Peas ae a Pannen, ¢ DRGwebinars Sharing and exchanging knowledge OS oes nl f fe | Fatigue Assessment cole ASME B&PV vill ie given by dr.ir. Frahk Bos = fa \ ~ ——— di F a So | f fi re bes \ 4 a E Dyna low Research GroupDynaflow Research Group Introduction = Pressure vessels are often subjected to cyclic loading of both pressures and temperatures = These cyclic loading is often the primary cause of fatigue failure at welded locations = Fatigue analysis is not covered by standard code calculations = Design by Analysis methods are required, allowing the use of Finite Element Analysis = The objective of this webinar it to provide an overview of the fatigue analysis approach according ASME B&PV Code Section VIII, Division 2. ‘© Dynatiow Research Group, all gf resered ‘Speaker: Dr. ir. Frank BosDynaflow Research Group Agenda Introduction to welding Fatigue analysis using Design by Analysis Fatigue assessment according to ASME and EN design codes Fatigue assessments of welds using FEA ‘© Dynafow Research Group, all ors reservedDynaflow Research Group Fatigue failures often occur at welded connections Failure at connection of flange and pipe _Failure due to lack of fusion Cd © Dynatow Re 2 Group, a nes reseedDynaflow Research Group Different types of crack failures = Transverse crack — Crack in longitudinal direction of the weld " Toe crack — Crack initiated at the toe of the weld through base shell/plate ™ Underbead crack — Crack on the rim of the underbead and base shell/plate ™ Root crack — Crack initiated at the root of the weld ‘© Dynaow Research Group, all grt reseredDynaflow Research Group Static calculations to assess weld strength Weld strength capacity depends on weld pattern, throat size and weld material Manual calculation procedure Stress acting on the weld ® Step 1: Calculation of pattern properties (areas, moments of inertia) ® Step 2: Calculation of shear (f,, f,) and axial (f,) forces based on the global forces, moments and weld properties ™ Step 3: Calculation of resultant force fy, (N/mm) = Step 4: Compare force f,, (N/mm) with allowable shear force of weld material: 1 ar, 1 fu Ste5 Sur f= Jf? + fa + fa? < te 3 Surs ‘© Dynafow Research Group, al gts reservedDynaflow Research Group Different weld types in pressure vessels Detailed geometry needed to estimate the throat and inertia properties Types of weld geometry Weld area terms (full pen and fillet) eo weatoe ror = “Tt pentaton Weidtoe =1 een dt = ‘© Dynafiow Research Group, all gts reservedDynaflow Research Group Joint efficiency Used in static design in pressure vessels (ASME VIII-1) and piping (ASME B31) Strength of the weld with respect to the strength of the parent metal (shell) Strength of the weld Strength of the parent metal Joint Efficiency, E = For a weld as good as the parent metal: E = 1.00 For a weld weaker than the parent metal: E < 1.00 Joint efficiency depends on weld type and degree of radiographi inspection ry ASME VIII-1 UW-12 provides an overview of the most relevant joint efficiency values Joint efficiency used for governing welds (Long./Circ. welds) ‘© Dynaow Research Group, all gts reservedDynaflow Research Group Agenda Introduction to welding Fatigue analysis using Design by Analysis Fatigue assessment according to ASME and EN design codes Fatigue assessments of welds using FEA Fina P<—. ‘© Dynatow Research Group, all gts reseredDynaflow Research Group Is fatigue analysis important? YES, a large number of failures occur due to fatigue = The Health and Safety Executive in the UK found that 25% of all severe failures were a result of fatigue = DNV reported that 25% of all serious failures are related to fatigue mechanisms = Surveys indicate that the overwhelming majority of fatigue failures occur at welds = We may not hear about fatigue failures, but this does not mean they do not occur Aloha Airlines Flight 243 ‘© Dynatow Research Group, all grt reseredDynaflow Research Group High cycle and low cycle fatigue assessment Weld assessment conform ASME VIII-2 and EN13445 Relevant failure mechanisms Fatigue is governed by cyclic stresses ® Low Cycle Fatigue: Damage accumulation due to oscillating stress/strain (LCF), typically ' occurs for less than 7000 cycles ares ® Ratcheting: Incremental collapse (Ratcheting) = High Cycle Fatigue: Crack initiation, pean stess progresses with crack growth, and finally fracture (HCF), typically occurs for more than 7000 - 10,000 cycles = LCF checked against Sps (2*Syie) = HCF checked against fatigue curve (S-N) for yes N the applicable material ‘© Dynafiow Research Group, all gts reserved "Dynaflow Research Group High cycle fatigue depends on peak stresses HCF is the governing failure mechanism at notches and welds High Cycle Fatigue * Crack initiation and propagation = Fracture due to unstable crack growth * Capturing of peak stresses in the model ® Peak stresses originate at notches in the model Low Cycle Fatigue = Accumulation of strain * Capturing the structural stresses (membrane + bending) = Peak stress is not resolved ‘©Djnatow Research Group, a nats reservedDynaflow Research Group Crack initiation and propagation High cycle fatigue Crack initiation Crack propagation = Under cyclic loading containing a tensile ® component, local yielding causes micro cracks, although the nominal stress < S, . Stress concentration around the crack tip Each time the stress becomes tensile, the crack tip grows a small amount = In ductile material, additional slip bands (shear deformation) are generated in the crystalline = Propagation stops at compressive stress structure of the metal, leading to cracks * Brittle material develop cracks more easily (no yielding) ‘© Dynafow Research Group, al gts reserved (momentarily) = Crack propagation is due to tensile stress and grows along planes perpendicular to the maximal tensile stress Preart Psin(t)Dynaflow Research Group Peak stresses originate at a concentration General concept of stress concentration Stress concentration factor is a stress intensification factor which accounts for the effect of a local structural discontinuity (stress concentration) on the strength of the configuration S (at the notch) SCF= S(away from the notch effect) SCF is determined by elastic analysis, analytical approaches or by means of Finite Element techniques ae Re Smax — From ‘© Dynaow Research Group, al gts reserved “4Dynaflow Research Group Different fatigue assessment methods Fatigue assessment methods are classified by type of used code stresses Common stress definitions used in various PVP design codes: 1. Nominal stress — Stress away from discontinuity (F/A or M/Z) 2. Structural stress - Membrane + bending stress 3. Notch stress — Peak stress at the point of failure 4. Hot spot stress - Extrapolated surface stresses The design code (ASME, EN, e.g.) allow one or more of these definitions Every fatigue analysis method is based on the corresponding stress definition (these stress definitions are not interchangeable) ‘© Dynaow Research Group, all gts reserved 5Dynaflow Research Group Common fatigue codes used for pressure vessel and piping industry Stress definitions used by some of the common fatigue codes in pressure vessel and piping industry: Code Stress definitions for fatigue Roe Notch Stress (welded, unwelded, bolts) Structural Stress Notch Stress (bolts only) Structural Stress Notch Stress (unwelded & bolts only) Structural Stress BS-5500 EN-13445 ASME B31 Piping codes | Nominal Stress Other guidance given by IIW, NORSOK, DNV, AWS, AISC, ASME FFS-1, AD-Merkblatter, CODAP, etc... ‘© Dynaow Research Group, al gets reservedDynaflow Research Group The nominal fatigue stress method Generally used in ASME B31 piping codes and construction codes (AISC, AWS) Easy to use, the weld area is not included in the method The nominal stress is usually F/A or M/Z, usually a membrane stress Mark''s testing of pipes with girth welds is the basis of the ASME B31 piping codes and relies on the nominal general bending stress in relation to Stress Intensity Factors (SIFs) Nominal Stress = F/A Nominal Stress = M/Z AISC: American institute for Steel Construction, ‘AWS: Americal Welding Society ‘© Dynatow Research Group, all gets reserved 7Dynaflow Research Group The hot spot fatigue stress method Useful for geometrical singularities The hot spot stress is an extrapolated stress at the failure site Surface stress extrapolation to exclude non-linear singularities The through the wall stress is not captured. In case that the shear stress dominates, through the wall, the surface stresses are under-predicted IIW utilizes the Hot Spot Stress method, other codes PD/BS-5500 only refers to this method Extrapolated Stress at Weld Toe (Hot Spot) ‘© Dynatow Research Group, a ngs reserved 8Dynaflow Research Group Factors influencing fatigue life Uncertain factors that have influence on the allowable number of cycles Load history and type of stress (bending versus membrane) Notch details & geometric concentrations Surface finish & quality of weld at the toe (inspection quality) Environment Thickness Residual welding stresses Mean static stress level ‘© Dynatiow Research Group, al gts reserved 19Dynaflow Research Group Agenda Introduction to welding Fatigue analysis using Design by Analysis Fatigue assessment according to ASME and EN design codes Fatigue assessments of welds using FEA ‘© Dynaow Research Group, all grt reservedDynaflow Research Group Fatigue design rules for welds in pressure vessel and piping codes Fatigue design rules for welds in the ASME boiler and pressure vessel code are based on: "= Fatigue Strength Reduction Factors (FSRF) " Code specific fatigue design curve generated from smooth base metal specimens without the presence of the welds ASME B31 Piping Codes use: = Stress Intensification Factors (SIF) = SIFs based on component S-N curves with a reference fatigue strength based on straight pipe girth welds conducted by Markl in 1950s Extensive fatigue testing to determine FSRFs and SIFs to take into account the stress concentration effects associated with: = Various types of component geometry, = Weld configuration, = Environmental effects, = Loading conditions. ‘© Dynaow Research Group, all gts resend aDynaflow Research Group Two main fatigue calculation methods in ASME VIII-2 Polished Bar Method (based on Notch Stress) = ASME VIII-2 coded releases before 2007 ® Determination of the “peak stresses” and comparing it to the S-N curves = Peak stresses can be calculated using FEA or approximated using FSRF’s Welded Method (based on Structural Stress) = ASME VIII-2 code releases after 2007 ™ Determination of “structural stresses” (linear far field stresses required to obtain general equilibrium) in the model. = Structural stresses are used to estimate the relevant peak stresses. = Effects of welds on the fatigue strength is accounted for in the Master S-N curve The method chosen willl depend upon the code of construction and/or contractual agreements. ‘© Dynatow Research Group, all gts resered 2Dynaflow Research Group Background of fatigue S-N curves EN and ASME codes related to Markl’s experiments (1950s) EN13445 and ASME VIIl-2 fatigue curves derived from Markl’s experiments (1950s) "= S-N curves are based on Mark's fatigue experiments (B31) on straight pipes with a girth (butt) weld ™ Design S-N curve based on smooth bar experiments for welded and un-welded parts = Design margins based on probabilistic (welded) and deterministic (unwelded) approach ‘or Sore ar cee gee Code Cycles | Stresses 8 EN-2, A-201, 5 ‘ASME Vil-2 | 20" 2.0 gx =”) EN 13445 10 15 é =o “Including three subfactors: #3 ~ Data scatter: 20 E34 = Sax effect 25 8 = Environmental, roughness: 4.0 wo ‘© Dynaow Research Group, all ots reserved FyDynaflow Research Group Polished bar method utilizes the notch peak stress Polished bar method is based on the prediction of the notch peak stress (M+B+F) The notch peak stress can be decomposed in membrane, bending and peak stresses Polished bar method is easy to implement using Finite Element Analysis techniques Polished bar method can be used for “welded and unwelded” components Polished bar method is allowed in ASME VIII-2 code released before and after 2007 Notch Stress ‘© Dynatiow Research Group, all gts reserved EyDynaflow Research Group Fatigue Strength Reduction Factor (FSRF) Required to calculated the notch stress based on the structural stress Fatigue strength reduction factor is a stress intensification factor which accounts for the effect of a local structural discontinuity (stress concentration) on the fatigue strength 5; (component without discontinuity or weld joint) 5; (component with discontinuity or weld joint) FSRF = Weld FSRF combines stress concentrations and other weld related effects on the reduced fatigue strength. ASME VIII-2 EN 13445 paisa vet sue Fg mci Fc ea ee = —— ae ee i. Ct SS ee ‘© Dynaiow Research Group, all ght reserved aDynaflow Research Group Weld Inspection Quality Fatigue Strength Reduction Factors depend on weld inspection levels Different inspection methods FSRF depends on inspection level = Volumetric inspection = Radiographic testing (RT) ‘Weld Surface Fatigue Strength Reduction Factors = Ultrasonic testing (UT) = Surface inspection = Magnetic particle (MT) = Penetrant testing (PT) ® Visual inspection (VT) {Svar meno hme ‘© Dynatiow Research Group, al oft reservedDynaflow Research Group Notch peak stress compared with S-N curves Design margin depends on uncertain factors (i.e. environment, surface finish) Notch peak stress compared to the applicable S-N curve of code for a specific material Design margin of the curve is 2 wrt. stresses and 20 w.r:t. cycles. This is no safety margin, but covers effects that can influence fatigue life, but were not investigated in the tests that provided the date for the S-N curves (i.e. environment, surface finish) When the secondary stress exceeds Spc, the additional plasticity is corrected by a fatigue penalty factor K, ‘© Dynatiow Research Group, al gets reserved aDynaflow Research Group Structural stress method ignores peak stresses Allowed by ASME VIII-2 after 2007 (welded fatigue curves) Relies on prediction of structural stress range The structural stress is defined as the membrane + bending stress required to satisfy general equilibrium of the structures Calculation of the peak stress (F) from FEA calculation is not required Peak increment (F) ‘© Dynafow Research Group, al gts resered FyDynaflow Research Group Structural stress method ignores peak stresses Effect of the notch is available in the Master S-N curve The method is generally insensitive for FEA accuracy (no resolving of peak stress) Master S-N curves are determined for welded geometries (including notch effect) No Fatigue Strength Reduction Factors (FSRF) needed Structural stress method is generally preferred above the classical polished bar approach The structural stress method may only be used if approved by the purchaser or the owner ‘© Dynatiow Research Group, all gts reservedDynaflow Research Group Agenda Introduction to welding Fatigue analysis using Design by Analysis Fatigue assessment according to ASME and EN design codes Fatigue assessments of welds using FEA ‘© Dynafow Research Group, all oft reservedDynaflow Research Group Fatigue analysis of the weld using FEA Beam, shell and brick = Two types of FEA models can be used in the analysis - Beam models only resolve nominal stresses - Shell elements (only solving linearized membrane and bending stresses) - Brick elements (resolving membrane, bending and peak stresses) = Shell and beam models do not capture fatigue stresses (these models rely on FSRFs and SIFs) = Both polished bar method or Welded method can be used with all FEA techniques, as long as the applicable S-N curve is known and the owner allows to use the welded method Bis ee ( & ‘© Dynatow Research Group, all gh reservedDynaflow Research Group Fatigue analysis of the weld using FEA shell models = Linearized membrane and bending stresses need to be multiplied by an appropriate Fatigue Strength Reduction Factor (FSRF) when the Polished bar method is used = When performing Welded method calculations, the stresses are directly obtained Table 5.11 Weld Surface Fatigue-Strength-Reduction Factors a a — — ‘Ascmided Lae mn i Lo les im “0 Pl src sachs 4 las] fzo as 159 law Ppetaireraion [rt swtceasoniee]na [4 fy foo Jes Ja a It Is Ia na fan dn Tau ‘© Dynatow Research Group, all ors reservedDynaflow Research Group Fatigue analysis of the weld using FEA brick models = Brick Models can capture fatigue stresses Peak stresses at the weld toe since resolution exists through the wall of the model Singularity at Weld Toe = Iflinear-elastic stress models are used notches should always have finite rounding's to obtain bounded stresses. = To perform a polished bar calculation the notches should be modelled in detail or the stresses should be linearized and multiplied with an applicable FSRF Va = When performing a welded method NO singularity calculation the stresses should be here linearized to obtain the membrane and bending components ‘© Dynatow Research Group, al gh reservedDynaflow Research Group Using FEA brick models a high quality mesh is needed Stress linearization to exclude the peak stresses Mesh required for structural stress Mesh required for notch stress (peak) ‘© Dynatiow Research Group, all gf reservedDynaflow Research Group How to select the appropriate FEA model? = Shell FEA models only provide membrane and bending stresses, so FSRF required to predict the peak stress = Brick FEA models also provide peak stresses, but more difficult and expensive to model accurately. Therefore, often linearised in combination with a FSRF Type Structural Stress Peak Stress (LCF and Ratcheting) (HCF Assessment) Part of solution Needs to be approximated by a FSRF Brick Part of solution, = Part of the solution (required detailed obtained by linearization modelling of the weld) = Linearization + application of FSRF (no detailed modelling of weld required) ‘© Dynatow Research Group, all gts reseredDynaflow Research Group Accumulative damage approach = If your problem consist of more different fatigue cycles, the fatigue damage for each cycle should be determined separately = Determine for each cycle the stress ranges and allowable number of cycles = The total damage can than be determine from Cumulative Damage Approach using Miner's rule: mH na nmi eee ea aur y= 10 time ‘© Dynatow Research Group, al gf reseriedDynaflow Research Group Cycle counting = When the fatigue cycles are much more random, it is often difficult to distinguish individual fatigue cycles = Methods like Rain Flow Counting can be used to count the repeating cycles = Then for each of these cycles different FEA runs can be made. ‘© Dynafow Research Group, all ges reseredDynaflow Research Group Fatigue assessment of a welded hub connection Problem description Geometry and FEA model Full penetration V-weld 2obarg | ---- 1Sbarg ‘© Dynatow Research Group, al gf reserved Example 1 Operating and modeling data "= Two different cycling loads are present — Pressure from 0 to 20 Barg (Nightly) (1) = Pressure from 0 to 15 Barg (Daily) (2) - Constant temperature "= Required number of cycles 25,000 for each cycle (1) and (2) = Carbon steel, ASME S-N curve Table 3-F.1-2 = Check the full penetration V-weld regarding High Cycle Fatigue > Resolve the peak stress induced by the hub curvatureDynaflow Research Group Fatigue assessment of a welded hub connection Stress calculation by means of linearization Stress ranges results Stress cycles Structural | FSRF | Fatigue stress range stress range Daily cycle (1) 240 15 360 Nighly eyele (2) 133, 15 200 ‘© Dynatow Research Group, all gts reserved High cycle fatigue assessment = Calculate structural stress ranges by linearizing stress intensities (Von Mises or by stress tensor components) = Determine Fatigue Strength Reduction Factor (ASME or EN) = Calculate fatigue stress ranges by multiplying the structural stress range with the according FSRF = Fatigue stress range will be used to determine the allowable number of cycles Example 1 ”Dynaflow Research Group Fatigue assessment of a welded hub connection °°" Determination and assess fatigue stresses Fatigue Strength Reduction Factor Accumulative Damage Approach = ASME Code only defines FSRF for types of 9 welds a = ASME disregards the influence of geometry effects like hubs = ASME prescribes a FSRF of 1.0 for a machine full penetration weld that receives volumetric, surface and visual inspection. If it ” is not machined, FSRF is 1.2. ueesampreuce fra Numbert ees = EN13445 specifies the influence of geometry =" Required number of cycles 25,000 for each and inspection using cartoons and weld cycle (1) and (2) classes. This leads to a FSRF of 1.5 = Accumulative damage approach (PASS) Ful penetration was rade tom [80 |e ‘| on fen sto ores neh pu pena ba ‘© Dynatow Research Group, all gts reserved eyDynaflow Research Group Fillet-weld throat failure Samer? = Acommon pipe support is a flat plate that is fillet welded to a vessel, structure or another pipe For this case the following fatigue design parameters are used: - ASME VIII-2: FSRF = 4.0 (cannot inspect the root of the fillet weld) ~ EN13445: Class 32 ats poreraton atin made or J by ‘bot ae (eta 0) DDD nang eaten | re L Throat Failure ~ [. = EN13445 uses the average stress on the weld throat (S = F/2a) ™ ASME S-N method uses the equivalent stress based on linearized M+B stress on the weld throat ‘© Dynatow Research Group, all gts reservedDynaflow Research Group DRG leading Engineering Consulting firm Focused on three activities ‘© Dynatow Research Group, a nats reservedJoin DRG on Social Media Follow us on Linkedin: https://www.linkedin.com/company/dynaflow-research-group Read the DRG Blog: www.dynaflow.com/engineering-blog ‘Subscribe to our newsletters: www.dynaflow.com/news Houtsingel 95 2719 EB Zoetermeer The Netherlands Dynaflow Research Group Reg nr. 27320315 T +31 79361 5150 F 431 793615149 E info@dynaflow.com W www.dynaflow.com