Effect of pitting corrosion on the ultimate strength of steel plates subjected to in-plane compression and bending

Corrosion pits with a circular cone shape are typically observed on coated hold frames of aged bulk carriers which carry exclusively coal and iron ore. In order to ensure the safety of these types of bulk carrier, it is necessary to understand the effect of pitting corrosion on the local strength of hold frames. In order to investigate this effect, a series of nonlinear finite-element (FE) analyses has been performed with pitted plates subjected to in-plane compressive loads and bending moments. It has been shown that the ultimate compression load or bending moment of pitted plates is smaller than that of uniformly corroded plates in terms of average thickness loss, and that predictions of the ultimate strength using the average thickness loss at the minimum cross section would be conservative. In order to establish a method of evaluating strength reduction due to pitting corrosion, it is important to identify the failure mode that would be most detrimentally affected by pitting corrosion. It was found that the reduction of the ultimate compressive load or bending moment due to pitting corrosion is smaller than that of the tensile strength in terms of equivalent thickness.     

Effect of pitting corrosion on local strength of hold frames of bulk carriers (2nd Report)—Lateral-distortional buckling and local face buckling

Pitting corrosion is typical corrosion observed on coated hold frames of bulk carriers which exclusively carry coal and iron ore. In order to secure the safety of these types of bulk carriers, it is important to understand the effect of pitting corrosion on local strength of hold frames.

In order to investigate this effect, a series of 4- and 3-point bend tests on structural models which consist of web, shell and face plates has been carried out. Artificial pitting was created on the web plate to simulate pitting. In the 4-point bend tests, two equal concentrated loads have been applied vertically at the one-third points of simply supported models so that compression load due to bending would act on the face plate. In this testing condition, lateral-distortional buckling occurred before reaching the ultimate strength and local buckling of the face plate was observed after reaching the ultimate strength. The effect of web plate pitting on the lateral-distortional buckling strength was found to be small but the ultimate strength decreases with increase in the degree of pitting intensity. In the 3-point bend tests, concentrated load has been applied vertically at the center of simply supported models so that compression load due to bending would act on the face plate. In this testing condition, local face buckling occurred just after reaching the ultimate strength. The ultimate strength is found to be decreasing with increase in the degree of pitting intensity.

A series of non-linear FE analyses has been performed to simulate the deformation behavior observed in the tests. It has been revealed that even in the case of randomly distributed pitting corrosion the ultimate strength of the structural models was almost the same as that of the structural models with uniform corrosion corresponding to the average thickness loss.     

Experimental and numerical study of localized pitting effect on compressive behavior of tubular members

Locally pitted tubular members are usually considered as stub columns to assess the ultimate strength. However, it is not suitable for those with relatively larger slenderness ratios as their failure behavior is more complex and closely related to corrosion features of localized pitting. This paper presents compressive column tests on locally pitted tubular members of a moderate slenderness ratio. Corrosion pits were artificially introduced on local surface of the members, forming corrosion patches with various corrosion features. A numerical modelling method was proposed to reproduce the test specimens. Localized pitting damage was proven to cause substantial declines in the load deformation capacity and ultimate strength, and have a significant effect on the failure mode. The failure of a pitted member is mostly initiated by local buckling after yielding occurs in the corrosion patch, concurrent with pitting closure, and even shear cracking of member wall due to the perforated pits. Moreover, shape change of the corrosion patch most likely results in the failure mode to alter from column buckling to local buckling or interactive buckling. The shape ratio of the corrosion patch is one of the critical factor to influence the ultimate strength of locally pitted members. The proposed modelling method is applicable for extensive stochastic simulations so as to develop an empirical formula and to clarify the probabilistic characteristics of ultimate strength.     

Compressive strength of tubular members with localized pitting damage considering variation of corrosion features

Localized pitting corrosion often occurs on marine and offshore structures in the form of patch corrosion with great uncertainties in the location, size and shape. The variation of corrosion features affects ultimate strength of tubular members significantly, but it is still not well understood. This paper presents a numerical study on tubular members of diverse slenderness ratios to clarify the localized pitting effect on ultimate strength. Numerical analyses were performed based on novel models of pitted members that were calibrated against benchmark column tests. Corrosion pits were randomly introduced on the local outside surfaces of members via stochastic simulation, forming corrosion patches varied in the location, size and shape. Numerical results obtained were regressed to propose a unified empirical formula to predict ultimate strength. It turned out that the shape of the corrosion patch has a significant influence on the ultimate strength. The shape change of the patch can alter failure modes of medium length columns. The reduction of ultimate strength is closely related to the shape ratio of the patch besides the volume loss of corroded material. The unified empirical formula incorporating the shape ratio and the volume loss shows a good ability to predict the experimental results.     

含坑点腐蚀的深海耐压球壳有限元分析

对于含坑点腐蚀等局部缺陷的球壳结构,由于结构的不连续性以及缺陷部位应力状态的三维特性,因此很难用传统的连续介质理论及板壳理论进行求解。为了对含坑点腐蚀的球壳的强度、稳定性进行精确分析,文中分别采用坑点腐蚀壳体单元(Pitting Corrosive Shell Element,PCSE)、基于多点约束(Multipoint Constraint,MPC)的壳体单元-实体单元集成以及实体单元三种方法进行对比计算,对比结果表明,采用PCSE方法的计算效率最高,且计算结果的精度满足工程应用要求。最后,基于PCSE方法并通过方差分析,讨论了坑点腐蚀对球壳强度及稳定性的影响。     

Strength and deformability of corroded steel plates under quasi-static tensile load

The objective of this study was to estimate the strength and deformability of corroded steel plates under quasi-static uniaxial tension. In order to accurately simulate this problem, we first estimated the true stress–strain relationship of a flat steel plate by introducing a vision sensor system to the deformation measurements in tensile tests. The measured true stress–stain relationship was then applied to a series of nonlinear implicit three-dimensional finite element analyses using commercial code LS-DYNA. The strength and deformability of steel plates with various pit sizes, degrees of pitting intensity, and general corrosion were estimated both experimentally and numerically. The failure strain in relation to the finite element mesh size used in the analyses was clarified. Two different steels having yield ratios of 0.657 and 0.841 were prepared to examine the material effects on corrosion damage. The strength and deformability did not show a clear dependence on the yield ratios of the present two materials, whereas a clear dependence was shown with respect to the surface configuration such as the minimum cross-sectional area of the specimens, the maximum depth of the pit cusp from the mean corrosion diminution level, and pitting patterns. Empirical formulae for the reduction of deformability and the reduction of energy absorption of pitted plates were proposed which may be useful in strength assessment when examining the structural integrity of aged corroded structures.     

Ultimate strength assessment of simply supported pitted platings: A new stochastic approach based on Monte Carlo simulation

The ultimate strength assessment of platings affected by random corrosion wastage is a key factor for the reliable design of new ships and the structural health monitoring of aged structures, as pitting corrosion wastage significantly affects the ultimate capacity of platings under compression. In this respect, significant efforts have been undertaken in the last decade to assess the ultimate strength drop-off of pitted platings under compression and several interpolating design formulas, based on a large number of FE simulations, have been developed. Nevertheless, current Rules and guidelines don't provide any explicit strength check criterion for pitted platings. Hence, the main aim of current research is the development of a new framework for the ultimate strength assessment of pitted platings, based on a stochastic approach and the endorsement of Monte Carlo simulation. A new formula, which allows evaluating the statistical properties of the plating ultimate strength in presence of random corrosion wastage, is developed. Subsequently, a benchmark study is carried out, to compare the new formula with the existing ones available in literature and a wide set of FE simulations, carried out by Ansys APDL. Current results are discussed, and the effectiveness of the new formula is verified.     

特征载荷下海工管状结构屈曲临界载荷分析

圆柱形管状结构在海洋工程领域中应用较多,在进行结构设计时,需重点关注其侧向受载时的屈曲强度问题。通过理论分析和数值模拟,对比研究径向线性载荷变化下圆柱壳的屈曲行为,以经典的Donnell壳体理论为基础,得到圆柱壳的屈曲控制方程,并通过本征值分析方法得到结构屈曲的临界条件。采用有限元软件ABAQUS对线性变化径压下圆柱壳的屈曲进行数值仿真。分析得出径厚比是径向线性分布载荷下圆柱壳屈曲临界载荷的主要影响因素,三角形径压下屈曲临界载荷值约为均布径压下屈曲临界载荷值的2倍。     

点蚀损耗对船体梁极限强度的影响（英文）

The paper focuses on the assessment of the hull girder ultimate strength,combined with random pitting corrosion wastage,by the incremental-iterative method.After a brief review about the state of art,the local ultimate strength of pitted platings under uniaxial compression is preliminarily outlined and subsequently a closed-form design formula is endorsed in the Rule incremental-iterative method,to account for pitting corrosion wastage in the hull girder ultimate strength check.The ISSC bulk carrier is assumed as reference ship in a benchmark study,devoted to test the effectiveness of the incremental-iterative method,by a comparative analysis with a set of FE simulations,performed by Ansys Mechanical APDL.Four reference cases,with different locations of pitting corrosion wastage,are investigated focusing on nine combinations of pitting and corrosion intensity degrees.Finally,a comparative analysis between the hull girder ultimate strength,combined with pitting corrosion wastage,and the relevant values,complying with the Rule net scantling approach,is performed.Based on current results,the modified incremental-iterative method allows efficiently assessing the hull girder ultimate strength,combined with pitting corrosion wastage,so revealing useful both in the design process of new vessels and in the structural health monitoring of aged ships.     

半圆环壳型肋骨加强的耐压圆柱壳结构稳定性研究

耐压圆柱壳通常采用环肋加强以提高在静水外压作用下的结构稳定性.本文提出了半圆环壳型肋骨加强的耐压圆柱壳结构形式,在理论和模型试验研究的基础上建立了设计计算方法.研究结果表明:半圆环壳型肋骨与耐压壳板有两个连接点,减小了相邻两肋之间的净距离,能较大幅度地提高肋间壳板的稳定性;由于半圆环壳型肋骨侧向稳定性较大,合理设计半圆环壳半径和厚度,增加半圆环面内惯性矩,可以较大幅度地提高耐压壳总体失稳压力.     

Computation of ultimate strength of locally corroded unstiffened plates under uniaxial compression

Over the past decades there have been many losses of the merchant vessels due to either accidents or exposure to large environmentally induced forces. The potential for the structural capability-degrading effects of both corrosion and fatigue induced cracks are of profound importance and must be both fully understood and reflected in vessel's inspection and maintenance programme. The present study is focused on assessing the effects of localized pitting corrosion which concentrates at one or several possibly large area on the ultimate strength of unstiffened plates. Over 256 nonlinear finite element analyses (FEA) of panels with various locations and sizes of pitting corrosion have been carried out. The multi-variable regression method is applied to derive new formulae to predict ultimate strength of unstiffened plates with localized corrosion. The results indicate that the length, breadth and depth of pit corrosion have weakening effects on the ultimate strength of the plates while plate slenderness has only marginal effect on strength reduction. Transverse location of pit corrosion is also an important factor determining the amount of strength reduction. When corrosion spreads transversely on both edges, it has the most deteriorating effect on strength. It was also found out that the proposed formulae can accurately predict the ultimate strength of unstiffened plate with localized corrosion.     

钢筋坑蚀对混凝土柱偏压性能的影响

坑蚀是混凝土钢筋锈蚀的主要形式之一。与钢筋均匀锈蚀相比,钢筋坑蚀具有显著的不确定性和更大的截面损失等特点,对混凝土构件的性能具有一定的影响。借助Monte Carlo模拟,分析了锈蚀钢筋混凝土柱的偏压抗力性能,研究了钢筋坑蚀对混凝土偏压柱承载能力的影响。结果表明,钢筋坑蚀的随机性对柱的可靠性有很大影响,钢筋坑蚀构件承载力的下降速度比均匀锈蚀更快,对柱的耐久性具有潜在危害。     

Experimental assessment of the ultimate strength of a box girder subjected to severe corrosion

The objective of this paper is to describe the experimental assessment of the ultimate strength of a severely corroded box girder subjected to a uniform bending moment resulting from four-point loading. Three box girders that could simulate the behaviour of midship sections have been deteriorated in corrosive seawater environment to simulate different levels of corrosion degradation of ageing ship structures. During the deterioration process, various parameters have been controlled and the total weight lost was registered. Corroded plate thicknesses have been measured in 212 points and a statistical analysis has been performed. The resulting corrosion wastage has been fitted by a non-linear time variant degradation model. The experimental results of the ultimate strength test of a severely corroded box girder subjected to a four-point loading have been analysed. The load-displacement and moment-curvature relationship is discussed, different failure modes are identified, and the strain gauges readings are analysed.     

Propagating buckles in corroded pipelines

Rigid–plastic solutions for the steady-state, quasi-static buckle propagation pressure in corroded pipelines are derived and compared to finite element predictions (ABAQUS). The corroded pipeline is modeled as an infinitely long, cylindrical shell with a section of reduced thickness that is used to describe the corrosion. A five plastic hinge mechanism is used to describe plastic collapse of the corroded pipeline. Closed-form expressions are given for the buckle propagation pressure as a function of the amount of corrosion in an X77 steel pipeline. Buckles that propagate down the pipeline are caused by either global or snap-through buckling, depending on the amount of corrosion. Global buckling occurs when the angular extent of the corrosion is greater than 90°. When the angular extent is less than 90° and the corrosion is severe, snap-through buckling takes place. The buckle propagation pressure and the corresponding collapse modes also compare well to finite element predictions.     

阴极保护30年码头钢板桩腐蚀状况

钢板桩入海35年,阴极保护运行30年。未发现板桩有腐蚀穿孔、腐蚀破损等现象,平均腐蚀减薄0.84 mm,平均蚀余厚度是原始厚度的95%;腐蚀减薄从大到小依次为水位变动区、浅水区、水中区和泥面区,泊位中段一根凸桩浅水区位置的减薄最大,为2.60 mm;凸桩和凹桩的平均蚀余厚度相差不大,凸桩不均匀腐蚀大于凹桩。阴极保护有效地抑制了海水对钢板桩的腐蚀。     

锥柱结构焊接残余应力及超声冲击消除的研究

随着高强钢潜艇锥柱结构的广泛应用,影响结构性能的焊接残余应力的测量和残余应力消除的技术备受关注。采用X射线衍射技术对高强钢潜艇锥柱结构内外壳的轴向焊接残余应力进行无损检测。内壳轴向残余应力的分布在焊缝两侧呈双峰形态,均为拉应力,而后随着与焊缝距离的增加,残余应力快速降低;而外壳轴向残余应力在锥端焊趾部分达到最大残余压应力值。还进行了超声冲击消除焊接残余应力前后的对比试验。试验结果表明,超声冲击处理对降低焊缝及近焊缝区的残余应力有很大的益处,残余拉应力经冲击处理后转变为对疲劳强度有利的较大幅值的压应力。     

钢筋阻锈剂在混凝土中的应用

通过不同掺量的钢筋阻锈剂在砂浆中的阳极极化试验,混凝土拌合物的坍落度、坍落度损失、凝结时间、含气量以及混凝土抗压强度试验,抗渗与抗冻融等耐久性试验,盐水浸烘试验,证明在混凝土中掺入FAC-13型钢筋阻锈剂对混凝土的坍落度与坍落度损失、凝结时间、抗压强度以及渗水高度、质量损失、相对动弹模量等耐久性能无明显影响,而氯离子扩散系数、钢筋的锈蚀率及失重率有显著降低,证明该阻锈剂对钢筋阻锈效果明显,在实际工程中应用取得了很好的效果。     

Assessment of IACS-CSR implicit safety levels for buckling strength of stiffened panels for double hull tankers

The present study aims at applying structural reliability methods to assess the implicit safety levels of the buckling strength requirements for longitudinal stiffened panels implemented in the IACS Common Structural Rules (CSR) for double hull oil tankers. The buckling strength requirements considered are used in the initial stage of the hull girder scantlings’ design to control the buckling capacity of longitudinal stiffened panels subjected to the compressive loads induced by the hull girder vertical bending. The following buckling collapse failure modes are explicitly considered in the design formulation: uniaxial buckling of the plating between stiffeners, column buckling of stiffeners with attached plating and lateral-torsional buckling or tripping of stiffeners.The paper presents the procedure used to assess the implicit safety levels of the strength requirements for the three buckling collapse failure modes above mentioned, which includes the optimization of the scantlings of the plate panels and longitudinal stiffeners in order to reflect the minimum strength required by the formulation. A first order reliability formulation is adopted, and stochastic models proposed in the literature are used to quantify the uncertainty in the relevant design variables. A sample of five oil tankers representative of the range of application of the IACS-CSR design rules is considered. The effect of corrosion in the implicit safety levels is quantified based on the three corrosion levels of the Net Thickness Approach (NTA) adopted in the design rules. Sensitivity analyses are also performed to quantify the relative contribution or importance of each design random variable to the implicit safety levels.     

Snap behaviour in the upheaval buckling of subsea pipelines under topographic step imperfection

Pipelines exposed to high temperature and high pressure with a topographic step imperfection are susceptible to the phenomenon of upheaval buckling potentially leading to a hazard for the structural integrity of the pipeline. To analyse this problem we derive analytical upheaval buckling solutions and obtain the locations of maximum displacement and maximum axial compressive stress. We also analyse the typical post-buckling behaviour and its dependence on step height, axial soil resistance and wall thickness. The difference in behaviour between a pipeline with step imperfection and one with a symmetric prop imperfection is discussed. Our results show that a pipeline with a step imperfection is more prone to upheaval buckling than a perfect pipeline. For sufficiently small step heights the pipeline may suffer a snap-back instability under decreasing thermal loading, raising the possibility of hysteretic snap behaviour under cyclic thermal loading (for instance caused by periodic start-ups and shut-downs). The snap-back buckling disappears for large enough step height and the minimum critical temperature difference decreases with increasing step height and wall thickness or with decreasing axial soil resistance. The maximum compressive stress decreases with increasing step height and axial soil resistance or with decreasing wall thickness. A pipeline with step imperfection is safer than one with a symmetric prop imperfection.     

Remaining fatigue life assessment of corroded mooring chains using crack growth modelling

Failures caused by the combined actions of fatigue, corrosion and wear are important safety concerns for mooring chains used on floating structures in the oil and gas industry. Prediction of remaining corrosion fatigue life based on surface condition could therefore be a useful tool for the continued safe operation of corroded chains. This paper investigates the use of crack growth modelling for estimating the remaining corrosion fatigue life of mooring chains that exhibit significant pitting corrosion damage. A crack growth modelling approach is used to produce remaining fatigue life estimates for a selection of severely pitted mooring chains. Using fatigue crack growth rate test results for grade R4 high strength mooring chain steel, empirical crack growth laws are presented for free corrosion and cathodic protection conditions at load ratio R = 0.1. Two different methods for establishing equivalent cracks from surface scans of corrosion damage are presented. The mooring chains are proof loaded as part of their manufacturing process. Residual stresses introduced during this process have therefore been determined by finite element analysis and accounted for in the fatigue crack growth predictions. One of the equivalent crack models, accounting for the single dominant corrosion pit, provided quite accurate fatigue life predictions when compared with full scale test results.