4102 - Chap 6A - Welded Structures PDF

MAAE 4102
Strength & Fracture Analysis

Chapter 6A
Welded Structures
Professor R. Bell
Department of Mechanical & Aerospace Engineering
Carleton University
2013
Chapter 6A - Welded Structures
Department of Mechanical &

Aerospace Engineering
Fatigue Behaviour of Welded

Components
Fatigue Performance Affected by:
Residual Stresses
Distortion
Imperfections
Lack of Fusion
Porosity
Solidification Cracks
Slag Inclusions
Undercuts
Stress Concentrations
Weld Imperfections
Geometrical Discontinuities

Design Codes - Offshore Structures

A.W.S. American Welding Society
HSE
H
Health
lth & S
Safety
f t E
Executive
ti UK
DNV
Norway
A.B.S.
S American Bureau of S
Shipping
pp g
C.S.A. Canadian Standards Assoc.


CODES -Flaw Assessment

ASME Pressure Vessel Code- Section XI Inspection of Nuclear Components
BS-PD6493 Guidance on Methods for

Assessing
g the Acceptability
p
y of Flaws in
Welded Structures
BS 7910
910 G
Guidance
id
on M
Methods
h d ffor A
Assessing
i
the Acceptability of Flaws in Fusion Welded
Structures

CODES -Flaw Assessment

ASME Pressure Vessel Code- Section XI Inspection of Nuclear Components
BS-PD6493 Guidance on Methods for

Assessing
g the Acceptability
p
y of Flaws in
Welded Structures
BS 7910
910 G
Guidance
id
on M
Methods
h d ffor A
Assessing
i
the Acceptability of Flaws in Fusion Welded
Structures

Steel Fixed Jacket

Semi Submersible
Semi-Submersible

Jack p Platform
Jack-up

Mobile Str
Structure
ct re
Semi-Submersible

M bil Structure
Mobile
St
t
Semi-Submersible
10

J k tT
Jacket
Transportation
t ti and
d Installation
I t ll ti
11

Di t ti off Welded
Distortion
W ld d Plates
Pl t
12

Stress Concentrations at Welds
13

W ld Imperfections
Weld
I
f ti
14

Tubular Joint Tests
15

C
Canadian
di Joint
J i t Tests
T t
16

Thickness Effect
Pl t Joints
Plate
J i t
Fatigue
Strength
Tubular
T b l Joints
J i t
22
S SB
t
1
4
22
Factor on Life
t
32
S SB
t
3
4
1
4
32
Factor on Life
t
3
4
Where SB is a reference stress

Chapter 8 - Welded Structures
17

H t
Hotspot
t St
Stress
18

H t
Hotspot
t St
Stress D
Definition
fi iti
19

SNC
S-N
Curves
r es for T
Tubular
b lar Joints
20

Thickness Effect
Thickness Effect
Attachment Length
21

Canadian Plate Test Specimen
Joint
T
(mm)
t
(mm)
l
(mm)
L
(mm)
A
(mm)
16
16
8 - 12
300
406
26
26
14 - 18
442
406
52
52
26 - 32
442
406
78
78
37 - 42
584
437
103
103
51 - 58
726
457
52
26
14 -18
442
406
22

T-Plate
T
Plate Specimen Results
Total Life
I iti ti Lif
Initiation
Life
23
T-Plate Results
Propagation /Total Life

24

Fatigue Life
f Prediction off Welded Joints
Paris law
da
C K m
dN
C k Sh
Crack
Shape D
Development
l
t
a
e ka
c
k 2.09 x 10
1.95
S P S N kt
25

Shape Development and Coalescence
26

Life Prediction
C k Sh
Crack
Shape D
Development
l
tM
Models
d l
27

Crack Shape Prediction Models

Np - k cycles from ai = 0.5 mm to aT/T = 0.5 ( = 150 MPa)
Plate
Thickness
(mm)
16
26
52
78
103
LEFM
Predictions
Statistical Analysis
of Experimental Data
SC1
SC2
MC1
MC2
CANMET
UW
Combined
1880
1400
1100
900
750
1080
890
595
435
315
1680
1170
620
470
365
1397
768
326
217
170
894
588
249
257
130*
1732
715
393
408
248*
1388
676
326
318
195*
* brittle pop
pop-ins
ins
SC1 natural growth of single crack (ai/2c = 0.5)
SC2 single crack with fixed aspect ratio (a/2c = 0.1)
MC1 single crack with forcing function for a/2c to account for coalescence
MC2 single crack with forcing function for a/2c to account for coalescence and edge cracking
Chapter 8 - Welded Structures
28

Fatigue Crack Growth Predictions
29

Relative Fatigue Strength
30

Offshore S-N Curves Design

C d ffor W
Codes
Welded
ld d Joints
J i t
The S-N
S N Curves are obtained by experimental tests
Welded joints are divided into classes (ref Gurney)
Tubular joints are assumed to be T class
The Design curve is defined as the mean minus two
standard deviations of Log N (i
(i.e.
e 97
97.6%
6% probability
of survival)
31

S-N
S
N Curves for Non
Non-Tubular
Tubular Joints
32

S-N
S
N Curves for Non
Non-Tubular
Tubular Joints
The S-N curve which corresponds to a 97.6% probability of survival is:
log N log a 2 log s m log log a m log

Where:
N = predicted number of cycles to failure
log a = intersection of the Log N axis by the S-N curve
l s = standard
log
t d dd
deviation
i ti off L
Log N
m
= negative inverse slope of S-N curve
log a log a 2 log s
33

S-N
S
N Curves for Non
Non-Tubular
Tubular Joints
log N log a m log
Details of Basic S-N Curve - Air
N 107
N 107
Class
log a
log s
log a
log a
15.3697
0.1821
15.01
4.0
17.01
5.0
14.0342
0.2041
13.63
3.5
16.47
5.0
12.6007
0.2095
12.18
3.0
15.63
5.0
15 5169
15.5169
0 2509
0.2509
12 02
12.02
30
3.0
15 37
15.37
50
5.0
12.2370
0.2183
11.80
3.0
15.00
5.0
F2
12.0900
0.2279
11.63
3.0
14.72
5.0
11.7525
0.1793
11.39
3.0
14.32
5.0
11.5662
0.1846
11.20
3.0
14.00
5.0
12.6606
0.2484
12.16
3.0
15.62
5.0
Tubular
34

S-N Cu
S
Curves
es for
o Welded
e ded Joints
Jo ts in Seawater
Sea ate
35

S-N Curves for Welded Joints in Seawater

Details of Basic S-N Curve
Seawater and Cathodic Protection
Class
log a
log s
log a
So
(MPa)
15.3697
0.1821
15.01
4.0
48
14 0342
14.0342
0 2041
0.2041
13 63
13.63
35
3.5
33
12.6007
0.2095
12.18
3.0
20
15.5169
0.2509
12.02
3.0
18
12.2370
0.2183
11.80
3.0
15
F2
12.0900
0.2279
11.63
3.0
13
11.7525
0.1793
11.39
3.0
11
11.5662
0.1846
11.20
3.0
10
12.6606
0.2484
12.16
3.0
19
Tubular
S0 is the cut
cut-off
off level at N = 2 x 108 cycles
36

S-N
S
N Curves for Tubular Joints
37

S-N
S
N Curves for Tubular Joints
38

Thickness Effect on Welded Joints

S-N
S
N Curves for Tubular Joints relate to a wall thickness of 32 mm
m
t
logg N log
g a log
g m logg
4
32
S-N Curves for Other Joints relate to a wall thickness of 22 mm
m
t
log N log a log m log
4
22
39

S-N Curve CSA Code
40

Weld Improvement
p
- Toe Grinding
g
European
C d
Code
41

Weld Improvement
p
Results
42

Weld Improvement
p
- a vs N
43

Life Prediction Multiple

p Crack Model
a vs N
Experimental & Predictions
44

Life Prediction Multiple Crack Model

t/T
mm/mm
Stress
Range
Expt
Np
kCycles
MC2
Np
kCycles
SC1
Np
kCycles
MSC1
Np
kCycles
52/52
300
71
78
163
84
52/52
250
169
162
280
186
52/52
200
349
400
544
19/19
300
270
146
304
175
31/31
250
137
223
340
184
31/31
200
506
582
663
360
Experimental Results for T = 52 mm

45

Multiple Crack Model - a vs N
46

TAPS Tanker Structural Failures

TAPS Trans Alaska Pipeline Service
47


TAPS Trans Alaska Pipeline Service
Failure study published in 1990

TAPS flfleett accounted
t d ffor 13% off th
the US fl
fleett
These vessels accounted for 59% of hulls fractures
Cracking in hull plates and connecting structural
members
Conclusion that these TAPS tankers suffered a
disproportionately higher number of structural
failures when compared to vessels in other trades
48
TAPS Tanker

170,000 ton
49

TAPS Tanker
82,000 ton
50

TAPS Vessel Hull Cracks

The TAPS study concluded that the hull cracks
were generally
ll attributed
tt ib t d to
t :
Poor design of structural details, resulting in hard spots and

extreme stress raisers
Poor weld workmanship including fabrication and fit-up during the

construction of the vessel resulting in stress raisers in butt and
seam welds
Use of advanced analytical techniques
Undercuts, Lack of penetration, Wrong amperage, Misalignment
Quality control and inspection
Great difficulty in performing visual inspections

Detectable crack size - 3 in (visual) 2 in (ultrasonic)
Exposure to the harsh environment in the Gulf of Alaska
51

Typical Cracks
52

Transverse Web Frame
53

TAPS Vessel Hull Cracks

The TAPS study concluded that the hull cracks
were generally
ll attributed
tt ib t d to
t :
Use of high tensile steel (HTS) either completely

constructed from HTS or in combination with mild steel
No account taken of fatigue behaviour of HTS

Fatigue strength of HTS equal to that of mild steel
The reduction in scantlings due to the use of HTS
Advanced analytical techniques optimized structures
The reduction of scantlings based on the use of

protective
t ti coatings
ti
in
i the
th tanks
t k
Lack of maintenance of corrosion control systems
54

Fatigue of High Strength Steel

Allowable stress
increases as HTS
yield strength
increases
Fatigue
g strength
g of
HTS weldments is
about the same as
that of mild steel
55

TAPS - Solutions
Frequent structural inspections
Critical area inspection plan
Redesign
g of critical details
Stress analysis and repair of cracked details
Repair of less severe cracks
Grinding of poor weld contours
Hammer peening
Drilled holes as crack arresters
Voyage planning severe storms are avoided

Improved ballasting procedures
56

References:
J.D. Snipes, Trans-Alaska Pipeline Service (TAPS) Tanker

Structural Failure Study, June 1990, Office of Marine Safety,
Security and Environmental Protection
Protection, United States Coast
Guard, Washington, D.C. 20593-001
Trans-Alaska
Trans Alaska Pipeline Service (TAPS) Tanker Structural Failure
Study Follow-Up Report, May 1991, Office of Marine Safety,
Security and Environmental Protection, United States Coast
Guard, Washington, D.C. 20593-001
57

Offshore Design Codes
References:
T. Gurney, Fatigue of welded Structures, Cambridge University

Press, 2nd Ed. 1979.
I. Lotsberg and H. Andersson, Section, Fatigue Design Handbook
(Ed. A. Almar-Naess), Tapir Publishers 1985.
AWS d1.1 (1983), Structural Welding Code, American Welding
Society
58

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MAAE 4102

Strength & Fracture Analysis

Department of Mechanical &

Fatigue Behaviour of Welded

Department of Mechanical &

Design Codes - Offshore Structures

C.S.A. Canadian Standards Assoc.

Department of Mechanical &

CODES -Flaw Assessment

BS-PD6493 Guidance on Methods for

Department of Mechanical &

CODES -Flaw Assessment

BS-PD6493 Guidance on Methods for

Department of Mechanical &

Steel Fixed Jacket

Chapter 6A - Welded Structures

Department of Mechanical &

Chapter 6A - Welded Structures

Department of Mechanical &

Chapter 6A - Welded Structures

Department of Mechanical &

Chapter 6A - Welded Structures

Department of Mechanical &

Chapter 6A - Welded Structures

Department of Mechanical &

Chapter 6A - Welded Structures

Department of Mechanical &

Chapter 6A - Welded Structures

Department of Mechanical &

Stress Concentrations at Welds

Chapter 6A - Welded Structures

Department of Mechanical &

Chapter 6A - Welded Structures

Department of Mechanical &

Tubular Joint Tests

Chapter 6A - Welded Structures

Department of Mechanical &

Chapter 6A - Welded Structures

Department of Mechanical &

Where SB is a reference stress

Department of Mechanical &

Chapter 6A - Welded Structures

Department of Mechanical &

Chapter 6A - Welded Structures

Department of Mechanical &

Chapter 6A - Welded Structures

Department of Mechanical &

Chapter 6A - Welded Structures

Department of Mechanical &

Canadian Plate Test Specimen

Chapter 6A - Welded Structures

Department of Mechanical &

Chapter 6A - Welded Structures

Chapter 6A - Welded Structures

Department of Mechanical &

Department of Mechanical &

Chapter 6A - Welded Structures

Department of Mechanical &

Shape Development and Coalescence

Chapter 6A - Welded Structures

Department of Mechanical &

Chapter 6A - Welded Structures