lNTfRIATIONRL,O”RNI\LOr

Pressure Vessels
and Piping
International Journal of Pressure Vessels and Piping 75 (1998) 1l-25

A parametric study of residual stresses in multi-pass butt-welded stainless

steel pipes
B. Brickstad”, B. L. Josefsonb
“SAQ Kontroll AB, Box 49306, S-100 29 Stockholm, Sweden
“Division of Solid Mechanics. Chalmers University of Technology, S-412 96 Gijteborg, Sweden

Received 15 November 1997; accepted 22 November 1997

Abstract

Multipass circumferential butt-welding of stainless steel pipes is simulated numerically in a non-linear thermo-mechanical FE-analysis. In
particular, the through-thickness variation at the weld and heat affected zone, of the axial and hoop stresses and their sensitivity to variation in
weld parameters are studied. Recommendations are given for the through thickness variation of the axial and hoop stresses to be used when
assessing the growth of surface flaws at circumferential butt welds in nuclear piping systems. 0 1998 Elsevier Science Ltd. All rights reserved

1. Introduction function of the heat input over wall thickness) is given by

The circumferential butt weld is a common type of joint
in piping systems in nuclear power plants. Owing to the
relatively large wall thickness in such piping systems,
the butt weld is often constructed of several weld passes.
This makes it difficult to predict the shape, in particular
through thickness variation, of the welding residual stress
field. When assessingthe risk for (further) growth of defects
suchassurface flaws in piping systems,the welding residual
stressesmay give a larger contribution to the total stress
field than stressescausedby design loads such as internal
pressure, temperature gradients and support reactions.
good estimation of the welding residual stressfield is then
needed. The welding stress field may also be important
when assessingthe risk for static fracture in piping systems
containing materials with brittle fracture behaviour. For
example, a large tensile axial residual stressin the Heat
Affected Zone (HAZ) at the inner surface of a stainless
steel pipe is believed to be one of three factors responsible
for intergranular stresscorrosion cracks, Fox [l] (the other
two being a sensitized material and a fluid containing high
oxygen content).
However, the shapeof the welding residual stressfield
dependson several factors like the structural restraint, the
wall thickness over diameter ratio, the heat input, the num-
ber of weld passes and weld pass sequence. Hence,
through-the-thickness variation of the residual stresscom-
ponentsmay be very complex. A collection of experimental
and numerical resultsand an attempt to provide an empirical
relation for the axial residualstresson the inner surface (asa
030%0161/98/$19.00 0 1998 Elsevier Science Ltd. All rights reserved
PII: SO308-0161(97)00117-8
Scaramangaset al. [2].
For the case of thin-walled pipes with relatively large
outer diameters, however, one may be able to predict the
residual stressfield. Then the heat depositedduring circutn-
ferential butt welding is high enough to result in a uniform
the temperatureincreasethrough the pipe thicknessat the weld.
The only deformation that will create thermal stressesis the
circumferential strain due to the radial expansion and sub-
sequentcontraction. This radial decreaseduring the cooling
after the welding together with the symmetry condition at
the centre section results in a almost linear through thick-
A nessaxial stressvariation with tensile axial stressesat the
inner surface (sometimesof yield stressmagnitude) and
compressive axial stresseson the outer surface. The
correspondinghoop stressesare normally tensile all through
the thickness and have about the samemagnitude as the
maximum axial stressesif the yield properties of the weld
and basematerial are about the same.Someearly analytical
models,employing the engineeringelastic thin shell theory,
are basedon these results [3,4].
For butt welds with larger wall thicknesses,and resulting
more complex through-the-thicknesstemperature gradients
present during welding, the magnitude of the residual axial
stressmay be much lower than the yield stressvalue (seefor
example Scaramangaset al. [21) Josefson[5], Josefsonet al.
the [6] and Gordon et al. [7]). As current codes still often
assumetensile axial stressesat the inner surface of yield
stressmagnitude and a rather large zone of tensile axial
stressesnear the inner surface [8], the assessmentof crack
growth may be unnecessarilyconservative.
12 B. Brickstad, B. L. Josefsonhtevtational
In the present paper, a procedure for determining the
residual stress field in multi-pass butt-welds in piping sys-
tems is proposed. The development of the temperature and
stress fields during the entire history during the welding is
simulated numerically by using a commercially available
FE-code [24] for non-linear analysis. The sensitivity of
this procedure to variations in values for weld parameters
(controlling the heat input) is investigated in particular.
Recommendations are given for the through thickness
variation of the residual axial and hoop stresses that can be
used when assessing the risk for growth of surface flaws at
circumferential butt welds in nuclear piping systems.
2. Numerical technique
In this section the numerical modelling of multipass butt
welds is reviewed. The numerical technique used in the
present analysis to compute the welding-induced residual
stresses is also described.
2.1. Numerical modelling of circumferential multipass butt-
welds in pipes
Several attempts have been made to follow, numerically
by use of FEA, the development of stresses during the con-
struction of multi-pass welds such as those in butt-welded
pipes. However, owing to the complexity of this problem,
some simplifications need to be made in order to obtain
reasonably long CPU-times, and possibly also to balance
the uncertainty in modelling the material behaviour and
in finding appropriate values for the entering material
properties.
2.1.1. Rotational symmetry
An assumption common for most analyses of multipass
butt welds is the assumption of rotational symmetry, i. e.
heat is assumed to be deposited at the same time around the
circumference. This assumption, which strongly reduces
the size of the FE-model and the CPU-time and disc memory
needed, can be justified by the fact observed in experiments
that residual stresses in circumferential butt welds is reason-
ably rotationally symmetric [9,10].
2.1.2. Simpli$ed temperature history
Another approach that reduces the CPU-time is to calcu-
late the temperature field present during welding by use of
the classical linear analytical solution by Rosenthal 1111
(see for example [6]), to use an envelope of temperatures
experienced during all weld passes [12,13] to group some
weld passes into weld layers [14], or to consider only the last
passes (or layer) [5]. One might also decide not to follow the
temperature history present during welding and cooling
after welding in detail [6]. This approach originates from
ideas put forward by Burdekin [15] and Umemoto and
Fumya [ 161, where it is assumed that all stresses are zero
Journal of Pressure Vessels and Piping 75 (1998) 11-25
during the welding (or at the holding temperature during
local stress relief annealing) and that the build-up of stresses
during cooling after welding (or after holding) could be
obtained in one step by loading the structure with the tem-
perature field present at the welding (holding temperature)
with opposite sign. Thus, a detailed analysis of elastic-
plastic material behaviour during cooling is not performed,
and the temperature history present during welding and
during cooling is not followed in detail.
2.1.3. Addition of weld jiller material
When analysing multi-pass butt-welds one also needs to
model the addition of (new) filler material as new weld
passes are deposited and the geometry of the weld joint is
being built-up. Formally, this can be treated in commercial
FE-codes by activating new elements through so-called
“element birth” options. However, this may give serious
numerical problems in the stress analysis as inactive
elements at the boundary between old, already deposited
material and new material deposited in the particular weld
pass may be strongly distorted when being activated. The
sides facing the old material have been deformed during
previous passes, while sides forming the new weld pass
are undeformed. Attempts to fit the undeformed filler ma-
terial to the deformed geometry will lead to a stress build-up
in this supposedly stress free material and a redistribution of
residual stresses from previous passes. One way to reduce
this problem would be to introduce the deformed geometry
from the previous pass to the filler material of the next pass,
possibly through some extra load steps [13,17]. Another
approach is to keep elements not yet activated at a high
“softening temperature’ ’ (see for example Troive et al.
[18] and Wilkening and Snow [19]). These elements will
then have a low stiffness and a very low yield stress. By
defining the reference temperature for the thermal expansion
coefficient for the weld metal as this softening temperature,
these elements will be thermal strain free. They will carry
very low stresses before they are activated and experience a
lower temperature. This latter method is used in the present
investigation as discussed in more detail below.
2.2. Present investigation
All analyses in this study are performed in two steps using
the finite element code ABAQUS, version 5.4 [24]. The
technique can be considered as well-established and the
procedure used in this study follows the one used by
Wilkening and Snow [ 191. First a transient thermal analysis
is performed during which the time-dependent temperature
distribution is determined for the successive build-up of the
welding passes. The temperature field at each time step is
then read for evaluating the stress and strain field in a sub-
sequent structural analysis. The problem is simplified by
assuming rotational symmetry and thereby neglecting
effects of heat flow in the circumferential direction.
 B. BI-i&fad, B. L. Josefson/lntenmtional
2.2.1. Thermal analysis
In the thermal analysis the addition of each weld passis
modelled by an element birth technique which meansthat
elementsbelonging to a certain passcan be activated at a
time corresponding to the time at which the molten weld
metal would be deposited. Heat input is modelled in
ABAQUS by a distributed heat flux DFLUX working on
individual elements (unit W mw3). It is connected to the
specific weld parameters,voltage U, current I and arc effi-
ciency 11by Eq. (1). The considered weld passvolume is
denoted by VP.
DFLUX = s
YP
The heat flux is applied with an assumedtriangular time
variation that can be said to correspond to the approach
and passing of the welding torch. The duration At of the
triangular time function is setto the time it takes for the weld
electrode with a travel speedv to move around a part of the
circumference that correspondsto the consideredweld pass
volume V,. In Appendix B, data of the net line energy Q and
travel speedv are given for the pipe weldsconsideredin this
study. The relation between the net line energy and weld
parametersis given by Eq. (2).
i7.I.q
Q=---
V
For the stainlesssteel welds consideredin this studiy, an arc
efficiency yeequal to 0.5,0.7 and 0.99 hasbeen assumedfor
the TIG, SMAW and SAW, respectively.
This procedureinvolves an unknown factor and that is the
fraction of the circumference that enters in the value of V,.
This comesfrom the axisymmetric approximation to what in
reality is a 3D heat flow problem. In a 3D-solution one
would simply let the welding electrode go around the cir-
cumference at the specified travel speed.Xna 2D..solution,
where the heat flux is actually applied instantaneously
aroundthe circumference, onehasto determine a reasonable
fraction of the circumference that determines V, and At.
This is done by adjusting this fraction of the circumference,
for the sets of best estimate weld parameters given in
Appendix 8, until a reasonablemolten zone size and dis-
tance to the HA2 (where the maximum temperature has
reached 800-900°C) from the fusion boundary, are
achieved. A reasonablemolten zone size is achieved when
at least the melting temperature (1340-1390°C) is reached
in all the finite elementsthat are included in the particular
weld pass.A reasonabledistanceto the HAZ is considered
to be a few mm from the fusion boundary. The variation of
the considered fraction of the circumference is done in a
consistentway, i.e. keeping the area (DFLUPAt /2) under
the time function constant, so the total amount of heat input
energy per unit volume is constant. In the consideredpipe
welds, a fraction of the circumference equalto l/16 to l/2 of
a radian was usedin general to obtain a best estimate solu-
tion. In the sensitivity analysis,when the net line energy Q is
Journal of Pressure Vessels and Piping 75 (1998) 1 l-25 13
varied, the distributed heat flux DFLUX is then varied while
keeping the duration At of the triangular time function con-
stant. After the down-ramp of the triangular time function
has reached zero, the weld pass is cooled down until a
specified interpass temperature is reached. In most cases
(except for the submerged arc welds SAW, which have
large travel speeds)this cooling time may be set to the
time it takes for the weld electrode to travel around
the whole circumference at the particular weld pass.
The thermal properties for the stainlesssteel base and
weld material in this study are given in Appendix A. They
are in general collected from specifications by the steel
(1) manufacturers. Above the melting point, the thermal con-
ductivity was doubled to simulate the convective stirring
effect in a molten material. Latent heat effects were
accountedfor by assuminga value of 260 kJ kg-’ between
the solidus temperature 1340°C and the liquidus tempera-
ture 1390°C.
The boundary conditions allow for both convection and
radiation. Radiation losses are dominating for higher
temperatures near the weld and convection losses for
lower temperaturesaway from the arc. A combined bound-
ary condition is used here [23], which accounts for both
convection and radiation. The resulting expression for the
temperature-dependentheat transfer coefficient ah is given
by Eq. (3).
ah = 0.0668.T w m-2, “c 0 < T < 500°C
c+,=0.231.T-82.1 Wm-‘, “C T > 500°C (3)
The boundary condition expressedby Eq. (3) was applied
for all free boundariesof the pipe including the successive
boundariescreated for each new weld pass.
The finite element meshesusedfor the pipes are given in
the Numerical Results section. The 8-noded axisymmetric
heat transfer element DCAX8 was used for all the thermal
analyses.Mesh refinement studieswere performed to deter-
mine a meshsize accurately enoughto resolve the tempera-
ture distribution aswell aslater the residual stressand strain
field. Automatic time stepping was used for the solution.
The accuracy of the solution is controlled by the specific
maximum allowed temperature change per time step. The
present analyses were performed using a value of 40°C
which proved to give accurate results and still avoided
unnecessarysmall time steps.The thermal analyseswould
typically include up to 200 increments for each weld pass
and about 3-5 iterations per increment.
2.2.2. Structural analysis
In the structural analysis,the temperaturehistory from the
thermal analysis is read for each time step increment. It is
possibleto use an element birth technique also in the struc-
tural analysis. However, introducing the undeformed filler
material into the deformed weld preparation after eachweld
passcan causeproblems.This will result in stressesbuilding
up in the supposedly stress-free filler material and a
 14 B. Brickstad, B. L. Josefson/lnternatiorlal Journal
Table 1
Pipe geometries and welds in the parametric study
Swedish BWR pipe system Pipe weld D Cm4
System 354 SS TIG 76.2
System 321 SS SMAW 219.1
System 312, 321 ss SMAW 324.0
System 3 12 SS SAW 451.2
System 313 SS SAW 680.0
D = outside diameter; TIG = tungsten inert gas; t= nominal pipe thickness;
weld
redistribution of the residual stresses in the previously laid
weld passes. This may be overcome by matching the weld
preperation nodal displacement after each pass to fit the
filler material. This will, however, imply rather time-
consuming manual work to prepare the input file, especially
for a weld with many passes. Instead, as mentioned above, a
simplified technique is used here, utilized, for example, in
Ref. [ 191. In [19], all weld material are active in the struc-
tural solution but nodes that belong to elements in weld
passes that have not yet been deposited are held at a high
temperature, the softening temperature TSOFT, until the
“birth time” of the elements of the particular weld pass.
The softening temperature is here taken to be 1200°C. At
this temperature, the stiffness and yield stress are so low that
the elements can be considered as effectively inactive.
Moreover, all computed temperatures were truncated to
TSOFT which would avoid excessively high computer
time. The heat-up portion of a particular weld pass is also
eliminated and the temperature in the pass during this part is
then set to TSOFT. This implies that elements in the current
weld pass are structurally inactive until the nodes in the
weld pass elements have cooled down to TSOFT. This
will in effect be the actual birth time of those elements.
With this technique, elements of new weld passes will be
bom almost stress-free. The modification of the temperature
history file to accomplish these changes is done with use of a
user subroutine in ABAQUS. An effect of this technique is
that even if unborn elements are practically stress-free, an
accumulated plastic strain will be developed in these
elements. However, this is believed not to influence the
residual stress results in the weld material other than in a
very local sense. This belief is supported by computations
performed with almost perfectly plastic material, which
gave some local differences of the residual stresses in the
weld centreline compared with a case using a normal hard-
ening modulus, but the general feature remained the same.
This observation was particularly true for the axial and
circumferential stress at the HAZ.
The mechanical properties for the materials in this study
are given in Appendix A. They are again in general
collected from specifications by the steel manufacturers.
Typical of the welded stainless steel BWR-pipes in Sweden
is that they are severely overmatched in yield stress. In
Appendix A, the yield stress for the stainless steel weld
material is assumed to be twice the value for the parent
of Pressure Vessels nnd Piping 75 (1998) II-25
1 (mm) No. of weld passes
7.1 4
12.5 10
17.5 14
25.0 21
40.0 36
SMAW = shielded metal xc weld: SS = stainless steel; SAW = submerged arc
material for lower temperatures. The yield properties are
best estimate values rather than minimum values. For higher
temperatures (above TSOFT) the yield stress, the elastic and
the hardening modulus are set to low values, essentially to
reset the hardening upon solidification. The von Mises yield
criterion and associated flow rule is used together with
kinematic hardening and a bilinear representation of the
stress-strain curve. Kinematic hardening is believed to be
the best model that can simulate the reverse plasticity and
Bauschinger effect that is expected to occur during welding.
The coefficient of thermal expansion 01is here set to a con-
stant value, independent of temperature. In this study CYis
set to the mean value between 20 and 600°C. This means
that only the initial temperature for each element needs to be
defined. For all elements belonging to the weld material, the
initial temperature is then set to TSOFT, and to 20°C for
the base material. In this way new weld pass elements will
be born thermal strain-free.
The same finite element meshes were used in the structural
analyses as in the thermal analyses. Eight-node biquadratic
axisymmetric elements CAX8 with full integration proved to
give the best convergence. Formally, use of the same FE-
mesh in both the thermal and mechanical analysis would
give incompatible thermal and mechanical strain fields.
However, the choice of a large number of quadratic elements
will lead to very small effects of this incompatibility. ABA-
QUS uses a Newton iteration method for solving the field
equations which can be improved by using a line search
algorithm when initial iterations are relatively far from the
solution. Also large deformations were accounted for in all
analyses. However, this proved generally to give only small
differences in the residual stress results compared with a
small deformation theory analysis. Using an automatic
time step procedure, typical solutions for the structural ana-
lyses would include up to 50 increments for each weld pass
and about 4-6 iterations per increment.
3. Numerical results
In this section the results of the parametric study are
presented. The specific pipe geometries are summarized in
Table 1.
All are girth butt welded pipes with geometries and
welding data taken from typical pipe systems in Swedish
 B. Bricbtad, B. L. Josefson/lnternalionnl Journal of Pressure Vessels and Piping 75 (1998) 11-25

HAZ

Fig. 1. Finite element mesh used for the 4-pass single-V bultt weld of
stainless steet. Inside radius R, = 31 mm and nominal pipe thickness f = --a- Q = 1.25 MJ/m
7.1 mm. -Q- Q = 0.72 MJ/m
--LY Q = 0.5 MJ/m
B WR-plants. In Appendix B details are given for each pipe --+- ASMEXI
of the net line energy and travel speed that correspond to the
best estimated values. Most of the specifications are taken 0 0.2 0.4 0.6 0.8 i
from Welding Data Sheets issued by Mannesmann Anlagenbau u/t
for Forsmark 3, which is the youngest BWR-plant in
Sweden. For the older BWR-plants in Sweden, no detailed Fig. 3. Axial stress at HAZ, 4-pass SS TIG-weld with varying net line
energy.
weld specifications generally exist for the pipe system
welds. A problem is that even for the cases where weld The complete investigation of this study is reported by
specifications exist, the data in terms of current, voltage Brickstad and Josefson [26] and the reader is referred to that
and travel speed are in general given with such wi’de limits report for more detailed information. In Ref. [26], a bi-
that the net line energy can easily vary with a factor of 4 and metallic weld in a large diameter pipe is also investigated.
still be inside the limits of the given welding parameters.
However, some combinations of weld parameters are 3.1. Four-pass stainless steel TIG weld
clearly unrealistic, i.e. they correspond to situajtions for
which either the melting temperature is not reached or a Fig. 1 shows the finite element mesh consisting of 328
too large molten zone size is achieved. It is, theriefore, an &node axisymmetric elements used for the 4-pass TIG
important part of this study to vary the net line energy of the welded pipe, Indicated in Fig. 1 are the weld pass sequence
considered pipe welds. The following parameters are and the HAZ-line at which the through thickness stresses are
included in the sensitivity analysis: evaluated besides the weld centreline. The line denoted by
Pipe size (pipe thickness and number of weld passes) HAZ is located approximately 2 mm from the fusion bound-
Net line energy Q ary. The pipe is unrestrained with a total length of 200 mm.
Ratio of pipe inner radius to thickness Rilt Figs 2-5 show the resulting axial and hoop stresses
Weld metal yield stress through the thickness of the pipe at the weld centreline
Interpass temperature and HAZ. The results are given as function of u/t, where u
is a coordinate that represents the distance along the weld

250 / I 500 , / / I I
4 weld passes
t,,,=7.1mm
400

200
2 IL it- Q = 1.25 MJ/m
-o- Q = 0.72 MJ/m i
3 -8- Q=1.2.5MJ/m
ir- Q = 0.5 MJ/m 100 1 - Q = 0.72 MJ/m
---e ASM!&XI + Q = 0.5 MJ/m
I I

0 I / /

0 0.2 0.4 0.6 0.8 1

u/t
Fig. 2. Axial stress at weld centreline, 4-pass SS TIG-weld with varying net Fig. 4. Hoop stress at weld centreline, 4-pass SS TIG-weld with varying net
line energy. line energy.
16 B. Brickstad, B. L. JoseSson/IntemntionaE
2
is
zP
882
G +
+
Q= 1.25 MJ/m
Q = 0.72 MJ/m
- Q = 0.5 Ml/m
-1.50 1 I
0 0.2 0.4 0.6
u/t
Fig. 5. Hoop stress at HAZ, 4.pass SS TIC-weld with varying
energy.
centreline or HAZ, starting at the inside of the pipe. The
stress curves have been smoothed before the presentation by
carrying out a five-point moving average. All stresses are
evaluated at 288°C which is the common operating tem-
perature for the BWR-plants. This is achieved by letting the
pipe experience a slow uniform heating to 288°C after cool-
ing down to room temperature following the last weld pass.
The reason for presenting the majority of the stress results at
this temperature is that stress corrosion cracks are generally
growing at the operating temperature. In Figs 2-5 the best
estimate line energy is considered to be 0.5 MJ m-‘. For this
line energy the analysis gives reasonable molten zone sizes
and distances to the HAZ-zone (where the temperature has
reached 800-900°C). For the highest line energy of
1.25 MJ m-l, the resulting molten zone sizes were large,
several millimeters into the base metal which actually are
too large to correspond to a realistic welding procedure. The
melting temperature is taken to be 1365°C.
Figs 2 and 3 show the axial stress distribution. The hoop
shrinkage causes the well known “tourniquet effect”, i.e. a
local inward deformation in the vicinity of the weld. This
means that the axial stresses for this thin pipe are of a simple
Fig. 6. Finite element mesh used for the Zl-pass single-u
Joumaf of Pressure Vessels and Piping 75 (1998) II-25
250
-250
0 0.2 0.4 0.6 0.8 1
0.8 1
u/t
Fig. 7. Axial stress at HAZ, 21.pass SS SAW with varying net line energy.
net line
linear bending in nature with tension over the inner wall
balanced by compression over the outer wall. The axial
shrinkage of later weld passes is not resisted by earlier
passes, since the whole thickness undergoes more or less
the same thermal cycle. It is possible to produce almost the
same weld residual stresses by only applying the last weld
pass which will heat the entire thickness to a relatively high
temperature. This is confirmed by analyses made in this
study. Moreover, it seems as though the axial residual
stresses are determined basically by the yielding properties
of the base material. There is not much difference for the
axial stresses between the weld centreline and HAZ. Note
that for lower temperatures the yield stress for the weld
material is twice the yield stress for the base material.
Also indicated in Figs 2 and 3 is the recommended distribution
by the ASME XI Task Croup for Piping Flaw Evaluation [8]
which is valid for t I 25 mm. The recommendation in Ref.
[8] seems to agree well with the present results for the
7.1 mm thick pipe.
Turning to the hoop stresses in Figs 4 and 5, they are
strongly tensile at the weld centreline. Their magnitude is
in general determined by the current material yield surface
and the axial stresses. This explains the high tensile stresses
butt weld of stainless steel. Inside radius Ri = 203.6 mm and nominal pipe thickness f = 25.0 mm.
 17

compressive axial stresses for the outer portion of the inner

wall for the lower line energies. Comparing with the ASME
XI recommendations for axial stress profiles in Fig. 7, it is
seen that the axial residual stress behaves neither as a thin-
walled pipe (t < 25 mm), nor as a thick-walled pipe (t >
25 mm). The hoop stresses are still tensile even if the mag-
nitude over the inner wall shows a reduced tension for the
best estimate heat input. It is believed that this is due to hoop
shrinkage of later weld passes that compresses the earlier
I passes. This explains why combination of axial and hoop
e Q=3.0MJ/m 21 weld passes
u Q = 2.5 MJ/m $)om=25mm stresses over the inner wall lie inside the yield surface in this
- Q = 1.78m/m Vt = 8.1 case.
T=288”C A few comments on the interpass temperature are appro-
OL L I I I b priate. The weld specifications normally specify a maximum
0 0.2 0.4 0.6 0.8 1 allowed interpass temperature of 100°C or 180°C depending
u/t on the type of stainless steel. In the present study, the inter-
Fig. 8. Hoop stress at HAZ, 21-pass SS SAW with varying net line energy. pass temperatures are reaching values between 100°C and
150°C. A lower interpass temperature than this does not
inside the weld and the lower hoop stresses in HAZ. This
seem to affect the residual stress results. If the time intervals
also explains why at the outer wall, which is experiencing
between each weld pass are constant, the interpass tempera-
axial compression, the hoop stresses are less tensile and
ture will slowly increase for each successive weld pass. It is
even compressive at the HAZ.
important that after each weld pass, to let the pipe cool down
to at least 150°C. This is especially important for the thick
3.2. Twenty-one-pass stainless steel SAW
pipes where the cooling rate is relatively slow. An interpass
temperature of say 300°C can influence the results signifi-
Fig. 6 shows the finite element mesh consisting of 788
cantly and will overestimate the heating of the pipe
g-node axisymmetric elements. The line denoted HAZ is
compared with a case with a lower interpass temperature.
here located approximately 2 mm from the fusion boundary
of the later passes. The unrestrained pipe has a total length
of 800 mm. The net line energy and travel speed are given in 3.3. Thirty-six-pass stainless steel SAW
Appendix B for a normal heat input with Q = 1.78 MJ m-l
for the later passes. The root pass is TIG-welded and Fig. 9 shows the finite element mesh consisting of 1136
SMAW is used for the second pass. The remaining passes &node axisymmetric elements. The line denoted HAZ is
are welded by SAW. The half groove angle is 12.5”. here located approximately 2.3 mm from the fusion bound-
The axial and hoop stress distribution at HAZ through the ary of the later passes. The unrestrained pipe has a total
pipe thickness are shown in Figs 7 and 8. The interaction of length of 1200 mm. The net line energy and travel speed
hoop and axial shrinkage leads to a more S-shaped axial are given in Appendix B for a normal heat input with Q =
stress profile through the thickness with the tendency of 2.38 MJ m-’ for the later passes. The root pass is TIG-welded

Fig. 9. Finite element mesh used for the 36pass single-U butt weld of stainless steel. Inside radius R, = 300 mm and nominal pipe thickness f = 40.0 mm
18 B. Brickssrad. B. L. Jos~fsorl/Intemarional Journal of Pressure Vessels and Piping 75 (199s) II-25

walled pipe with t = 40 mm, the axial stress profiles in Fig.

0 0.2
Fig. 10. Axial stress at HAZ,
10 are S-shaped and display tension-compression-tension-
compression from the inner wall and outwards. This is in
agreement with most other investigations for thick-walled
pipes (cf. Scaramangas (251). For all line energies studied,
the axial stresses are tensile at the inside of the pipe and turn
into compression after about 20% or less of the pipe
thickness. At about half the pipe thickness the axial stresses
become tensile again and for the last lo-20% of the
thickness, the axial stresses are compressive. For comparison
the ASME XI recommendation for t > 25 mm is also given
in Fig. 10. They agree qualitatively well with the present
results up to about 40% of the thickness. However, the
compressive part of the ASME XI recommended stress pro-
0.4 0.6 0.8 1 file seems to be too large. For instance, it does not satisfy
u/t force equilibrium. The net membrane stress resulting from
36-pass SS SAW with varying net line energy. the ASME XI stress profile is - 17.5 MPa. Also, the ASME
XI axial stress at the outside pipe wall is tensile which does
not agree with the results in this study as well as most other
investigations.
The hoop stresses in Fig. 11 are still tensile. However, at
the inside of the pipe at HAZ and also locally at the outside
of the pipe, a distinct reduction of the tensile hoop stresses
can be observed. This is also in agreement with other inves-
tigations (cf. Refs [8,25]).

-o- Q = 3.0 MJ/m 3.4. Injuence of pipe radius to thickness ratio Ri/t
-c+ Q = 2.38 MJ/m
+ Q= 1.79MJ/m All the pipes studied so far have ratios of Rilt less than 10.
In this section a limited study has been performed of the
effect of using a higher Rilt. A 16pass stainless steel
0 0.2 0.4 0.6 0.8 1 shielded metal arc weld with thickness t = 17.5 mm is
u/t chosen for closer study. Fig. 12 shows the finite element
mesh consisting of 502 8-node axisymmetric elements.
Fig. 11. Hoop stress at HAZ, 36.pass SS SAW with varying net line energy.
The line denoted HAZ is here located approximately
and SMAW is used for the second pass. The remaining passes 2.5 mm from the fusion boundary of the later passes. The
are welded by SAW. The half groove angle is 10”. unrestrained pipe has a total length of 600 mm. The net line
The axial and hoop stress distribution at HAZ through the energy and travel speed are given in Appendix B for a
pipe thickness are shown in Figs 10 and 11. For this thick- normal heat input with Q = 1.14 MJ m-l for the later

Fig. 12. Finite element mesh used for the 14-pass single-u butt weld of stainless steel. Inside radius R, = 144.5 mm and nominal pipe thickness t = 17.5 mm.
 B. Brickstad, B. L. Josefson/frztenlational Joumat of Pressure Vessels and Piping 75 ji998) II-25 19
250 I I I I I 250 1 1 I
--f Q = 2.28 MUm, R,/t = 8.3 --D- Q = 2.28 MJ/m
200 i --it Q= 2.28 MJ/m, equal yield stress
----t Q = 2.2s MJ/m, R,h = 30 z 200
!t u Q= l.l4MJ/m
z 150 i -
--o-
Q=1.14MJ/m,Ri/t=8.3
Q=1.14MJ/m,Ri/t=30
2 150 r + Q = 1.14 MJ/m, equal yield stress
.L
gi 100

P 50
2
0

Fj -5:
14 weld passes
kom = 17.5 mm
-100 i
/ T=288”C ~
-150 1 1 4
0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1
u/t u/t

Fig. 13. Axial stress at HAZ, 14-pass SS pipe with varying line energy and Fig. 15. Axial stress at weld centreline, 14.pass SS pipe with varying weld
Rift. metal yield stress.

passes. The root pass is TIG-welded with SMAW for the
remaining passes. The half groove angle is 8”. Figs 13 and
14 show the axial and hoop stresses at HAZ for two 14-pass
welded pipes and for two line energies. For the first pipe,
Rilt = 8.3 and in the second pipe the radius is expanded to
RJt= 30, keeping the thickness constant. The heat input
energy, measured per unit weld volume, is kept constant
between the pipes which means that it is possibllz to just
examine the influence of the difference in R,lt.
As can be seen in Fig. 13, the tensile axial stresses at the
inner part of the pipe wall are decreasing with increasing
RJt. This is consistent with the increasing compliance of the
pipe with Rilt = 30. The net bending moment over the pipe
thickness will thus be lower as the pipe flexibility increases.
This trend agrees well with the study by Gordon et al. [7],
who analysed a 16 mm thick pipe with Rilt = lo,25 and 50.
The hoop stresses at HAZ, Fig. 14 are not showing much
difference at the inside of the pipe wall for the varying Rilt.
The higher values of the hoop stresses at the outside of the
wall thickness at HAZ for Rilt = 30, are consistent with
the higher values for the axial stresses at the same position,
keeping the stress combinations on the yield surface.
3.5. Influence of weld metal yield stress
Typical of the welded stainless steel BWR-pipes in
Swedenis that they are severly overmatched in yield stress.
In Appendix A, the yield stressfor the stainlesssteel weld
material is assumedto be twice the value for the parent
material for lower temperatures.In this sectionthe influence
of the weld metal yield properties is investigated. The
14-passstainlesssteel shielded metal arc weld with thick-
nesst = 17.5 mm is again chosen for closer study. Two
casesare studied. The first one is the reference case with
the weld metal yield stresstwice the parent material yield
stress.In the secondcase,the yield properties of the weld
are assumedto be identical with the parent material, see
Appendix A.

250

200

150
2
100
$
‘J 50
2
gY) 0
3
G -50

-100

-150
0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1
Ii/t u/t
Fig. 14. Hoop stress at HAZ, 14-pass SS pipe with varying line energy and Fig. 16. Axial stress at HA& 14-pass SS pipe with varying weld metal yield
R,/t. stress.
20 B. Brickstad, B. L. Josefsor~~~~ternationnE Journal of Pressure Vessels and Piping 75 (1998) I1 -25

500 , / I I -D- t=7.lmm,Q/t=lOlMJ/m2

14 weld passes, T = 288 “C * t = 12.5 mm, Q/t = 91 MJ/m2
r t“OIlI = 17.5 mm, RJt = 8.3 * t = 17.5 mm, Q/t = 98 MJlm2
300 * t=25mtn,Q/t=lOOMJ/m2
2
-a 400 1 f- t=40rnm,Q/t=75MJ/m2
+ ASMEXI,t<25mm
2
T;;i 200 __ ASMEXI,t>25mm
I?s
2e 300 2
B 5 100
9 8
5 E
+d 200 23 0
L 3
B z
u Q = 2.28 MJ/m D -100
B^ 100 --3t Q = 2.28 MJ/m, equal yield stress
G - 4 Q= 1.14M.Vm
jE -200
-D- Q = 1.14 MJ/m, equal yield stress r Upper estimate
0
0 0.2 0.4 0.6 0.8 1 -300 I I I / I I
0 0.2 0.4 0.6 0.8 1
u/l
u/t
Fig. 17. Hoop stress at weld centreline, 14-pass SS pipe with varying weld
Fig. 19. Axial stress at weld centreline, 5 stainless steel pipes, upper esti-
metal yield stress.
mate heat input.

As shown in Figs 15-18, it is only the hoop stress at
the weld centreline that significantly changes with different
weld metal yield stress. This is consistent with the observation
that the axial residual stresses, both at the weld centreline
and at the HAZ, are determined basically from the yield
properties of the base material. The residual hoop stress is
then determined by the axial stress and the current yield
surface. That is the reason for the lower hoop stresses at
the weld centreline for the case when the yield
properties in the weld are the same as for the base material,
see Fig. 17.
4. Recommendations for axial and hoop residual stresses
for austenitic stainless steel pipe welds
In this section recommendations will be given for weld
residual stresses that can be used for subcritical crack
Q = 1.14 MJ/m, equal yield stress
growth due to stress corrosion in stainless steel pipes. In
order to make such recommendations, all results for the
different pipes are plotted in the same diagrams. A question
is then which line energy that should be used. Scaramangas
[25] suggested that the important parameter in determining
the shape of axial residual stress distributions besides the
pipe thickness is the line energy relative to the pipe thick-
ness, Qlt. Since the stresses will in general be higher for
increasing values of Q/t and since often it is not known
precisely what heat input has been used for a particular
weld, an upper estimate of heat input is used which here
corresponds to values of Q/t between 7.5 and 101. The
recommendations are also based on FEM-evaluations of a
pipe with 10 weld passes and thickness t = 12.5 mm,
although the detailed results of this evaluation are not
shown here owing to space limitation. For details of the
complete investigation, cf. [26].
U t=7.1mm,Q/t=101MJ/m2
+ t = 12.5 mm, Q/t = 91 MJ/m2
* t = 17.5 mm, Q/t = 98 MJ/m2
--O- t = 25 mm, Q/t = 100 MJ/m2
+ t=40mm,Q/t=75MJ/m2
+ ASMJ%XI,t<25nun
~ ASMEXI,t>25mm

I
14 weld passes
t,,, = 17.5 mm
0 R,/t = 8.3
T=288”C ~ I
-50 / / 1 I
0 0.2 0.4 0.6 0.8 1
u/t

Fig. 18. Hoop stress at JYIAZ, 14-pass SS pipe with varying weld metal yield Fig. 20. Axial stress at HAZ, 5 stainless steel pipes, upper estimate heat
stress. input.
 B. Brickstad, B. L. Josefson/lntei7zfltional Jozrrnal of Pressure Vessels and Pipirzg 75 (1998) II-25 21

500 1 I I
Upper estimate

q, = 297 - 9.88.t [MPa]

3
-G 200
2 -o- t = 7.1 mm, Q/t = 101 MJ/mZ
+ t = 12.5 mm, Q/t = 91 MJlm2
B0)
+ t = 17.5 mm, Q/t = 98 MJlm2
6% 100 - -c+ t=25mm,Q/t=100MJ/m2 i
-t- t=40mm,Q/t=75M.Vm2

0 / / , , 0 J 1
0 0.2 0.4 0.6 0.8 1
0 5 10 15 20 25
u/t
Pipe thickness t [mm]
Fig. 23. Hoop stress at weld centrefine, 5 stainless steel pipes, upper
Fig. 21. Equivalent bending stress versus pipe thickness for the axial estimate heat input.
residual stress at weld centreline and HAZ. Upper estimate heat input.

4.1. Axial stresses
Figs 19 and 20 show the axial residual stresses at the weld
centreline and at the HAZ for all five stainless steel pipes
considered in this study. For each location the upper esti-
mate of Q/t is used. In all casesthe temperature is 288°C.
The resultsagree qualitatively well with Scaramangas[25],
who concluded that the root axial stresswill not exceed half
yield tension if the heat input per pass Q/t, is less than
70 MJ m-‘.
For the axial stressesup to a pipe thicknessof 25 mm, the
recommendationsare based on a simplified procedure. An
equivalent linear bending stress or, over the normalized
thickness is calculated that has the same net bending
moment as the actual stressdistribution. A local bending
stresssatisfiesthe condition of zero net axial force, which is
a necessarycondition for a pipe with no end-restraint. This
is done for the upper estimate heat input. Also, it is found
that in terms of the equivalent bending stress,there is not
2.50 , / ,
it ASMEXI,t>25mm
-----t t=40mm,Q=3.0MJ/m
Polynomial fit, 5:th degree
a I
-150
0 0.2 0.4 0.6 0.8
u/t
Fig. 22. Polynomial fit for the axial stress at weld centreline and HAZ for
the 36pass stainless steel weld with r = 40 mm. Upper estimate heat input.
much difference between the weld centreline and the HAZ.
Taking the mean value of the equivalent bending stress
between the weld centreline and the HAZ for each pipe
thickness, the result is shown in Fig. 21. The broken line
in Fig. 21 representsthe piecewiselinear curve that connects
the equivalent bending stressfor each pipe thickness. The
linear curve between t = 7.1 and 25 mm representsa con-
servative estimate. Fig. 21 reflects the distinct trend in all
thesecomputations, i.e. asthe pipe thicknessincreases,the
axial residual stressesin terms of a net bending moment will
decrease. This is true even for increasing line energy
with increasing pipe thickness, i.e. keeping the ratio Qlt
constant.
Somewherebetween t = 25 and 40 mm, the axial residual
stressdistribution for high heat inputs changesand will be
more S-shapedwith compressive stressesbetween 20 and
50% of the thickness counting from the inside of the pipe,
balancedby tensile stressesin other parts. This suggeststhat
the distribution might be represented by a polynomial
/ I
expression.Again it is observed that there is not much dif-
ference between the resulting stressfor the weld centreline
and the HAZ. Taking the mean value of the stressesfor the
upper estimateheat input between the weld centreline and
the HAZ for the pipe thickness t = 40 mm, the resulting
stressprofile and the polynomial fit are shown in Fig. 22.
The evaluated temperature is 288°C.
The 5th degree polynomial in Fig. 22 for the axial resi-
dual stressdistribution is recommended for pipes with a
large thicknesswelded with many weld passes.It is different
from the recommendation in ASME XI Task Group for
Piping Flaw Evaluation [S], at least for u/t exceeding 0.3.
4.2. Hoop strefseS
1
Figs 23 and 24 show the corresponding hoop residual
stressesat the weld centreline and at the HAZ for the five
stainless steel pipes considered in this study. For each
22 B. Brickstad, B. L. Josefson/htemational Journal of Pressure Vessels and Piping 75 (1998) II-25

200 / I axial stresses in this region, and that the hoop and axial
Upper estimate A. ’ stress combinations in general finish on the yield surface.
Looking at Fig. 24, the hoop stresses are very near the base
material yield stress for the inner half of the pipe thickness.
Possible stress corrosion cracks are likely to initiate at the
inside wall and therefore no credit is here taken of
the decreasing hoop stress at the outside wall. However,
there is a distinct decrease in the hoop stress in the HAZ
for the pipe thickness equal to 40 mm. For thick pipes it is
therefore recommended in the HAZ for the hoop stress to
use a membrane stress cm equal to 75% of the base material
yield stress at 288”C, i.e. 121 MPa in this case.

4.3. Summary of recommendations

0 0.2 0.4 0.6 0.8 1

u/t The recommendations for the residual stresses are sum-

Fig. 24. Hoop stress at HAZ, 5 stainless steel pipes, upper estimate
input.
location the upper estimate of Q/t are used and in all cases
the temperature is 288°C.
At the weld centreline, the hoop stresses are strongly
tensile and in general of yield magnitude of the weld
material. In HAZ the hoop stresses are smaller, mainly
reflecting the lower yield stress of the base material. At
288°C the yield stress is 322 MPa and 161 MPa for the
weld and base material, respectively. Looking at Fig. 23,
there does not seem much point in distinguishing between
different pipe thicknesses at the weld centreline. The recom-
mended hoop stress at the weld centreline is therefore a
membrane stress urn equal to the weld material yield stress
at 288°C i.e. 322 MPa in this case. This recommendation is
valid regardless of the pipe thickness even if a slightly
reduced tensile stress can be seen at the inside of the pipe
for large pipe thicknesses.
At the HAZ, the recommendation for the hoop stress for
smaller pipe thicknesses is still a membrane stress u, equal
to the base material yield stress at 288”C, i.e. 161 MPa in
this case. It is observed that the hoop stresses at the outside
of the pipe are less tensile, which is a result of the compressive
heat marized in Table 2. They are valid for stainless steel welds
with relatively high heat input relative to the pipe thickness
and with the material properties for stainless steel as given
in Appendix A. All values refer to a temperature of 288°C.
At 288°C the yield stress is 322 MPa and 161 MPa for the
weld and base material, respectively. For other combina-
tions of weld and base material yield stress, appropriate
adjustments of these recommendations can be made. (Tb,
u. and u, can then be adjusted according to the current
base material yield stress, except for the circumferential
stress at the weld centreline, which should be adjusted
with respect to the current weld material yield stress.
5. Discussion
The present analysis is focused on the shape of the
residual stress field. It is therefore possible to make several
simplifying assumptions in the temperature analysis regard-
ing the high temperature behaviour. Formally, one may
perform FE-analyses where the fluid motion within the
weld pool is considered together with heat conduction in
the solidified material [27]. Examples of models for the

Table 2
Recommended axial and circumferential residual stress distributions for austemtrc stainless steel pipe welds at 288°C

Axial stress Circumferential stress Circumferential stress

Weld centreline and HA2 Weld centreline HAZ

ub=228MPa O<t~7mm cm = 322 MPa all t tr,=161MPa O<tSSOmm

eb = 297-9.88-t MPa 7 < t 5 25 mm
o,=121MPa t>30mm
>I ;~;,ytt;3y~

li = 79.4 MPa
a0 = 1.0000
a, = 3.8116
a2 = - 99.820
a3 = 339.97
a4 = - 404.59
a5 = 158.16
 B. Brickstad, B. L. Josefson/lnternational
weld pool behaviour with different levels of complexity are
discussed by Radaj [20]. Comparing results from, for exam-
ple, Ref. [27] with corresponding FE-analyses where only
the heat conduction equation is employed and with experi-
mental results for the residual stress field, one normally
finds that both FE-analyses agree equally well with the
experimental results. It is therefore concluded that in
the present case it is sufficient to obtain a qualitatively
correct shape of the temperature field, in space and time,
at high temperatures as an “initial condition” for the cal-
culation of temperature gradients at lower temperatures,
which possibly have a stronger influence on the residual
stress field.
When discussing the high temperature behaviour one
may also recall that our knowledge of the constitutive beha-
viour is limited. For example, the experimental information
on the yield and hardening behaviour during rapid heating
and cooling at temperatures near the melting point and dur-
ing possible phase transformations is very scarce. One is
therefore in practice forced to employ classical elasto-plastic,
or possibly visco-plastic, material models. This means that
the plastic deformations experienced by material located in
the weld metal and HAZ, in compression at high Itempera-
tures and in tension during cooling at lower temperatures
will be modelled by simple kinematic or isotropic hardening
models. As the numerical simplifications indicate that these
plastic strains may be rather large in the weld region one
should, in principal, employ a large strain formulation.
The present investigation deals with the build-up of weld-
ing stresses in butt-welded pipes of stainless steel. One
obvious question is then whether one would obtain the
same shapes of the residual stress field in butt-welded
pipes made of ferritic steels. There is one principal differ-
ence between these materials in their behaviour during
welding. The ferritic material experiences phase transfor-
mations in the solid state which will influence, primarily,
the mechanical analysis. It is well known that ferritic
material which is rapidly cooled, will exhibit a volume
increase during the phase transformation from austenite to
bainite and martensite. This will lead to local compressive
stresses which may or may not remain and be visible in the
residual stress field. In fact if the material is stressed there
will also be an additional plastic strain developed during this
final phase transformation, so-called transformation plasti-
city. For butt-welded pipes one may speculate that the effect
of phase transformation will be seen in the hoop stress
component [21]. During cooling after the phase transforma-
tion, the strong restraint from the symmetry condition will
lead to a considerable change in the axial stress, hence one
may not see any effects of phase transformations in this
stress component. The hoop stress component is, however,
not governed by symmetry conditions and changes relatively
little during the final cooling [9]. Numerical simulations then
indicate that effects of phase transformations may be visible
121I. Later FE-simulations where transformation plasticity
is modelled with a visco-plastic model [22] verify that the
Journal of Pressure Vessels and Piping 75 (1998) 11-25 23
hoop stresses are more difficult to model, which indicates
that they are more sensitive to the choice of constitutive
model. For multi-pass butt welds, however, one may
argue that the repated heating and cooling of material in
the HAZ will lead to a relaxation of any effects of phase
transformations in the residual stress field (after each pass).
Thus, the difference in shape in residual stress field between
stainless and ferritic steel pipes would be rather small. How-
ever, it should be noted that for butt welds of stainless steel
there is often a large difference in yield stress between the
weld metal and the HAZ. This is normally not the case when
working with ferritic steels. Our FE-simulations indicate
that also this difference between stainless steel pipes and
ferritic steel pipes does not seem to give large differences in
the residual stress field, at least not for the axial stress
component, see Figs 15-18. Thus, if no other data exist, it
should be possible to use the results in Table 2 to approx-
imate the weld residual stress distributions also for ferritic
piping, at least for the axial stress component. Proper adjust-
ments have to be made for the actual yield properties of the
ferritic pipe weld.
The recommended stress distributions in Table 2 are
aimed to be used for subcritical crack growth analysis for
intergranular stress corrosion cracks in stainless steel pipe
welds in BWR plants. Until now, the most widely used
residual stress data in Sweden have been the recommenda-
tions given by ASME XI Task Group for Piping Flaw
Evaluation [S]. It this therefore of some importance to
compare the residual stresses from the present study with
the recommendations in Ref. [S] and their respective impact
on the stress intensity factor Kr. For this purpose Ki-calcula-
tions have been performed for long circumferential surface
cracks in stainless steel pipes using a PC-program by
Bergman [28]. The stresses are then applied both using
the recommended values given in this study (Table 2),
and those given in Ref. [S]. The PC-program uses published
solutions of Ki, in this case a solution for circumferential
surface cracks by Bergman and Brickstad [29]. For non-
linear stress distributions through the thickness a lineariza-
tion procedure is used in Ref. [28]. The stress state is
linearized with the condition that the same normal force
and moment is retained as the actual stress distribution,
measured over the crack face. This technique has proved
to give good results compared with finite element solutions.
The following qualitative results can be given in terms of
the thickness t of the pipe and referring to the deepest point
of the crack:
5.1. Circumferential su$ace cracks (weld and HAZ)
1. For small pipe thicknesses (t 5 9 mm), the present study
gives somewhat higher KI than ASME XI [S].
2. For intermediate pipe thicknesses (9 < t 5 25 mm), the
present study gives lower KI than ASME XI [8].
3. For large pipe thicknesses (t > 25 mm), the present study
24 B. Brickstad, B. L. Josefsonhtemational Journal qf Pressure Vessels and Piping 75 (1998) II-25

gives lower K1 than ASME XI [S] for small crack depths, Swedish stainless steel nuclear piping. For longer cracks,
ult up to 0.25-0.35. the situation wiI1 be more complicated. It is expected that
the lower circumferential residual stresses in the HAZ and
further into the basematerial, will reduce the values of K1.
5.2. Axial su$ace cracks

For axial surfacecracks acrossthe weld, no evaluationsof Acknowledgements

Kr have been performed. This is partly due to the strong
variation of the residual stressesalong the crack length if
the crack extendsbeyond the weld metal zone (seeTable 2).
This is a 3-dimensional problem for which no simple KI-
solutionsexist. If a short axial surface crack is completely
within the weld metal zone, Table 2 indicates that the pre-
sentstudy will result in higher K1 than ASME XI [8]. This is
due to the relatively high weld metal yield stress of the
The financial support from The Swedish Nuclear Power
Inspectorate (SKi) is gratefully acknowledged. The authors
are also indebted to Mr M. Rogowski at Mannesmann
Anlagenbau and Mr P. Almkvist, SAQ Kontroll AB, for
helpful information of pipe weld proceduresand to Mr 0.
BjGmdahl, SAQ Kontroll AB, for valuable help with some
of the finite element meshes.

Appendix A Thermal and mechanical properties

Appendix A. I Material properties for stainlesssteel baseand weld material

T (“C) cp(Jkg-‘, “C) h (W m-l, “C) E ( X 10” Pa) v uY base (MPa) uY weld (MPa) ET/E a ( x 10-6”c-‘)

20 442 15.0 2.0 0.278 230 460 0.014 19

200 515 17.5 1.85 0.288 1x4 367 0.014 19
400 563 20.0 1.70 0.298 132 264 0.014 19
600 581 22.5 1.53 0.313 105 209 0.014 19
800 609 25.5 1.35 0.327 77 154 0.014 19
1000 631 28.3 0.96 0.342 50 50 1 x lo-” 19
1200 654 31.1 0.50 0.350 10 10 1 x 10-4 19
1340 669 33.1 0.10 0.351 10 10 1 x 1o-4 19
1390 675 66.2 0.10 0.353 10 10 1 x 1o-4 19
675 66.2 0.10 0.357 10 10 1 x 10-4 19

T = temperature; Y = Poisson’s constant; I+ = specific heat; uY = yield stress; X = conductivity; ET z hardening modulus; E = elastic modulus; my = mean
coefficient of linear thermal expansion

Appendix B Net heat line energy and travel speedfor the welds

Appendix B.l Net heat line energy and travel speedfor 4- Appendix B.3 Net heat line energy and travel speedfor 21-
pass single-V stainlesssteel butt weld passsingle-U stainlesssteel butt weld

Pass Net line energy Q Travel speed Pass Net line energy Q Travel speed
(MJ W’) (mmmm ‘) (MJ m-‘) (mm mill-‘)

l-4, TIG 0.5 60 1, TIG 0.69 65

2, SMAW 1.11 75
3-21, SAW 1.78 415

Appendix 8.2 Net heat line energy an.dtravel speedfor 14- Appendix B.4 Heat line erzergyand travel speedfor 36-pass
pass single-U stainlesssteel butt weld single-U stainlesssteel butt weld

Pass Net line energy Q Travel speed Pass Net line energy Q Travel speed
(MJ m-l) (mm min -I) (MJ m-‘) (mm min-‘)

1, TIG 0.48 60 1, TIG 0.70 50

2-4, SMAW 1.09 80 2, SMAW 1.14 110
5-14, SMAW 1.14 110 3-36, SAW 2.38 400
 B. Brickstad, B. L. Josefsonhtemational Journal of Pressure Vessels arld Piping 7.5 (1998} 11-25 25

References [15] Burdekin FM Local stress relief of circumferential butt welds in cylin-
ders. British Welding Journal, 1963;10:482-490.
[l] Fox M An overview of intergranular corrosion cracking in BWRs. [16] Umemoto T, Furuya S A simplified approach to assess weld residual
Journal of Materials in Energy Systems, 1979;1:3. stress distribution through pipe wall. Nuclear Engineering and Design,
1’21 Scammangas A, Porter Goff RFD, Residual stresses in cylinder girth 1989;111:159-171.
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