Transactions, SMiRT 16, Washington DC, August 2001

Paper # 1983

Residual Stresses in Butt and Socket Welded Joints

Xiangyang Lu and Tasnim Hassan Center for Nuclear Power Plant Structures, Equipment and Piping, North Carolina State University, Raleigh, NC ABSTRACT A finite element scheme for simulation of welding residual stresses is presented in this paper. Detailed thermal and residual stress analyses for butt-welded and socket-welded pipes are performed using ANSYS and ABAQUS. The calculated distribution of axial stress and hoop stress at welded joint are validated against experimental results. Furthermore, residual stress relaxation under high amplitude cyclic loading is studied. INTRODUCTION Fatigue failures in many nuclear power plants have resulted in unscheduled plant downtime and considerable financial loss ([ 1], [2]). Most of these fatigue failures occurred at welded-joints of small-bore piping or at fillet weld attachments under high- and low-cycle vibration conditions. Despite the general notion that the current fatigue design methodologies are conservative, fatigue failures are still occurring and sometimes much earlier than the estimated life. Hence, understanding the mechanisms that contribute to welded joint fatigue failures and incorporating that knowledge into design procedures in a scientific manner are critical. Fatigue behavior of welded joint is complicated due to many factors, such as stress concentration, environment and residual stress. This study will make an effort to estimate residual stresses in socket-welded joints initially and after fatigue loading. Residual stresses that arise in welded joints by heating and cooling cycles during the welding process is an important factor in fatigue failure of welded structures. It has been shown that a tensile residual stress in welded structure can be as high as the yield stress and can have detrimental effect on the fatigue life of welded structures ([3], [4], [5]). Magnitude and distribution of residual stress in a welded joint depend on the weld-bead sequences ([6], [7]). In the presence of high residual stress, materials at or near welded joints experience repeated excursions into the plastic range, even for small amplitude fatigue loading cycles. Moreover, residual stress acts as a mean stress to the fatigue loading. In the presence of mean stress, repeated excursion of "stress-controlled" loading cycles into the plastic range can lead to degradation and failure of structures due to the accumulation of deformation or ratcheting ([8], [9]). This fatigue failure mechanism is not well understood and has not been incorporated into design in a scientific manner. In this paper, detailed thermo-elastic-plastic finite element analyses are performed to estimate residual stresses during welding process. The calculated distribution of axial stress and hoop stress at welded joint are validated using experimental results. Furthermore, residual stress relaxation under high amplitude cyclic loading is studied. FINITE ELEMENT ANALYSIS In order to understand the effect of welding residual stress on fatigue failure, it is essential to numerically simulate its initial distribution and subsequent response of material (relaxation and ratcheting) during fatigue loading. This requires a robust, reliable and numerically efficient method of modeling residual stresses. Methods of residual stress calculation in butt welded joints have been developed by Ueda et al. [ 10], Rybicki et al. [ 11 ], Wilkening and Snow [ 12], Brickstad and Josefson [13]. Most of these studies were conducted based on either axisymmetric or two-dimensional plane assumption. Although some of the basic residual stress characteristics can be reasonably captured with axisymmetric model as shown by Karlsson [ 14] and Dong et al. [ 15], it is also demonstrated that the residual stresses in welded joints are not always symmetric. High tensile and compressive residual stress concentrations have been observed at welding start/end point (Shack et al. [16], Karlsson and Josefson [ 17] and Lindgren and Karlsson [ 18]). Fatigue failures in welded structures usually initiate at the stress concentration point. Hence, a two-dimensional simplified model can not always simulate the fatigue failure of welded joints accurately. Therefore, it is essential to conduct a detailed three-dimensional analysis in order to simulate the fatigue responses of welded joints. Along this line, some insightful results on welding residual stresses for butt-welded joints are published ([5], [15], [17], [19], [20]). Methods developed by Rybicki et al. [11], Wilkening and Snow [12], Li [5], Brickstad and Josefson [13] are used in this study. The numerical method for predicting residual stresses of welded joints consists of two parts: heat transfer and residual stress analyses. The prediction of welding residual stresses using the finite element method can be simplified by uncoupling the thermal and mechanical aspects of the problem. In this approach the heat transfer analysis can be solved independently of the stress analysis [21 ]. The link between the heat transfer and stress analyses is obtained through the temperature history, which is the input as thermal load for residual stress calculation. First a transient thermal analysis is performed during which

the time-dependent temperature distribution is determined for the successive build-up of the welding passes. The temperature field at each time step is then used as an input for evaluating the stress and strain field in welded joints. After residual stress fields of welded joints are established, fatigue responses (relaxation and ratcheting) at critical points of welded joints are studied. In this study, residual stress calculation is performed using the finite element codes ANSYS [22] and ABAQUS [23].

Thermal Analysis
In the thermal analysis, in order to simulate the multi-pass welding process, one need to model the addition of filler material as new weld passes are deposited and the geometry of welded joint is built-up. This is done through element birth/death technique in ANSYS [22] and ABAQUS [23]. With this technique, a finite element mesh of the welded joint is generated first. Subsequently, the element groups representing each weld pass are deactivated (element death) before welding. These elements are reactivated (element birth) sequentially as the welding arc (heat source) advances along the circumferential direction.

The principal parameter of the welding heat source at the welding spot is the heat flow expressed as

[Joule/sec], which can be

Q-rl.U.I
where, rl is the arc efficiency, U is the arc voltage, I is the arc current [24]. The equivalent heat flow is assumed as the combination of both surface heat flux ( Q s ) and body heat flux ( Q B ) [25],

Qs+ The surface heat flux was assumed to be a Gaussian distribution, while the body heat flux was assumed constant in this study. In 3D analysis, during a time step, the welding arc is allowed to stay at the element with constant heat flux and then move to the next element. For simplified axisymmetric model, in order to enable a 2D model to include the effect of a 3D moving arc in a consistent manner and to avoid numerical problems because of sudden increase in temperature, a ramped heat input model developed by Wilkening and Snow [ 12] is used. The latent heat, the heat energy that the system stores or releases during a phase change, is accounted for by assuming a value of 260 kJ/kg between the solidus temperature 1340 C and the liquidus temperature 1390 C for 304 stainless steel in ABAQUS [ 13]. In ANSYS, latent heat is accounted for by defining the enthalpy of the material as a function of temperature. Heat losses from the pipe surface through both convection and radiation are included in the calculation. Radiation losses are dominating for higher temperatures near the weld and convection losses for lower temperatures away from the heat source. A combined boundary condition is used in the analysis, accounting for both convection and radiation [26]. Temperature dependent thermal material properties of specific heat (c) and conductivity (k), are used in the analysis as listed in Table 1 for stainless steel 304.
Table 1 Temperature Dependent Thermal and Mechanical Properties of Materials [ 13] T (C) 20 200 400 600 800 1000 1200 1340 1390 2000 Thermal Material Properties k c (W m "l, C) (Jkg "l, C) 15.0 442 17.5 515 20.0 563 22.5 581 25.5 609 28.3 631 31.1 654 33.1 669 66.2 675 66.2 675 Mechanical Material Properties O'y ET/E v (x 10-6 c'l) (Mpa) 0.014 19 230 0.278 0.014 19 0.288 184 19 0.014 0.298 132 19 0.014 105 0.313 19 0.014 0.327 77 l x l 0 -4 19 0.342 50 19 10 0.350 l x l 0 -4 19 10 0.351 l x l 0 -4 19 10 0.353 l x l 0 -4 19 10 0.357 l x l 0 -4

E (GPa) 200 185 170 153 135 96 50 10 10 10

T = temperature; c = specific heat; k = conductivity; v = Poisson's ratio E - elastic modulus; ET = hardening modulus; c~ - thermal expansion

Two-pass butt-welded stainless steel plate joints

The thermal analysis was first validated by performing a 2D finite element analysis for a two-pass butt-welded stainless steel plate joint using ANSYS. The problem was simplified by assuming plane strain condition and neglecting effects of heat flow in the weld direction. The finite element model is shown in Fig.1. Two-dimensional thermal element, PLANE55, was used in the modeling. Automatic time stepping was used in the analysis. The numerical results of temperature history and the experimental data from Murugan et al. [27] is compared in Fig.2. This figure shows that the temperature history at midthickness points with distances of 11.5 mm, 16.5 mm, 21.5 mm and 26.5 mm from weld centerline is simulated quite well.
700 6o
11 ~ ~ \ \ , , v c . , . ~ L A - 1 5 1 k

600
L-'k.J / / / / I i

Distance 11.5 m m Distance 16.5 m m Distance 2 1 . 5 m m

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=(1)

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Distance 2 6 . 5 m m

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300

t'~ 200

o 0 100 200 Time (sec.) 300 400

Fig.1 Finite element model for butt-weld plate

Fig.2 Calculated temperature history during welding pass in comparison with experimental data

Four-pass girth-welded stainless steel pipe joints

Thermal analysis of a girth-welded stainless steel pipe was conducted using ANSYS and ABAQUS. The groove geometry and finite element model are presented in Fig.3a and 3b, respectively. The outer diameter of the pipe is 406 mm. The weld was completed in four continuous welding passes with the same start-stop position for each pass. The analysis assumes that symmetry exists about the centerline of the weld bead, so only half of the weld joint is modeled. Eight-noded 3-D thermal solids elements SOLID70 were used for the thermal analysis. The half model shown in Fig.4b includes 7 layers of elements along the length, 120 layers of elements along the circumferential direction and 4 layers of element across the thickness. The total number of elements is 3360. This analysis included up to 480 time steps with 20 sub-steps in each and 3-~5 iterations per sub-step. Fig.4 shows a comparison between the calculated and experimentally measured temperature histories [5] at 6.35 mm away from the weld centerline and on the inner surface from weld centerline (see inset in Fig.4). As seen in this figure, the correlation between the experimental and finite element results is quite satisfactory.

WCL 12.7 mm

1.6 mm

200 mm

(a)

(b)

Fig. 3a Groove geometry of girth-weld pipe

Fig. 3b 3D finite element model for girth-welded pipe

1000 900 800 700 600 500 400

= |

Test data from Li, et.al.[10]

Starting ~/,~"~ -'~

0
. . . . . . . . . . . . . . . . . . . . . . . . .

9
o Experiment ANSYS 3D ABAQUS 3D

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i i I i i i i

1000

2000 3000 Time (see.)

4000

5000

Fig.4 Comparison of temperature history between numerical results and experiment Residual stress analysis

Four-pass girth-welded stainless steel pipe joints

The finite element model used in the residual stress analysis is the same as the one used in the thermal analysis (Fig. 3b). The temperature history determined in the thermal analysis was prescribed as the thermal load in this analysis. Element birth/death technique was used to simulate the progress of welding sequence. Three dimensional structural element SOLID45 (equivalent to the thermal element SOLID70) was used. The temperature dependent mechanical properties from Brickstad and Josefson [ 13] (see Table 1) were used. Newton iteration method with line search algorithm was used in the solution. The von-Mises yield criterion and associated flow rule was used together with the kinematic hardening rule and a bilinear representation of stress-strain curve. Using an automatic time step procedure, a typical solution for this 3D residual stress analysis would include 120 time steps, with each time step 26 sub-steps and 3-~5 iterations per sub-steps. Figs. 5 and 6 show the axial and circumferential residual stress distributions, after completion of the welding, on the outer and inner surface of the pipe as a function of distance from weld centerline. The residual stresses shown in the figure are at a location 180 away from the welding start/stop point. From these figures, it is shown that the finite element results from ANSYS and ABAQUS generally agree with each other. The agreement between calculated results and experimental data from Li et al. [5] is basically reasonable. These results demonstrate that, (1) high tensile residual stress in the order of yield stress exists at the vicinity of weld toe area, (2) axial residual stresses are compressive on the outer surface and tensile on the inner surface at the weld area, (3) circumferential residual stresses are always tensile at the weld area and changed to compression at a distance of 35 mm from weld centerline for the joint considered.
250
200

(a)
p m w m ~ m ~

O ......

150
r/l o

Experiment ANSYS 3D ABAQUS 3D

250 200 . .

(b) .

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Experiment ANSYS 3D

100 50 r~
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0 -50 -100 50 100 150 200 Outer Surface Distance from Weld Center Line (mm)

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Distance from Weld Center Line (mm)

Fig.5 Axial residual stress distribution along pipe outer and inner surface

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Fig.6 Hoop residual stress distribution along pipe outer and inner surface

Three-pass stainless steel socket-welded joint

A residual stress analysis of a socket-welded joint was performed for understanding the influence of residual stress in fatigue failure of socket welds. Using a similar numerical technique as in the butt-weld, a 3D f'mite element residual stress analysis of a three-pass socket-welded joint was performed using ANSYS. The geometry and f'mite element model of socket weld pipe joint is shown in Fig.7a and 7b, respectively. Same material, 304 stainless steel, is chosen in this study. SOLID45 are used in the analysis. A total of 9160 solid and 240 contact elements were used to model the joint. Figs.8a and 8b show the axial and hoop residual stress distribution along the pipe outer surface and root section respectively. From Fig.8a, it is found that the residual stresses are compressive at weld toe and tensile at weld root for the geometry and weld sequence considered. From Fig.8b, it is observed that the tensile residual stress at weld root could be as high as the yielding stress (230Mpa) for both axial and hoop stress.

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Pipe Outer Surface

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I

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re -150 -200 -250

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Fig.8 Residual stresses distribution along pipe outer and root surface

Effect of Fatigue Loading on Weld Residual Stresses and Material Responses

In the ASME fatigue design method, the effect of mean stress on reducing fatigue life is considered for high-cycle (lowstress amplitude) fatigue loading, but neglected for low-cycle (high-stress amplitude) fatigue loading. This design method is based on elastic-perfectly plastic material behavior as shown in Figs 9a and 9b, for elastic and elastic-plastic fatigue loading cycles, respectively. In Fig. 9a, it is seen that the mean stress Smeanis not changed or relaxed during the elastic loading cycle BDBD... While in Fig. 9b, it is observed that after one complete loading cycle BCDEB, the mean stress in the fatigue cycle becomes zero. Recent experimental studies by Chiarelli et al. [28] showed that even after extensive, large amplitude fatigue loading cycles, the residual stresses do not relax completely as assumed in design. Moreover, the residual stresses act as mean stresses to the fatigue loading and reduces fatigue life due to ratcheting. In order to study the residual stress and material responses under high amplitude, low-cycle fatigue loading, 3D finite element analyses of a socket welded joint were performed. A cantilever set-up as shown in Fig.10 was considered. The analysis started with the initial residual stress field calculated using ANSYS. Analyses for displacement- and force-controlled fatigue loading (saw-tooth cycles) were performed. The amplitude of loading is chosen such that the axial stress exceeded the yield stress at the welding area and elastic away from welding area.
A rB _. A E B

//!
1

s'~, Strain ~l ~

i!i......................... . ..
" ', ~

~i~i~i~i~i~i~i~i~i~i~}~i~i~i~i~i~i~i~i~i~i~i~i~i~i~i~i~i~i~i~i~{~!~i................~i~i~i~!~22~ ~i~i~!~i~i~i !:~!~2~2.~!!~2~-~!!!!!!!~!!!!!~!!!!2!!~-~!!:~!~-~!2~!!!!22~!2~2~!!!2!!.~2!!22!~:

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Fig.9 Idealized stress vs. strain history during fatigue loading cycles (a) elastic loading (b) elastic-plastic loading

Fig.10 Cantilever set-up of socket welded joint

The residual stresses and strains initially and at the 6th cycle along the pipe outer surface are shown in Fig.11. A significant relaxation in the maximum compressive residual stress is observed up to 6 th cycle (e.g., -226.29 MPa relaxed to -73.66 MPa in Fig.1 l a), whereas the tensile residual stresses do not show any such changes. In case of residual strains, compressive axial strain peaks show some changes, increase in compressive axial strain (Figs. 1 l e, f) and decrease in compressive hoop strains (Figs.11 g, h). The tensile axial strains do not change much, and little change in tensile hoop strain up to 6th cycle is observed. In case of a force-controlled fatigue' loading, the cycling was continued up to 104 cycles, but no significant changes compare to the 6th cycle were observed, and hence the results are not presented. CONCLUSIONS AND DISCUSSIONS In the current research, a finite element scheme for simulation of welding residual stresses is developed. Detailed thermal and residual stress analyses for butt-welded and socket-welded pipes are performed using ANSYS and ABAQUS. Results form the finite element analyses are validated using experimental data from literature. Furthermore, residual stress relaxation in socket-welded joint under high amplitude fatigue loading is studied. It is found that high tensile residual stress in the order of yield stress exists at the vicinity of the weld area. For the socket welded joint considered, the residual stress is compressive at weld toe and tensile at weld root for the geometry and sequence considered. Under high amplitude fatigue loading, the compressive residual stresses relax during the first cycle, but not much change occurs thereafter. However, it does not relax to zero as assumed in the ASME Code. The constitutive model used in this study is a bilinear model. It does not well represent the real material behavior in cyclic loading [29]. Hence, use of more sophisticated material model [30] is needed to improve the simulation of welded joint response.

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REFERENCE

1. Smith, J.K., "Vibrational Fatigue Failures in Short Cantilevered Piping With Socket-Welded Fittings", ASME PVP-Vol. 338, Pressure Vessels and Piping Codes and Standards, Volume 1, 1996, pp. 21-24. 2. Vecchio, R. S., "Fatigue Evaluation of Socket Welded Piping in a Nuclear Power Plant", ASME PVP-Vol. 338, Pressure Vessels and Piping Codes and Standards, Volume 1, 1996, pp. 25-41. 3. Berge, S., and Eide, O.I., "Residual Stress and Stress Interaction in Fatigue Testing of Welded Joints", American Society for Testing and Materials, 1982, pp. 115-131 4. Maddox, S.J.,"Fatigue Strength of Welded Structures", Woodhead Publishing Ltd. Abington Hall, Abington, 1991 5. Li, M. (1995), "An Experimental and Finite Element Analysis of Temperature and Stress Fields in Girth Welded 304L Stainless Steel Pipes", Ph.D. dissertation, Oregon Garduate Institute of Science and Technology, Portland, Oregon. 6. Yamashita, T., Hattori, T., Lida, K., Nomoto, T., Sato, M (1997), "Effects of Residual Stress on Fatigue Strength of Small Diameter Welded Pipe Joint", J. of PVT, Vol. 119, pp.428-434. 7. Higuchi, M., Nakagawa, A., Lida, K., Hayashi, M., Yamauchi, T., Saito, M., Sato, M. (1998), "Experimental Study on Fatigue Strength of Small-Diameter Socket-Welded Pipe Joints", ASME J. ofPVT, Vol.120, pp. 149-156. 8. Beaney, E.M. (1988), "The Response and Failure of Pipes with Stress Concentrations under Seismic Loading", CEGB, Berkeley Nuclear Laboratories, Report No.RD/B/6050/R88. 9. EPRI (1992), "Draft Final Report on the Piping and Fitting Dynamic Reliability Research Program, Vol. 2 - Component Test Report, Vol. 3 - System Test Report", (Limited access) 10. Ueda, Y., Fukuda, K., and Kim, Y.C. (1986), "New Measuring Method of Axisymmetric Three-Dimensional Residual Stresses Using Inherent Strains as Parameters", Journal of Engineering Materials and Technology, Vol. 108, pp.328-334 11. Rybicki, E.F., Schmueser, D.W., Stonesifer, R.W., Groom, J.J., Mishler, H.W. (1978), "A Finite Element Model for Residual Stresses and Deflections in Girth-Butt Welded Pipes", J. of PVT, Vol. 100, pp.256-262 12. Wilkening, W.W., and Snow, J.L. (1993), "Analysis of Welding-Induced Residual Stresses with the ADINA System", Computers & Structures, Vol.47, No.4/5, pp.767-786 13. Brickstad, B., and Josefson, B.L. (1998), "A Parametric Study of Residual Stresses in Multi-pass Butt-welded Stainless Steel Pipes", International Journal of Pressure Vessels and Piping, Vol.75, pp.11-25 14. Karlsson C.T. (1989), "Finite Element analysis of temperatures and stresses in a single-pass butt-welded pipe --influence of mesh density and material modeling", Eng. Comput., Vol.6, pp.133-141 15. Dong, P., Ghadiali, N., and Brust, F.W. (1998), "Residual Stress Analysis of a Multi-Pass Girth Welcf', PVP 373, Fatigue,Fracture and Residual Stresses, pp.421-431 16. Shack, W.J., Ellingson, W.A. and Pahis, L.E. (1980), "Measurement of Residual Stresses in Type 304 Stainless Steel Piping Butt Weldments", EPRI NP- 1413 17. Karlsson, C.T., and Josefson, B.L. (1990), "Three-Dimensional Finite Element Analysis of Temperature and Stresses in Single-Pass Butt-Welded Pipe", Journal of Pressure Vessel Technology, Vol.112, pp.76-84 18. Lindgren, L., and Karlsson, L. (1988), "Deformations and Stresses in Welding of Shell Structures", International Journal for Numerical Methods in Engineering, Vol.25, pp.635-655 19. Teng, Tso-Liang, and Lin, Chih-Cheng (1998), "Effect of Welding Conditions on Residual Stress due to Butt Welds", International Joumal of Pressure Vessels and Piping, Vol.72, pp.857-864 20. Zhang, J., Dong, P., and Brust, F.W. (1997), "A 3D Composite Shell Element Model for Residual Stress Analysis of MultiPass Welds", SmiRT 14, pp.335-344 21. Hibbitt, H.D. (1972), "A Numerical Thermal-Mechanical Model for the Welding and Subsequent Loading of a Fabricated Structure", Ph.D. Thesis, Brown University 22. ANSYS Version 5.6, Swanson Analysis Systems, Inc., Houston, PA 15342-0065 23. ABAQUS Version 5.8, Hibbitt, Karlsson and Sorensen, Inc., Providence, RI 02906 24. Dieter Radaj (1992), "Heat Effects of Welding", ISBN 0-387-54820-3, Springer-Verlag 25. Hong, J.K., Tsai, C.L., and Dong, P. (1998), "Assessment of Numerical Procedures for Residual Stress Analysis of Multipass Welds", Welding Research Supplement pp.372s-382s 26. Argyris, J.H., Szimmat, J., and Willam, K. (1983), "Finite Element Analysis of Acr-Welding Process", Numberical methods in thermal problems, Proceeding of the Third International Conference, Seattle WA, USA, Pineridge Press, Swansea UK, pp.249-258 27. Murugan, S., Sanjai Rai, Kumar, P.V., Jayakumar T., Raj, B., and Bose, M.S.C. (1999), "Temperature distribution during welding and residual stresses in weld pads of low carbon steel and type 304 stainless steel", IWC99, pp.951-958 28. Chiarelli, M., Lanciotti, A., Sacchi, M. (1999), "Fatigue Resistance ofMAG Welded Steel Elements", International Journal of Fatigue, Vol.21 pp.1099-1110 29. Bari, S. and Hassan, T. (2000), "Anatomy of Coupled Constitutive Models for Ratcheting Simulation", International Journal of Plasticity, Vol.16, pp.381-409 30. Bari, S. and Hassan, T. (2001), "An Improved Constitutive Model for Multiaxial Ratcheting", To be Published in the International Journal of Plasticity (in Press)