Stress concentration factors at welds in pipelines and tanks subjected to internal pressure and axial force

In this paper, analytical expressions for stress concentration factors in pipes subjected to internal pressure and axial force are derived for a number of design cases based on classical shell theory. The effect of fabrication tolerances in simple butt welds is assessed. Analyses based on classical mechanics are compared with results from axisymmetric finite element analyses for verification of the presented methodology. Stress concentration factors are presented for circumferential butt welds in pipes welded together from pipes with different thicknesses, welds at buckling arrestors, welds at flanged connections in pipelines, and welds at ring stiffeners on the inside and the outside of the pipes. It also includes stress concentration factors at end closures in pipes for gas storage. Larger pipes are fabricated from plates with a longitudinal weld. This fabrication process introduces out-of-roundness in the pipes. The actual out-of-roundness is a function of internal pressure. An analytical expression for the bending stress in the pipe wall due to this out-of-roundness is presented. The derived stress concentration factors can be used together with a hot spot stress S–N curve for calculation of fatigue damage.     

响应面法模拟轴肩和搅拌针形状对铝合金搅拌摩擦的影响(英文)

The present paper discusses the modeling of tool geometry effects on the friction stir aluminum welds using response surface methodology. The friction stir welding tools were designed with different shoulder and tool probe geometries based on a design matrix. The matrix for the tool designing was made for three types of tools, based on three types of probes, with three levels each for defining the shoulder surface type and probe profile geometries. Then, the effects of tool shoulder and probe geometries on friction stirred aluminum welds were experimentally investigated with respect to weld strength, weld cross section area, grain size of weld and grain size of thermo-mechanically affected zone. These effects were modeled using multiple and response surface regression analysis. The response surface regression modeling were found to be appropriate for defining the friction stir weldment characteristics.     

等壁厚钢管桩横向焊缝应力集中系数的数值模拟

大型海洋工程结构多常用钢管桩,在钢管桩的制作和安装过程中通常会产生环向对接焊缝,由管节偏位引起的环向焊缝应力集中现象是焊缝疲劳热点应力评估和焊缝疲劳安全分析的重要影响因素.通过实用近似分析方法,研究在轴向拉力和平面内弯矩单独作用下等壁厚对接焊缝应力集中间题,得出等壁厚拉弯构件对接焊缝应力集中系数的近似计算公式;根据对钢...     

搅拌工具轴肩和搅拌头轮廓对铝合金搅拌摩擦焊的影响一对比研究(英文)

In marine application,marine grade steel is generally used for haul and superstructures.However,aluminum has also become a good choice due to its lightweight qualities,while rusting of aluminum is minimal compared to steel.In this paper a study on friction stir welding of aluminum alloys was presented.The present investigation deals with the effects of different friction stir welding tool geometries on mechanical strength and the microstructure properties of aluminum alloy welds.Three distinct tool geometries with different types of shoulder and tool probe profiles were used in the investigation according to the design matrix.The effects of each tool shoulder and probe geometry on the weld was evaluated.It was also observed that the friction stir weld tool geometry has a significant effect on the weldment reinforcement,microhardness,and weld strength.     

基于三线激光结构光的船体大拼接焊缝交叉类型辨识

为实现船壁面的大拼接焊缝的全自主移动除锈,提出一种基于三线激光结构光的激光视觉焊缝辨识方法。针对船体大拼接焊缝的纵横交叉,根据三线激光的特征,对描述激光形态和激光条纹间距的5个变量进行定义,归纳3条激光条纹在焊缝交叉处的特征参量的变化规律,建立十字形、T字形焊缝交叉的统一辨识模型。试验验证:采用三线激光具有更好的抗干扰性、信息量丰富,在各种工况下都能准确辨识焊缝接头交叉类型。研究结果为后续的焊缝实时跟踪和轨迹规划奠定基础。     

Structural behavior and design of high-strength steel welded tubular connections under extreme loading

The present work is motivated by the increasing need for cost-efficient solutions in offshore structural systems for wind energy production and for improvement of their structural performance. The structural behavior and design of high-strength steel welded tubular connections (yield strength higher than 700 MPa) subjected to monotonic and strong cyclic loading is investigated. In the first part of the paper, an experimental investigation is presented on high-strength steel tubular X-joints subjected to monotonic and cyclic loading far beyond the elastic limit of the material, leading to weld fracture. Two grades of weld metal material are employed in the welding process of the specimens. The experimental results indicate that the weld material grade has a significant influence on the deformation capacity of the welded connection under monotonic loading conditions, and its low-cycle fatigue life. The experimental procedure is simulated using advanced finite element models, elucidating several features of joint behavior and complementing the experimental results. Overall, a good agreement is found between numerical simulations and experimental results, in terms of both global response and local strains at the vicinity of the welds. Furthermore, the structural performance of the welded tubular joints under consideration is assessed using available design methodologies in terms of both ultimate strength and low-cycle fatigue resistance, in an attempt to validate an efficient design methodology for low-cycle fatigue. The results from this research effort are aimed at developing the necessary background for the possible use of high-strength steel in tubular steel lattice structures, particularly in offshore platforms for renewable energy production. They can also be used as a basis for the possible amendment of relevant design specifications and recommendations for including special provisions for high-strength steel structural systems.     

低强匹配焊接接头匹配特性研究

焊接接头的屈服强度匹配方式对接头的设计、制造工艺、裂纹敏感性以及破坏行为有重要影响,焊缝金属、母材、焊接接头强度以及焊接接头强度匹配系数的分布是焊接结构强度、寿命和可靠性计算的基础.文章介绍了对12Ni3CrMoV钢焊接接头屈服强度匹配系数的分布进行的研究,并给出了分析结果.作者认为控制母材和焊缝金属的屈服强度分布的标准差,是降低失配概率的主要途径.     

铝合金活性TIG焊接接头性能研究

针对6061铝合金,采用自行研制的混合活性剂配方,利用正交设计法进行焊接工艺试验,得到一组性能良好的焊接工艺参数。在此焊接工艺条件下,混合活性剂增加熔深效果显著,可一次焊透10 mm的铝板,实现单面焊双面成形。焊后对焊缝的微观组织进行了观察和分析,并通过力学性能试验分析了活性剂对焊缝力学性能的影响。结果表明：与常规TIG焊相比,活性TIG焊的焊缝组织细密,基本不存在气孔、裂纹、夹杂等焊接缺陷;活性TIG焊接接头的拉伸强度和断裂伸长率均可达到与母材相当的水平,焊缝区的硬度明显提高,焊接接头性能良好。     

MAG冷焊及其在轴失重型失效修复中的应用研究

针对轴和转子的失重型失效,比较了几种焊补方法的优缺点,选定熔化极混合气体保护冷补焊(MAG冷焊)修复方法,进行了大比尺模拟修复试验,并做了相应的金相、硬度分布和应力分析。试验结果表明,MAG冷焊方法可实现焊补焊缝与艉轴100%冶金结合,100%致密,无剥离风险,且与被修复件材质相近,既能保证失重轴强度恢复,又可有效的抑制焊接残余应力。     

大型核电厚壁结构X射线衍射法残余应力测试

采用X射线衍射法（ XRD）对大型核电厚壁结构堆芯板端面、堆芯板与吊篮筒体环焊缝焊前焊后残余应力进行无损测量。研究堆芯板端面、环焊缝焊前焊后残余应力的分布情况及变化规律。结果表明：堆芯板焊前残余应力主要是机加工应力,且焊接过程对其残余应力影响不大;1＃和2＃堆芯板环焊缝轴向残余应力分布趋势明显,呈现焊缝为压应力,母材为拉应力;测试的环向应力在各区域分布不一致;焊接对远离焊缝区域的应力没有影响,远离焊缝区域呈现较大的加工应力。     

不同强度匹配10CrNi3MoV船体钢焊接结构的安全评定

为了研究不同强度匹配对焊接接头安全性能的影响,基于"欧洲工业结构完整性评定程序(SINTAP)"提供的失效评定图FAD方法,针对不同强度匹配的10CrNi3MoV船体钢焊接接头,建立了对应的失效评定曲线。根据母材与焊缝的拉伸试验及CTOD(裂纹尖端张开位移)试验结果,对比分析了3种匹配条件下的接头安全评定结果。研究表明,对于选定的评定级别,不同强度匹配系数对FAD图形状的影响很小;焊缝强度较高时,接头对塑性失稳的抵抗能力取决于母材性能;接头韧度水平相似时,低匹配接头对塑性失稳及脆性断裂的抵抗能力均稍差,弱于等匹配与高匹配;焊缝强度稍高于母材的"等强匹配"安全裕度最大,安全性最佳。     

SAW焊接型剖面预报的模糊逻辑系统开发(英文)

A fuzzy model was presented to predict the weldment shape profile of submerged arc welds(SAW) including the shape of heat affected zone(HAZ).The SAW bead-on-plates were welded by following a full factorial design matrix.The design matrix consisted of three levels of input welding process parameters.The welds were cross-sectioned and etched,and the zones were measured.A mapping technique was used to measure the various segments of the weld zones.These mapped zones were used to build a fuzzy logic model.The membership functions of the fuzzy model were chosen for the accurate prediction of the weld zone.The fuzzy model was further tested for a set of test case data.The weld zone predicted by the fuzzy logic model was compared with the experimentally obtained shape profiles and close agreement between the two was noted.The mapping technique developed for the weld zones and the fuzzy logic model can be used for on-line control of the SAW process.From the SAW fuzzy logic model an estimation of the fusion and HAZ can also be developed.     

Weld toe versus root fatigue failure mode and governing parameters: A study of aluminum alloy load-carrying fillet joints

In load-carrying fillet welded connections, two fatigue failure modes are possible i.e. weld toe cracking and weld root cracking. The fatigue life associated with weld root cracking is typically much lower than weld toe cracking, exhibiting a wider scatter band, especially for welded aluminum alloys. This paper examines fatigue failure mode transition behaviors in load-carrying fillet welds made of aluminum and their governing parameters, among plate thickness, weld penetration, joint misalignment, weld material, and ultrasound impact peening(UIP). Through both experimental and theoretical studies, a quantitative fillet weld sizing criterion was proposed for avoiding weld root cracking in fillet-welded aluminum connections.     

Prediction of residual stresses induced by low transformation temperature weld wires and its validation using the contour method

Welding residual stresses are one of the main factors influencing the engineering properties of welded structures, and should be taken into account during designing and manufacturing products such as ships, bridges, etc. Recently, both computational and experimental methods play a significant role for providing residual stresses. The contour method (CM) became one of the most powerful techniques that can provide measurement of residual stresses normal to a plane of interest. In this method a component is cut at any plane of interest. Displacements normal to the cut surface are measured and then processed. Using the Thermal–Elastic–Plastic Finite Element Method (TEP-FEM), residual stresses after welding can be predicted. As well as, the elastic FEM can be used to reproduce residual stresses from measured longitudinal displacements in the CM.The main objective of this paper is to evaluate the effectiveness of different low transformation temperature (LTT) weld wires using TEP-FEM and the CM. In the simulation part, a computational approach is developed to numerically simulate both of welding and the CM. In the TEP-FEM, phase transformation is considered for LTT welds, additionally volume change and variation of mechanical properties with temperature are considered. In the simulated CM, welded specimens to be measured are replaced by TEP-FE models. Then the procedure of the CM is examined before applying it to real measurements. The simulated CM successfully predicted how the CM would reconstruct the residual stresses if applied experimentally. In the experimental part, welding is conducted using conventional and various LTT weld wires. Longitudinal residual stresses produced due to welding are measured using the CM. The results of TEP-FE simulation and the CM show the effectiveness of the different LTT weld wires in introducing compressive stresses in the weld. It is also observed that the applied LTT weld wires, which have almost the same martensitic transformation start temperatures, do not show big difference in the induced compressive residual stresses in the weld metal.     

Stress concentrations at butt welds in pipelines

This is a technical note that is written to correct a mistake made by the author and to add some significant information to an already published paper in Marine Structures 2008. An additional assessment of analysis result is used to enhance and substantiate conclusions on stress concentration at weld root in pipeline welds resulting from fabrication tolerances.     

船体结构填角焊缝的设计规范分析

说明船体结构角焊缝的受力分析及强度条件，阐明角焊缝剪切强度系数的涵义及其在填角焊缝设计中的应用。     

Effect of weld geometric profile on fatigue life of cruciform welds made by laser/GMAW processes

The effect of weld geometric profile on fatigue life of laser-welded HSLA-65 steel is evaluated. Presented are results of cruciform-shaped fatigue specimens with varying weld profiles loaded cyclically in axial tension–compression. Specimens with a nearly circular-weld profile were created at 133 cm/min, as part of this effort, with a hybrid laser gas-metal-arc welding GMAW (L/GMAW) process. The ability of the laser-welding process to produce desirable weld profiles resulted in fatigue life superior to that of conventional welds. Comparison of finite-element analyses, used to estimate stress-concentration factors, to the hot spot and mesh insensitive approaches for convergent cases with smooth weld transitions is presented in relation to the experimental results. When a geometry-based stress concentration factor is used, the fatigue tests show much less variability and can be lumped into one master curve.     

中厚板高强钢冷热多丝复合埋弧焊热循环参数测量

为解决中厚板高强钢埋弧焊(Submerged Arc Welding, SAW)焊缝热影响区(Heat Affected Zone, HAZ)热循环参数准确测量难题，自主研制多通道热电偶测温软/硬件系统，测量并比较不同焊丝组合(单丝和冷热多丝复合)对应的焊缝HAZ热循环主要参数。试验结果表明：与单丝SAW工艺相比，冷热多丝复合SAW工艺可解决SAW较大热输入产生的焊缝HAZ脆化问题，提高焊缝组织性能和焊接质量；在中厚板高强钢焊接过程中，冷热多丝复合SAW工艺可为温度场数值模拟计算分析提供实测数据，为各种工艺参数的确定与优化、焊缝HAZ的组织性能改善提供必要的理论基础。     

球扁钢对接工艺改进研究

球扁钢对接的新设计工装,可以重复使用,拆除时不需割除,避免马脚焊缝补涂,可以节省传统方法中大量使用卡马的工装材料,节省相应的工时物力。通过试验,比较采用传统方法和新工装的球扁钢对接焊缝的无损探伤质量,分析了在分段建造阶段的工艺改进作了可行性研究。     

The effect of weld residual stress on fracture toughness at the intersection of two welding lines of offshore tubular structure

Due to the spatial complexity and fabrication characteristics of offshore platforms, it is inevitable to encounter overlaps or proximity of weld lines in tubular joints. Several international standards such as American Petroleum Institute (API), American Welding Society (AWS), and American Institute of Steel Construction (AISC) regulate the minimum distance between primary weld beads; however, any logical and detailed background of this limitation has not been presented. For a non-compliant weld joint where the regulation is not met, fracture toughness calculation is a typical index to verify the structural integrity.This research consists of two parts. First, weld residual stress distributions are calculated by a 3D thermo-mechanical nonlinear Finite Element Analysis. Two crossing welds, a T-weld crossing on a butt weld, are simulated in one model. A separate tee and a butt welding simulations are also performed for a comparative purpose. Second, SIFs and J-integral values are calculated at the surface and deepest crack tip locations for four different types of semi-elliptical surface cracks. Four cracks are embedded into the weld model and the residual stress distribution from the 3D thermo-mechanical FEA are mapped to a 3D FE crack model as initial conditions. An additional axial tensile load is also imposed. SIF values are compared with those using the weighting function method for the butt weld model subject to three load cases, i.e., tensile stress only, weld residual stress only, and both of them. From the simulation, a tubular joint containing a chord girth weld intersected with weld beads of brace is found to show lower the SIF values than that having only a girth weld on chord.