 shows the values of \ at different da/dN in the
case for aged condition could still keep safe at low R.
little information of residual stress distribution or need quick
estimation, the FKM or WES (most conservative) curves are
the good choice, because these are defined as one curve for BM of 30Cr2Ni4MoV at R=0.9 before and after long-term
each guide with simple equations. If the user has the detailed aging treatment. The result is different from the one at R=0.3.
information of residual stress distribution and other specific Some of equations are suitable for the BM in the as-received
conditions and more precise estimation is required, it is condition. It is observed that if safety could be assured in the
observed from Fig. 1 that, the BS7910, JSME and ASME as-received condition, the case for long-term aged would also

The values of \ at different da/dN in the WM of the


curves are recommended, as R and other factors are taken into be safe.
account. It is worth noting that fatigue assessment may lead to
some degree of conservativeness if the effect of R is not 30Cr2Ni4MoV welded joint with R=0.3 are listed in Table 6.
considered in the near-threshold FCG regime. It can be observed that risk exists for some of the fatigue
assessment curves at the as-received condition. Some of
APPLICATION OF FCG RATE MODELS equations are suitable for the WM in the as-received condition.
It is observed that if safety could be assured in the as-received
Our previous work has provided a solid foundation for
The values of \ at different da/dN in the WM of the
condition, the case for long-term aged condition may be risky.
failure mechanisms and modelling of the crack growth
behavior in the near-threshold regime of Ni-Cr-Mo-V rotor 30Cr2Ni4MoV welded joint at R=0.9 are listed in Table 7.
steels and welded joints [2, 4, 15, 18, 19]. To evaluate the Some of the equations are suitable for the WM in the

or rules, a new parameter \ is defined, which represents the


applicability of the assessment curves in different guidelines as-received condition, while it may be at risk after long-term
aging treatment.
ratio between the difference value of'K between the

da/dN, and the 'K of experimental data. If \ !0, the fatigue


experimental data and assessment FCG curves at the same DESCRIPTION OF FCG CURVE
Based on the study on transition behavior of FCG
assessment curve show non-conservativeness; when \ equals
assessment curve is conservative and safe; otherwise, the
behavior in the near-threshold regime, FCG curve can be
divided into two parts by the transition point: the Paris regime
0, it represents the best economic performance.
and the near-threshold regime. The Paris regime is described
Welded Joint
by the two parameter model, such as Zhang’s model [11]. Eq.
The FCG data are from a 25Cr2Ni2MoV welded joint,
f ( R ) exp(K R )
(1) represents the correction factor in Zhang’s model.
\ in three situations (da/dN=10-6, 5u10-7 and 10-7 mm/cycle)
where were reported in our previous work [18]. The values of
(1)
are compared at low and high R. The result at R of 0.1 is listed where K is material parameter of Zhang’s model.
in Table 2. It is observed that all the equations except BS7910 By defining a transition point, the whole FCG curve can
be modelled as below,
C [ f ( R ) 'K ] 'Kt 'Kt
are suitable for FCG assessment of the 25Cr2Ni2MoV welded
m
joint. It is also worth noting that when the applicable models da / dN (2)
are employed to assess the BM though with some degree of
) log( A)  n log( 'K ) 'Kd 'Kt
conservativeness, they are suitable for assessing the weld da
log( (3)

where da/dN is FCG rate in mm/cycle, 'Kt is the stress


metal (WM) and heat-affected zone (HAZ) with a lowered dN
conservativeness. In other words, a safety fatigue design
guideline applied at the BM can assure the whole integrity of intensity factor range at transition points, MPa˜m0.5, A, C, n

The values of \ at R of 0.9 is listed in Table 3. Most


the welds at R of 0.1. and m are materials parameters.
At the transition point, Eq. (2) equals to Eq. (3), thus,
equations are not fit for 25Cr2Ni2MoV welded joint, and the

2 Copyright © 2016 by ASME


da da in the long-term aged condition was expected if it was already
log[( )t / ( ) th ] safe in the as-received condition at lower R; while a safe WM
dN dN
log( 'K t / 'K th )
n (4) in the as-received condition could not assure the safety in
aged condition at lower R.

) th ˜ 'K th
(3) A new bilinear model of FCG independent of R for
da n
A ( (5) FCG assessment was developed based on the transition

where da/dNt is FCG rate at transition points; 'Kth is fatigue


dN behavior during FCG in the near-threshold regime, which was
useful to generalize the effect of R for description and
threshold and (da/dN)th is FCG rate at fatigue threshold, often assessment of FCG in the near-threshold regime.

The method to determine the parameter K is given in


defined as 10-7 mm/cycle.
ACKNOWLEDGEMENTS

and the parameters K of BM and WM are determined as 0.617


reference [11]. In this work, similar procedures are employed The authors are grateful for the supports provided by the
National Natural Science Foundation of China (Nos.
and 0.816, respectively, in the 25Cr2Ni2MoV welded joint, as 51325504, 51205131 and 51575182).
shown in Figs. 2 and 3. As a result, the FCG curve in the Paris

The da/dNt , 'Kt and 'Kth of 25Cr2Ni2MoV in BM and


regime at different R can be predicted. REFERENCES

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3 Copyright © 2016 by ASME


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Table 1 Summary of equations of FCG rate and 'Kth for ferritic steels in current codes and standards
Standard Equation C n 'Kth R
ASME C 3.78 u10 S S 25.72(2.88  R)
9 3.07
3.07 'K th 5.5(1  0.8 R) 0dR1
JSME C 3.78 u10 S
9 S 25.72(2.88  R ) 3.07
3.07 0dR1
FKM 1.37u10-7 2.25 2 0dR1
2.6u10-8 2.75 2 Most conservative
WES 2805 No residual stress
4.34u10-9 3.3 3.5
and R=0
C 'K n
2.10u10-14 8.16 Stage a R0.5
da / dN
BS7910 8.32u10-9 2.88 Stage b R0.5
Mean curve 2.14u10-10 5.10 Stage a Rt0.5
1.22u10-8 2.25 Stage b Rt0.5
7.59u10-14 8.16 Stage a R0.5
BS7910 1.41u10-8 2.88 Stage b R0.5
Mean+2SD 9.38u10-10 5.10 Stage a Rt0.5
2.70u10-8 2.25 Stage b Rt0.5

Table 2 Relationship between deviation \ and da/dN in 25Cr2Ni2MoV welded joint at R=0.1
da/dN WES 2805 No WES 2805 BS7910 BS7910 mean+2SD
Location ASME 0.1 JSME 0.1 FKM
(mm/cycle) residual conservative mean <0.5 <0.5
1.00E-06 0.18299 0.18299 0.66723 0.28488 0.48139 -0.20052 -0.02562
BM 5.00E-07 0.29371 0.29371 0.73505 0.37199 0.5633 -0.19479 -0.02072
1.00E-07 0.14527 0.52608 0.66216 0.40878 0.66216 -0.11182 0.05016
1.00E-06 0.22153 0.22153 0.68293 0.31862 0.50586 -0.14388 -0.02562
WM 5.00E-07 0.34721 0.34721 0.75512 0.41956 0.59638 -0.10427 -0.02072
1.00E-07 0.16913 0.5393 0.67159 0.42529 0.67159 -0.08078 0.05016
1.00E-06 0.19078 0.19078 0.6704 0.2917 0.48634 -0.18907 -0.01584
HAZ 5.00E-07 0.21013 0.21013 0.7037 0.29767 0.51162 -0.33617 -0.1415
1.00E-07 0.06985 0.48426 0.63235 0.35662 0.63235 -0.20992 -0.03365

4 Copyright © 2016 by ASME


Table 3 The values of \ at different da/dN in 25Cr2Ni2MoV welded joint at R=0.9
da/dN WES 2805 WES 2805 BS7910 BS7910
Location ASME 0.9 JSME 0.9 FKM
(mm/cycle) Noresidual conservative mean >0.5 mean+2SD >0.5
1.00E-06 -0.10455 -0.10455 0.36834 -0.35742 0.01559 -0.36876 -0.02444
BM 5.00E-07 -0.15202 -0.15202 0.39323 -0.43821 0 -0.56183 -0.16894
1.00E-07 0.19372 -0.04621 -0.04712 -0.83246 -0.04712 -0.74749 -0.3079
1.00E-06 -0.19167 -0.19167 0.31852 -0.46448 -0.06205 -0.47672 -0.10524
WM 5.00E-07 -0.18022 -0.18022 0.37838 -0.47341 -0.02457 -0.60006 -0.19755
1.00E-07 0.21429 -0.01952 -0.02041 -0.78571 -0.02041 -0.70291 -0.27453
1.00E-06 -0.21914 -0.21914 0.30281 -0.49824 -0.08654 -0.51077 -0.13072
HAZ 5.00E-07 -0.29824 -0.29824 0.31622 -0.62076 -0.12703 -0.76006 -0.31731
1.00E-07 0.20207 -0.03537 -0.03627 -0.81347 -0.03627 -0.72938 -0.29434

Table 4 The values of \ at different da/dN in the BM of 30Cr2Ni4MoV welded joint at R=0.3
da/dN WES 2805 WES 2805 BS7910 BS7910
Condition ASME 0.3 JSME 0.3 FKM
mm/cycle No residual conservative mean >0.5 mean+2SD >0.5
1.00E-06 0.10368 0.10368 0.60663 0.15465 0.38695 -0.41915 -0.2124
As-received
5.00E-07 0.21319 0.21319 0.68196 0.24616 0.4758 -0.43417 -0.22523
condition
1.00E-07 0.14868 0.4697 0.59267 0.28717 0.59267 -0.34052 -0.14522
Long-term 1.00E-06 0.12223 0.12223 0.61477 0.17215 0.39964 -0.38978 -0.1873
aging 5.00E-07 0.24168 0.24168 0.69348 0.27345 0.49478 -0.38225 -0.18087
condition 1.00E-07 0.12552 0.45527 0.58159 0.26778 0.58159 -0.37698 -0.17637

Table 5 The values of \ at different da/dN in the BM of 30Cr2Ni4MoV welded joint at R=0.9
WES 2805 No WES 2805 BS7910 BS7910
Condition da/dN ASME 0.9 JSME 0.9 FKM
residual conservative mean >0.5 mean+2SD >0.5
1.00E-06 -0.18499 -0.18499 0.32234 -0.45628 -0.0561 -0.46845 -0.09905
As-received
5.00E-07 -0.03224 -0.03224 0.45632 -0.28867 0.10389 -0.39944 -0.0474
condition
1.00E-07 0.47973 0.32491 0.32432 -0.18243 0.32432 -0.1276 0.15605
Long-term 1.00E-06 -0.09597 -0.09597 0.37325 -0.34687 0.02324 -0.35812 -0.01648
aging 5.00E-07 -0.13651 -0.13651 0.40141 -0.41884 0.01338 -0.54079 -0.1532
condition 1.00E-07 0.3125 0.10792 0.10714 -0.5625 0.10714 -0.49005 -0.11522

Table 6 The values of \ at different da/dN in WM of 30Cr2Ni4MoV at R=0.3 under as-received and long-term aged conditions
da/dN WES 2805 No WES 2805 BS7910 BS7910
Condition ASME 0.3 JSME 0.3 FKM
(mm/cycle) residual conservative mean >0.5 mean+2SD >0.5
1.00E-06 -0.02081 -0.02081 0.55199 0.03724 0.3018 -0.61626 -0.38078
As-received
5.00E-07 0.16699 0.16699 0.66329 0.2019 0.44502 -0.51838 -0.29716
condition
1.00E-07 0.10874 0.44482 0.57356 0.25373 0.57356 -0.4034 -0.19894
Long-term 1.00E-06 -0.10913 -0.10913 0.51323 -0.04606 0.24139 -0.7561 -0.50025
aging 5.00E-07 -0.01577 -0.01577 0.58942 0.0268 0.32326 -0.85151 -0.58176
condition 1.00E-07 -0.19771 0.25393 0.42693 -0.00287 0.42693 -0.88595 -0.61118

5 Copyright © 2016 by ASME


Table 7 The values of \ at different da/dN in WM of 30Cr2Ni4MoV at R=0.9 under as-received and long-term aged conditions
da/dN WES 2805 No WES 2805 BS7910 BS7910
Condition ASME 0.9 JSME 0.9 FKM residual conservative mean >0.5 mean+2SD >0.5
(mm/cycle)
1.00E-06 -0.19504 -0.19504 0.3166 -0.46862 -0.06505 -0.48089 -0.10836
As-received
5.00E-07 -0.19696 -0.19696 0.36957 -0.49431 -0.0391 -0.62275 -0.21454
condition
1.00E-07 0.06098 -0.21845 -0.21951 -1.13415 -0.21951 -1.03519 -0.52322
Long-term 1.00E-06 -0.20525 -0.20525 0.31076 -0.48117 -0.07415 -0.49355 -0.11784
aging 5.00E-07 -0.26896 -0.26896 0.33165 -0.5842 -0.10161 -0.72036 -0.28759
condition 1.00E-07 0.24138 0.01564 0.01478 -0.72414 0.01478 -0.64419 -0.23058

Fig. 1 FCG curves for ferritic steels in air environments Fig. 3 FCG of WM at R=0 in Paris regime
based on different codes

Fig. 2 FCG of BM at R=0 in Paris regime Fig. 4 Experimental and predicted result at various R using
new method for notch in the BM

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Fig. 5 Experimental and predicted results at various R Fig. 7 Comparation between predicted FCG curves in WM
and the design curves from different codes in air environments

Fig. 6 Comparation between predicted FCG curves in BM


and the design curves from different codes in air environments

7 Copyright © 2016 by ASME

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