Treatment of Primary and Secondary

Stresses in Fracture Assessment with

and without Elastic Follow-Up

Bob Ainsworth
The University of Manchester

ESIS TC1 December 2012 1

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 Contents of Presentation

Treatment of Combined Loading in FFS Standards

Simplified Methods

Detailed Methods

Recent Developments for Combined Loading

Kim et al

James et al

New Approach Based on Stress Relaxation

General Solution

Simplified Estimate

Concluding Remarks

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Schematic Variation of J with Load

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 FFS Procedures

R6

Based on Failure Assessment Diagram (FAD)

Combined loading treated in definition of Kr

BS7910

Combined loading has the same basis as R6

FITNET

Combined loading has the same basis as R6

ASME/API579

Combined loading has the same basis as R6 but tabulated
values in R6 fitted by polynomial functions

RSEM

Differs from R6 but for specific loadings (thermal shock)
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 Failure Assessment Diagram

Two Parameters
K r = (K1p + VK1s ) / K mat

L r = F / FL (a, y ) = pref / y
Limits
K r f(L r )
L r Lmax
r

A parameter also used but equivalent to V so not discussed

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further here

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Failure Assessment Diagram

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 Validation of R6 for Residual Stress
1.8

Kr
1.6

1.4

1.2

0.8

Option 1 FAD 1S (full scale)

0.6
5K1 (1/4 scale) 2P (full scale)

5K3 (1/4 scale) 2S (full scale)

0.4
P1 (1/4 scale) 3P (full scale)

0.2 S1 (1/4 scale) 3S (full scale)

1P (full scale)

0
0 0.2 0.4 0.6 0.8 1 1.2 Lr 1.4

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 Procedures for Estimating V

Simplified Estimate
Elastic calculation for secondary loading
Conservative in absence of elastic follow-up
Limited range of applicability
Detailed Estimate
Elastic-plastic calculation for secondary loading
Based on reference stress methods
Conservative in absence of elastic follow-up
Finite Element Analysis
Elastic-plastic calculation for combined loading

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 Simplified Procedure to Estimate V
Applicable provided:

There are some primary stresses

Elastic follow-up is not significant

Secondary stresses are not very large, K1s /(K1p /L r ) = 4

V = 1 + 0.2L r + 0.02 [K 1s /( K 1p / L r )](1 + 2L r ) L r < L*r

V = 3 .1 2 L r L*r < L r < 1.05

V =1 L r > 1.05

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Simplified Estimate of V
R6 currently limits to
V>1 (>0) but likely to
be relaxed to V>0.4 in
the future.

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 Detailed Procedure to Estimate V

Calculate K sJ
> inelastic analysis of cracked body
> inelastic analysis of uncracked body to define stress and
strain based K values
> plastic zone correction to K 1s

Define
V = (K sJ /K1s ),

where = (L r ,K sJ /(K1p /L r ) = * )

is given in R6 and API579

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Values of V for Detailed Procedure

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 Recent Developments

James et al
Extensive finite element analyses for plates
Development of g or h approach where g = [V /V0 ]/f(L r )
Reported at ASME PVP conferences
Empirically based

Kim et al
Extensive finite element analyses for cylinders
Refined estimation of V
Allows for elastic follow-up
Empirically based

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Estimates of J for SENB, a/w=0.5
(James et al)

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 Cylinder with Axial Load (Kim et al)

Results are not sensitive to crack size

Current methods in FFS Codes are conservative.
Kim et al proposed simplified methods which are more
accurate [Eqn (20) is R6 Option 2 curve]
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Comparison of Recent Proposals

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Evidence from Recent Developments

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 New Relaxation Approach
Assume relaxation of secondary stresses is controlled by:

Total stress level in the absence of plasticity

Plastic strain
Elastic follow-up (Z)

0ref =pref +sref

0ref ref =(E /Z)[ pl (ref ) pl (sref ) pl (pref )]

Solution leads to:

ref = ref (Z, L r , )

and
V /V0 = function(ref , L r , )
Based on an approach used to predict creep relaxation of secondary
stresses in R5
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Specific Solutions of Relaxation Equation

Z=1 V/V0 f(L r ),

(L r +)f(L r ) L r
Z V= (upper bound)
f(L r +)

V Z1
Small , L r f(L r )+ 43 L r (+L r )
V0 Z

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 Solutions for No Elastic Follow-Up, Z=1

Absence of elastic follow-

up (Z=1) shown by a
number of the solutions
obtained by James et al
and Kim et al.
In these cases V0 is
approximately unity

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 Solutions for Large Elastic Follow-Up

Can get V0 significantly greater than unity for stress fields with a uniform
region in the neighbourhood of the crack; low strain hardening materials
(high n); small defects.
Upper bound corresponds to treating secondary stress as primary

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 General Solution
Guided by the solution for small loads an approximate general
solution has been developed as
Z 1
V /V0 =f(L r )+ 43 L r ( + L r )[f(L r )]2 f()
Z
For routine applications without significant elastic follow-up this is
weakly dependent on the magnitude of secondary stress and bounded
for Z=3 by
V /V0 =f(L r )+0.42L r (0.72 + L r )[f(L r )]2

For larger elastic follow-up an explicit dependence on follow-up

factor can be retained similar to Kim et al.

For no elastic follow-up, conservatism can be reduced and an estimate

is V /V0 =f(L r )
Note, solution depends on the shape of the FAD

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Weak Dependence on Secondary Stress
Magnitude

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Comparison with Recent Proposals

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 Comparison with James et al for
Weakly Strain Hardening Material

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Comparison with Kim et al FE Results:
Weakly Strain Hardening Material

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Comparison with Kim et al FE Results:
Strongly Strain Hardening Material

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 Concluding Remarks

There has been significant effort recently to address fracture

under combined loading

Results show that procedures can be developed which are:

Simplified (weak or no dependence on magnitude of secondary
stress);

Less conservative (reduced values of V) than existing methods;

Can allow for elastic follow-up (for secondary loads alone and for
combined loading).

Future Work

Draft Revisions to R6

Finalise options and validate using existing data
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 Acknowledgments

EDF Energy for support and Peter Budden for discussions

Discussions/FE Data with Prof Yun-Jae Kim (University of
Korea) - ongoing

Discussions with Mr P James (Amec) - ongoing

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