Mir Ali Ghaffari

Department of Mechanical and Industrial Engineering and Center for Computer-Aided Design, The University of Iowa, Iowa City, IA 52242 e-mail: ali-ghaffari@uiowa.edu

Fatigue Crack Propagation Analysis of Repaired Pipes With Composite Patch Under Cyclic Pressure
The pipes in offshore and marine structures are mainly made of low-strength structural steels such as A537 steel and are subjected to the effects of both corrosive medium and cyclic loading caused by many factors. Reinforcement and repair of components using composite patches can be used for piping to reduce the stress intensity factors at the crack-front of a corrosion fatigue crack. In this paper 3D nite element analyses in general mixed-mode fracture condition are performed to study the crack growth behavior of repaired pipes subjected to internal cyclic pressure. The required formulations, crack growth modeling, and remeshing are automatically handled by developing an ANSYS parametric design language (APDL) program. For this purpose an offshore pipe made of lowstrength steel containing an initial fatigue corrosion crack repaired by glass/epoxy composite patch is considered. A parametric study will be performed to nd the effects of patch thickness on fatigue crack growth life extension and crack-front shape of the repaired pipes. [DOI: 10.1115/1.4023568] Keywords: cyclic pressure, pipes, fatigue, repair, composite, crack growth

Hossein HosseiniToudeshky
Professor Fatigue and Fracture Laboratory, Amirkabir University of Technology, Tehran, Iran e-mail: hosseini@aut.ac.ir

Introduction

There are many types of pipes and pressure vessels in different industries such as offshore engineering, gas and oil transmission, power plants, and reneries subjected to cyclic loadings such as variation of internal pressure and/or external loadings. These components have to be capable of withstanding fatigue damages in their safe life. Corrosion may also occur on the internal and/or external surface of these components due to their environmental working conditions. Previous studies mainly focused on the estimation of plastic collapse load or creep behavior of pipes containing these kind of corrosion effects, and also fatigue phenomena in pipes with aws have been examined during recent decades. A few investigations have been undertaken on internally pressurized pipes with longitudinal surface cracks [14], and research works have also been performed on circumferential aws in hollow cylinders under tension and bending loading [5,6]. Generally, fatigue crack growth behavior of notched components depends on the state of stress at the notch front, geometry of the component, shape and size of the notch, and loading conditions. Standard tests for measurement of fatigue crack growth rate have been performed signicantly using compact tension or three point bend specimens following ASTM E647 [7]. The mode-I fatigue crack growth under pulsating internal pressure is examined through a theoretical model based on the Paris law, by assuming a semielliptical shape for the crack-front during the propagation period by Carpinteri et al. [8,9]. They also numerically simulated the fatigue growth of a circumferential external surface aw in a thick-walled round pipe subjected to rotary bending and compared the results with those for cyclic bending. Ivankovic and Venizelos [10] performed a nite volume method for modeling of crack propagation in uid pressurized plastic pipes. They compared the results with experiments and realized that results with backll showed an increase in critical pressure. External axial surface aws in metallic round thick- and thin-walled pipes have been
Contributed by the Pressure Vessel and Piping Division of ASME for publication in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received November 21, 2012; nal manuscript received February 1, 2013; published online May 21, 2013. Assoc. Editor: Saeid Mokhatab.

examined by Brighenti [11]. In this study, a two-parameter theoretical model has been employed for the analyses of fatigue growth of such longitudinal surface defects under a pulsating internal pressure. Yeon-Sik et al. [12] have also performed fatigue crack growth studies on full scale piping components. Crack growth studies on through-wall cracked pipes in terms of initiation of fracture toughness and the fracture resistance curve (JR) have been studied in Refs. [13,14] for explaining the integrity of piping components. Singha et al. [15] presented a systematic study to determine the fatigue crack initiation, fatigue crack growth rate, and fracture resistance behavior of pipes to demonstrate the satisfaction of the leak-before-break (LBB) design criterion. Shahani and Fasakhodi [16] demonstrated FEM analysis based on the remeshing technique to predict the dynamic crack propagation and crack arrest in a brittle material. In this method, an extremely rened mesh near the crack region and a large amount of computational work are required. Ayatollahi and Khoramishad [17,18] compared the stress intensity factors resulting from a twodimensional analysis of similar cracks in plane strain condition with those of the deepest point in the three-dimensional crack model. They also calculated the stress intensity factors of external semielliptical cracks in a buried pipe. Moreover, they determined the mode-I and mode-II stress intensity factors KI and KII for an internal crack in a pipe buried in the soil. Their results, which were presented in nondimensional forms, can be used for evaluating the load bearing capacity of cracked buried pipes. Composite patches have been used to repair damaged pipelines for a long time. The majority of these works involved the repair of onshore pipelines subjected to corrosion fatigue cracks. Onshore pipelines are typically concerned with circumferential stresses associated with internal pressure. Repairing the pipes with composite patch involves the restoration of hoop strength. Review of the open literature demonstrates addressing of this stress state as the primary focus of research efforts up to now [1923]. Additionally, mechanical damage such as pitting has been repaired by composite materials [24,25]. Information available to industry is mainly based on the results of several research programs that integrated composite coupon tests, as well as full-scale burst and fatigue testing on pipelines with simulated damage. An JUNE 2013, Vol. 135 / 031402-1

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experimental and theoretical fatigue crack propagation analysis of steel pipes, each with an inclined semielliptical crack, subjected to tensile stress was performed by Bian et al. [26] and recently the use of an optical dynamic 3D displacement analysis technique to evaluate the crack propagation in a threaded pipe assembly was presented by Van Wittenberghe et al. [27] The ASME codes for gas (ASME B31.8) and liquid (ASME B31.4) pipelines address the use of composite materials [28,29]. More recently, ASME developed a document focused on the repair of pressure equipment [30]. However, it is well known that during the extrusion of a pipe, numerous local defects and inclusions can be produced. In service, the combination of these factors under loading condition (internal pressure) and the environmental effect (humidity, temperature, and time) tends to reduce signicantly the lifetime of these components. The pipes in offshore and marine structure are mainly made of low-strength metals such as A537 steel subjected to the effects of both corrosive medium and cyclic loading caused by many factors. Therefore, failure of these pipes may occur due to the corrosion fatigue cracking. Prevention of a catastrophic failure and fatigue life extension of such cracked pipes is possible using a proper repair technique. Reinforcement and repair of components using composite patches is a well-known technique in civil and aerospace engineering. It can be used for piping to reduce the stress intensity factors at the crack-front of a corrosion fatigue crack. After performing a proper repair by composite patch, the main issue is estimation of fatigue crack growth life of the repaired components. For this purpose it is required to perform crack growth analyses, including both crack trajectory and crack growth rate analyses for a 3D medium (repaired pipe). In this paper an automatic procedure using the APDL feature of ANSYS code is adapted to handle 3D nite element analyses for both crack trajectory and crack growth rate of repaired pipes subjected to internal cyclic pressure. For this purpose an offshore pipe made of low-strength steel containing an initial fatigue corrosion crack repaired by glass/epoxy composite patch is considered. A parametric study will be also performed to nd the effects of patch thickness on fatigue crack growth life extension and crack-front shape of the repaired pipes.

Fig. 2 (a) Modied crack closer technique for an eight nodes solid element; (b) crack deection angles u0 and w0 for a general mixed-mode condition [35]

Computational Fracture Analysis

Figure 1 shows a typical geometry and loading of the repaired cracked pipe containing one side through the thickness crack. Having the displacement and stress elds around the crack-front, fracture parameters such as KI, KII, and KIII are calculated, and then they are used to predict the new fatigue crack-front shape, crack propagation path, and crack growth life of the repaired stiffened panels. Linear elastic fracture mechanics (LEFM) assumptions are used for the analyses. It is also presumed that the cracks will grow in the pipe only and there is no debonding between the patch and the panel. The computational fracture analyses are based on the calculation of strain energy release rates (SERRs) by

the aid of the modied virtual crack closure technique (MVCCT) to obtain the local SERR along the crack-front. The stress intensity factor is calculated from the stress state near the crack-front. For obtaining the stress intensity factor, it is more convenient to evaluate that in terms of energy release rate G, with crack extension. By assuming a virtual crack extension (Da) and estimating the variation in strain energy, at any crack length, strain energy release rate can be obtained. The basic formulations for fracture analyses and crack growth of repaired panels in general mixed-mode condition are fully explained by Hosseini-Toudeshky et al. in [3336]. The same formulation and procedure are adapted for repaired pipes here. The calculation procedure in the virtual crack closure technique (VCCT) is performed in two stages. In the rst step, the internal nodal forces are computed at the crack-tip Fj and in the second step the crack is extended for a value of Da and the analyses are performed to calculate the displacements at nodes j and j*, which have been coincided before crack growth. For a crack-front modeling using the three-dimensional eight-node elements (Fig. 2(a)) the energy release rates are calculated as follows:

Fig. 1

Typical geometry and loading of a repaired pipes

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1 i j F u ujy 2DA y y 1 i j F u ujx GII 2DA x x 1 i j F u ujz GIII 2DA z z GI

(1)

Considering Fig. 2(a), DA b Da, b is the element thickness at z direction and GI, GII, and GIII are the energy release rates for modes I, II, and III, respectively. Then the stress intensity factors can be computed from the following relations: p KI E0 GI p (2) KII E0 GII p KIII 2lGIII where E0 is the modulus of elasticity, and E0 E for plane stress condition and E0 E/(1 2) for plane strain condition problems and l and  are the shear modulus of elasticity and Poissons ratio, respectively. For three-dimensional general mixed-mode problems the criteria of Richard et al. [31] have been used for crack growth analyses. Richards criteria suggested an equivalent stress intensity factor that depends on the stress intensity factors in various modes. In this generalized fracture criterion, an equivalent stress intensity factor Keq is dened comparable with the equivalent stress, req, for multiaxial stress failure criterion in classical stress theories, which relates to the stress intensity factors KI, KII, and KIII as follows: q KI 1 KI2 4a1 KII 2 4a2 KIII 2 (3) Keq 2 2 where a1 KIc/KIIc, a2 KIc/KIIIc, and KIc, KIIc, and KIIIc are fracture toughness in various fracture modes. Deection angles at any point of the crack-front are dened by u0 and w0 as typically shown in Fig. 2(b) and they can be calculated by the following relations [31]. "  2 # jKII j jKII j B (4) /0 6 A KI jKII j jKIII j KI jKII j jKIII j "  2 # jKIII j jKIII j w0 6 C D (5) KI jKII j jKIII j KI jKII j jKIII j where the conditions of u0 < 0 deg and w0 < 0 deg have to be satised for KII > 0 deg and KIII > 0 deg, respectively. u0 > 0 deg for KII < 0 and KI  0 and also w0 > 0 deg for KIII < 0 and KI  0. Considering the values of A, B, C, and D parameters to be 140 deg, 70 deg, 78 deg, and 33 deg, respectively, the results of Eqs. 5 and 6 agree well with the crack deection angles predicted by the Shollman criterion [31]. Another ingredient to calculate the fatigue crack growth is denition of a law relating the crack length to the loading cycles. For this purpose the wellknown Paris law is used as follows: da cDK m dN
Table 1 Fig. 3 Fatigue crack growth rates for A537 steel in various temperatures [32]

In general mixed-mode condition DK can be substituted by the effective stress intensity factor range DKeq according to that explained in Eq. (3). The values of a1 1.155 and a2 1 are used in this equation. The values of a1 1.155 and a2 1 are used in this equation according to the Richards study to obtain an excellent approximation of the fracture limit curve of the maximum tangential stress criterion [31]. Having the crack growth rate and orientation, the position of each point at the new crack-front in the local polar coordinates (Da, u0, w0) is determined. Then the projection of each point of the new crack-front in the local rectangular coordinates is determined to nd the components of Da in the X, Y, and Z directions. More details of this procedure can be found in Refs. [33,35].

Finite Elements Analysis

(6)

The considered repaired pipes as typically shown in Fig. 1 are made of ASTM A537steel, the patch material is glass/epoxy composite, and the adhesive material is FM-73. Material properties of the steel pipe, adhesive, and composite patch are given in Table 1. The advantages of glass/epoxy repairs compared to graphite/epoxy and boron/epoxy composites are the cost, availability, and more compatible thermal coefcient with the steel pipe. It was shown in Hosseini-Toudeshky et al. study [36] that low curing temperatures with long curing cycles did not have a considerable effect on fatigue crack-growth life of the repaired panels with glass/epoxy patch and had minor effects for repaired panels with graphite/epoxy and boron/epoxy composite patches. It was also shown that considering the thermal residual stresses, the obtained FEM fatigue life, and crack-front shapes of the repaired panels using glass/epoxy patch are in good agreement with those obtained from the experiments. Fatigue crack propagation tests on steel A537 at room and lower temperatures were partly reported in a previous study and are presented in Fig. 3 [32]. The stable fatigue crack propagation in A537 steel follows the Paris law, but the Paris exponent m varies with temperature, presenting a much larger value at lower temperatures. The material constants in the Paris equation were calculated based on the ASTM E-647 method for T 273 K and leads to m 2.8578 and C 6 1012.

Material properties of glass/epoxy patch, ASTM A537 steel, and adhesive Elasticity modulus (GPa) Poissons ratio ASTM A537 steel [38] Adhesive FM-73 [35] E E 192 1.83 t t 0.3 0.33

Elasticity modulus (GPa) Shear modulus (GPa) Poissons ratio Glass/epoxy [35] E11 E22 E33 27.82 5.83 5.83 G12 G13 G23 2.56 2.56 2.24 t12 t13 t23 0.31 0.31 0.41

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In the three-dimensional analysis, an isotropic eight-node-solid element (SOLID45) was used to model the steel pipe and adhesive layer. Furthermore, a layered eight-node-solid element (SOLID46) was used to model the composite patch. Figure 4 shows a typical used FEM mesh of the component. In these analyses a ne mesh was generated near the crack, eight elements along the pipe thickness, two elements along the adhesive thickness, and two elements along the patch thickness were used. Distribution of elements along the thickness are shown in Fig. 4(a) and overall meshing from outside view of a repaired pipe in the last steps of crack growth analyses is shown in Fig. 4(b). A small debounded area equal to the element size at the crack edges has been considered in the FEM modeling. This is necessary for FEM modeling and it is almost compatible with experimental evidence [34]. The stress and strain elds of the repaired pipes were obtained using the elastic solution of ANSYS nite element program. A macro program using ANSYS parametric design language (APDL) was also developed to conduct the automatic crack growth modeling process. In this program, after nite element modeling of the repaired pipe with the initial crack size, a crack propagation procedure using the recursive method has been developed. At each crack growth increment a three stage modeling for the crack-front is required [36]. In this procedure, an elastic solution is performed for the repaired pipe with the existing crack conguration. In addition, the incremental crack length at each point of the crack-front is calculated based on the obtained three stress intensity factors and DKeq values, crack growth direction angles, Paris law, and the assumed crack increment size at the unpatched surface of the pipe. For doing this, after calculation and comparing of DKeq for all crack tip nodes through the thickness, the biggest DKeq is selected and then by putting this DKeq to Paris law and consider-

ing assumed 0.8 mm maximum crack increment, the fatigue cycles amount necessary for 0.8 mm crack growth is obtained. Afterward, having this cycle amount, which is calculated based on max DKeq, the increments of the other crack tip nodes based on their own DKeq are calculated. By considering an assumed small crack increment at the unpatched side of the repaired pipe the corresponding required load cycles (DN) can be calculated from the Paris law. Having DN and the values of stress intensity factors at the crack-front nodes, the ratio of crack growth at each node with respect to the considered increment at the unpatched side and its direction are calculated. It is noted that each increment may contains the X-, Y-, and Z-coordinate values for each node. Displacements of crack tip nodes should be calculated on their own X-Y plane without moving in the Z direction. For doing this, after nding the increments of crack tip nodes in X-, Y-, and Z-coordinate the new positions of the points are calculated by the linear interpolation of each of the two nearest points to obtain a threedimensional new crack-front shape in the second step. The procedure is exactly explained in Ref. [36]. To create a new crack-front, the obtained points are rearranged along the thickness of the pipe right at the crack-front. In the second step, the new positions of the considered points at the crack-front are calculated by the linear interpolation of each two neighboring points to obtain a three-dimensional new crack-front shape. In the third step, new mesh of the repaired pipe is constructed using the updated crack-front geometry. This procedure is repeated for each crack growth increment. The main steps of the developed APDL program to perform the automatic 3D crack propagation procedure are as follows [33,35]: (i) geometry and nite element mesh generation of repaired pipe

Fig. 4 Typical FEM mesh, (a) distribution of elements along the thickness, (b) overall meshing from outside view

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(ii) (iii) (iv) (v) (vi) (vii)

dening of loading, constraints, and material properties performing a linear elastic solution calculation of nodal forces and nodal displacements at crack-front in three directions calculation of GI, GII, and GIII and then KI, KII and KIII at crack-front using modied crack closure technique (Eqs. (1) and (2)) calculation of crack deection angles uo and wo at various points of crack-front calculation of Keq at various pints of crack-front using Eq. (3)

(viii) (ix)

(x) (xi)

considering 0.8 mm crack increment at unpatched surface at each increment and calculating the corresponding load cycles (DN) using the Paris law having DN and values of KI, KII, and KIII at crackfront nodes the ratio of crack growth at each node with respect to the 0.8 mm growth at the unpatched surface are calculated and the new crack-front shape is generated as explained above construction of new geometry of repaired pipe with new crack-front shape updating the nite element model based on the new crack length and the crack-front conguration

Fig. 5 (a) Half section of cracked pipe repaired by composite patch lay-up of [90]4 that clearly shows crack trajectory and crack front shape; (b) fatigue crack-front evolution and type of meshing for repaired pipes with patch lay-up of [90]2

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(xii) (xiii)

If Keq  KIc or crack length at the unpatched surface is less than a dened value, return to step (iii) process the results and stop the solution.

A sensitivity study on crack increment size was also performed. For the virtual crack closure technique, the energy release rates are dened as the virtual crack closure integral over a nite crack closure length. This crack closure length corresponds to the lengths of the elements adjacent to the crack front. This element length a must be chosen to be small enough to assure a converged FE solution but large enough to avoid oscillating results. The approach used must be consistent with the denition of the energy release rates used for fracture predictions as well as that employed for material characterization. This does not imply that the material tests must be evaluated by FE-models, but it should be established that the data reduction scheme is in agreement with the denition of a nite crack closure length. Consequently, it has been suggested to use element lengths at the crack tip in such a manner that the computed results are insensitive to the variation of the element length a at the crack tip as Krueger [37] recommends considering a Da/h value between 0.01 and 0.1 for this purpose. Da is the elements length and h is the thickness of the cracked panel. It was seen that for the increment sizes of larger than 0.8 mm, the obtained crack fronts and crack trajectories were not smoothly predicted. In the meanwhile we did not see signicant differences between the results (crack-front, trajectory, and life) obtained for values smaller than 0.8 mm. Figure 5(a) presents a half section of cracked pipe for clearly showing the crack trajectory and crack-front shape after a certain crack growth of the repaired pipe. In this gure initial crack and

Fig. 7 Variation of stress intensity factors along the initial crack-front (Da 5 0) for various patch layers, (a) KI, (b) KII, and(c) KIII

crack trajectory are shown for half of the cracked pipe. It also shows the crack-fronts and ne meshing around the crack tips. This gure shows that the crack growth path is almost parallel to the straight side of the pipe. This is due to the loading condition and the signicant values of circumferential stresses. The crackfront conguration and updated mesh at three different crack increments for the repaired pipe with the patch lay-up of [90]2 are shown in Fig. 5(b). The half section of the repaired pipe is shown here to be able to observe the crack-front in the pipe thickness clearly. As the crack length and crack-front are changed according to the described calculation procedure, the mesh distribution is also changed considering the crack trajectory and new crack-front shape at each step.
Fig. 6 Comparison between the predicted crack growth behaviors with experimental results of Ref. [34]; (a) unrepaired panel, (b) results at unpatched surface of repaired panel with patch lay-up of [105]4

Results and Discussions

To verify the developed FEM procedure, the predicted crack growth behavior of an unrepaired plain panel without stiffener Transactions of the ASME

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Fig. 8 Variation of KI versus half of the crack length (Xctip), (a) [90]2 patch and (b) [90]16 patch

and containing a 45 deg central inclined crack shown in Ref. [34] is compared with the available experimental results [34] in Fig. 6(a). The predicted crack growth behavior is also obtained for the same panel with a single side composite repair of [105]4 glass/epoxy and compared with the experimental results in Fig. 6(b). These gures show a good agreement between the experimental and the predicted nite element results indicating the verication of FEM analyses for crack propagation modeling. Figure 7 shows the variations of stress intensity factors (KI, KII, and KIII) along the initial crack-front for the unrepaired and repaired pipes with various patch layers before the occurrence of

Fig. 9 Predicted crack growth versus number of cycles for repaired pipes with various patch thickness

any crack growth. Figures 7(b) and 7(c) indicate that the values of KII and KIII stress intensity factors along the crack-front are very small and, therefore, mode-I is the dominant fracture mode. Figure 7(a) shows that the mode-I stress intensity factors at the crack-front of the repaired pipes are considerably reduced. It also shows that with increasing the number of patch layers the values of KI at each point of the crack-front are decreased. This reduction is more signicant near the patched side than the inside of the pipe. It is also observed that the reduction rate of KI is decreased with increasing the patch layers. Figure 8 shows the variation of stress intensity factors for three points at the free surface, middle, and patched face along the crack-front versus the crack length for two typical patch lay-ups. These gures indicate that all stress intensity factors are increased with enlarging the crack length; however, as the number of patch lay-ups is increased the difference between the stress intensity factors at the middle point and the patched surface is decreased. This behavior is mainly due to the variation of the crack-front during the fatigue crack propagation, as will be shown later in this paper. Figure 9 exhibits the variation of crack length versus number of load cycles for unrepaired and repaired pipes with various numbers of glass/epoxy patch layers. It is worth noting that the major component of crack growth in both inside and outside of the repaired pipes is in the X-direction, e.g., for crack growth of DaX 72 mm the Y-component is DaY 0.2 mm only. Therefore, variations of fatigue crack growth lives are presented with respect to the X-coordinate of crack increments in all cases. This gure shows that fatigue crack growth life of repaired pipes is considerably extended when compared with the unrepaired pipe results. The crack growth lives of the repaired pipes are also increased signicantly with increasing the number of patch layers. But the efciency of repair is decreased by increasing of the patch layers; e.g. differences of load cycles of repaired pipe with two layers of patch and eight layers of patch are much larger than the differences of 12 and 16 layers of patch. It can be also concluded that using more than 16 layers of patch may not increase the fatigue life extension signicantly. Table 2 presents the fatigue crack growth lives of unrepaired and repaired pipes with various patch lay-ups for a small crack growth of 0.8 mm (restarting crack growth) and crack extension of 63 mm at inside surface of the pipe. This table shows that using various patch layers may lead to the life extension between 65% to 90% for restarting crack growth and 145% to 280% for crack growth of 63 mm. Figures 10(a) and 10(b) show the variations of crack-front shapes with the patch lay-ups of [90]4, and [90]16 in the X-Z plane at various crack growth steps up to a certain crack growth with XCtip 68 mm at the unpatched side (inside) of the repaired pipes. Obviously, it is observed that the crack grows nonuniformly along the pipes thickness for all patch lay-up congurations. This behavior is due to the asymmetry conditions of the repaired pipes that lead to the change of stress eld near the crack-front and along the pipe thickness. These gures show that the crack-front shape curvatures of the repaired pipe with the patch lay-up of [90]16 are more bended than those obtained from the patch lay-up of [90]4. The crack-front shape affects the stress intensity factors at the crack-front especially at the unpatched surface. Figure 11 shows comparison of the obtained crack-front shapes at Xctip 90 mm for unrepaired and repaired pipes with various patch lay-ups in the ZX plane. This gure shows that the obtained crack-front for unrepaired pipe after a certain value of fatigue crack growth is quite different from the repaired pipes. The curvatures of the crack-front shapes for the repaired pipes are also increased with increasing the patch thickness. This gure obviously shows that the crack-front shapes obtained for the pipes with the patch lay-ups of [90]8, [90]12, and [90]16 have almost the same conguration, indicating that the crack-front shapes are not signicantly changed for the more than eight patch layers. In fact as the number of layers is increased the curvature of crack-tip is slightly increased. JUNE 2013, Vol. 135 / 031402-7

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Table 2 Fatigue lives for initial small growth of 0.8 mm and crack growth of 63 mm from each side Fatigue crack growth life (DaMAX 63 mm) Patch lay-ups Unrepaired [90]2 [90]4 [90]8 [90]12 [90]16 Cycles 2.88e5 7.05e5 8.09e5 9.30e5 10.25e5 10.94e5 Percentage 0% 145% 180% 223% 256% 280% Restarting crack growth(DaMAX 0.8 mm) Cycles 15,723 25,994 26,660 27,747 28,810 29.913 Percentage 0% 65% 70% 77% 83% 90%

Fig. 12

Deformed repaired pipe under internal pressure

These crack-front curvatures generated during the fatigue crack propagation are due to the distribution of stress components near the crack front and local bending of the cracked area. Figure 12 shows also the local bending in the crack area of the deformed repaired pipe under internal pressure.

Conclusion

In this paper 3D nite element analyses considering a general mixed-mode fracture condition were performed to obtain the crack growth behavior of repaired pipes subjected to internal cyclic pressure. For this purpose an offshore pipe made of lowstrength steel containing an initial through the thickness crack repaired by glass/epoxy composite patch was considered. It was shown that repair of cracked pipes with glass/epoxy composite leads to signicant life extension for both restarting crack growth and crack propagation period; even a repair with two layers of composite leads to a 65% life extension for restarting crack growth. It was also shown that the crack-front shape curvatures of the repaired pipes are more bended with increasing the patch layers, but the crack-front shape changes are not signicant for more than eight patch layers.

References
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Fig. 10 Crack-front development for repaired pipes with various patch lay-ups in X-Z plane; (a) [90]4, (b) [90]16

Fig. 11 Comparison of the obtained crack-front shapes at XCtip 5 90 mm for repaired pipes with various patch thickness and unrepaired pipe

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