焊接残余应力与变形分析

1、Double-V 6-Pass Butt-WeldAt Vessel Bottom“Bending” Type Residual Stresses in Other Weld Configurations其它焊接结构的“弯曲”型残余应力双坡口6道对接焊Double-V 30-Pass Butt-WeldAt Vessel End容器末端双坡口30道对接焊Nozzle to VesselWeld接管焊接焊接残余应力与变形分析Validation by Experiments and Parametric Analyses Stainless Steel Pipe Girth Weld试验验证和参

2、数分析不锈钢钢管环焊 Bending Type弯曲类型焊接残余应力与变形分析Validation by Experiments and Parametric Analyses Carbon Steel Pipe Girth Weld (Mochizuki ,00) 试验验证和参数分析碳钢钢管环焊(Mochizuki ,00)焊接残余应力与变形分析Validations of Self-Equilibrating Type自平衡类型的验证焊接残余应力与变形分析Pipe Radial Restraints: A Key Controlling Parameter for Bending Conte

3、nt in Residual Stress Distribution管的径向约束：残余应力分布中弯曲中心(?)的关键控制参数Hoop strain环向应变：Hoop stress环向应力：Hoop line force环向力：Radial line force径向力：Radial modulus径向模量：Characteristics length特征长度：Displacement wave length位移波长：iyitStF2rEtk rt.EIk285144r/tSr/tr/FFiyirrt.a942焊接残余应力与变形分析Pipe Radius Effects on Axial Resi

4、dual Stress Distributions钢管半径对轴向残余应力分布的影响焊接残余应力与变形分析Thickness Effects on Through-Thickness Residual Stress Distributions at Toe (r/t=10)板厚对焊趾处厚度方向残余应力分布的影响(r/t=10)Axial Residual Stress轴向残余应力Hoop Residual Stress环向残余应力焊接残余应力与变形分析Axial Residual Stress Through Thickness Bending Component轴向残余应力厚度方向上的弯曲分量

5、Unit length bending moment:单位长度的弯矩：焊接残余应力与变形分析Parametric Descriptions of Through-Wall Axial Residual Stress Distributions整个厚度上轴向残余应力分布的参数描述焊接残余应力与变形分析Residual Stress Influence Region Can be Scaled by残余应力影响区域可由 确定rtrt焊接残余应力与变形分析Residual Stress Profiles in the New API 579-1/ASME FFS-1新版API 579-1/ASME

6、FFS-1中对残余应力的概述焊接残余应力与变形分析Observations小结:nA residual stress typing method is proposed to provide a framework for developing a comprehensive residual stress prescriptions for FFS purpose 为进一步理解残余应力描述，提出了一种残余应力分类方法的框架nTwo fundamental types of axial residual stress distributions are identified 确定了两种基本类型

7、的轴向残余应力分布nAn general residual stress distribution can be estimated by a proper mixture of the two fundamental types 一般残余应力的分布可由这两种基本类型来评估nSome of the critical parameters controlling bending to selfequilibrating composition are established (t and r/t, or sqrt(rt) 确定了控制弯曲到自平衡分量的（？）一些关键参数nThe contribut

8、ions of residual stresses to K should be treated as displacement controlled conditions 残余应力对K的作用被视为位移控制条件焊接残余应力与变形分析Fracture Mechanics Treatment of Residual Stresses in Defect Assessment缺陷评估时断裂力学对残余应力的处理n Fracture mechanics driving force characterization 断裂力学的裂纹扩展特性n Proper treatment of residual str

9、esses in fracture Assessment 在断裂评估方面残余应力的适当处理n Contributions of residual stresses to fracture 残余应力对断裂的贡献 焊接残余应力与变形分析J-Integral: Path Dependency of J in Conventional FormJ积分：传统形式中J的路径相关性n Through-wall self-equilibrating residual stress component 厚度上自平衡残余应力分量n Significant non-proportional Loading 明显的非

10、比例加载焊接残余应力与变形分析Stress-Strain Behavior in Residual Stress Field Upon External Loading Validity of K基于外部载荷下的残余应力场中应力-应变行为K的有效性焊接残余应力与变形分析3D Finite Element Alternating Method for K Calculations K计算的3D有限元交替法Unique Features: 独特性：Direct use of a 3D CAD Model 三维 CAD模型的直接使用Rapid solution method 快速求解方法Partia

11、l and fully imbedded cracks 部分或完全的嵌入裂纹Multiple cracks solved simultaneously 多裂纹同时求解Propagating cracks 裂纹扩展焊接残余应力与变形分析Equilibrium Based Residual Stress Decomposition Technique基于平衡条件的残余应力分解技术Actual Residual Stress State实际残余应力状态Residual Stress Decomposition残余应力的分解焊接残余应力与变形分析Approximate K Solution Displ

12、acement Controlled近似K求解位移控制焊接残余应力与变形分析Effects of Through-Wall Residual Stress Distribution on K厚度上残余应力分布情况对K值的影响焊接残余应力与变形分析Validation - a Stainless Steel Core Shroud H4 】Weld验证不锈钢芯座 H4 焊接焊接残余应力与变形分析Residual Stress Decomposition for a Stainless Steel Joint不锈钢接头的残余应力分解焊接残余应力与变形分析C-Mn Vessel Shell Repa

13、ir with Temper Bead Techniques用焊道回火技术修复C-Mn容器壁Analysis performed at Battelle Measurements:Surface: MBELThickness: Bristol University在Battelle做分析测量：表面：MBEL（英国三井巴布科克公司）厚度：布里斯托尔大学Microstructure ModelPredictions: Relativelyhigh volumetric fractionsFor martensite, but verylocalized within 1 mmrange显微结构模型

14、预测：马氏体的成分较高，但是集中在1mm范围内焊接残余应力与变形分析Residual Stress Decomposition: 60 Pass Temper-Bead Repair Weld残余应力分解：60道回火修复焊缝焊接残余应力与变形分析K SolutionsK求解焊接残余应力与变形分析Stress Intensity Contributions from Residual Stress, Notch Stress, and Structural Stress残余应力、缺口应力和结构应力对应力强度的贡献焊接残余应力与变形分析H4 Weld Stress Corrosion Cracki

15、ng in Core Shroud芯座的H4（？）焊缝应力腐蚀裂纹n Negligible external loading 很小的外部载荷n Circumferential crack growth up to about 1m longnot surface breaking 环形裂纹增长至约1m长非表面断裂n Needs: 需要：l Identify crack driving force 确定裂纹扩展力Establish how crack will potentially grow 确立裂纹如何扩展焊接残余应力与变形分析Residual Stress Analysis and Res

16、ults H4残余应力分析及结果H4焊接残余应力与变形分析Analysis of A Growing Surface Crack扩展中的表面裂纹分析焊接残余应力与变形分析K Solution for a Long Surface Crack长表面裂纹的K求解焊接残余应力与变形分析SSC Growth Behavior Estimation in a Storage Vessel船舶存储罐的SSC（硫化物应力裂纹）扩展行为估计n Background 背景n Residual stress solutions for a girth weld 环焊的残余应力求解n Stress intensit

17、y factor solution techniques 应力强度因子求解技术n Crack growth behavior in residual stress fields 在残余应力场中裂纹的扩展n Summary 概要焊接残余应力与变形分析Background背景n Cracks detected at various welds in high level waste storage tanks 在高级废料存储罐不同焊缝上发现裂纹n External loading: small 外部载荷：小n Weld residual stresses: believed to play dom

18、inant role in crack initiation and growth 焊接残余应力：认为其对裂纹的萌生和增长起主导作用n Comprehensive FFS evaluation were performed: 深入理解FFS评估： Residual stress estimate for typical welds 典型接头的残余应力预测 Stress intensity factor calculations for propagating cracks 扩展裂纹的应力强度因子计算 Recommendations for FFS assessment incorporatin

19、g residual stress effects 结合残余应力影响的FFS评估建议焊接残余应力与变形分析Typical Weld Configurations in High-Level Waste Tanks高级废料存储罐中典型焊缝分布焊接残余应力与变形分析Residual Stress Model for Horizontal Girth Welds水平环焊的残余应力模型焊接残余应力与变形分析Predicted Residual Stress Distributions Horizontal Girth Welds残余应力分布的预测水平环焊焊接残余应力与变形分析K Behavior fo

20、r A Growing Transverse Surface Crack: Before and After Breaking Surface横向表面扩展裂纹的K值表面开裂前后焊接残余应力与变形分析3D FEAM Model: Through-Wall Crack Definitions三维有限元模型：厚度方向上裂纹的定义FEAM Model有限元模型Transverse Crack横向裂纹Simulated CrackConfiguration模拟裂纹形态Longitudinal Crack纵向裂纹焊接残余应力与变形分析K for A Growing Through-Wall Crack T

21、ransverse to Weld垂直于焊缝厚度方向上的扩展裂纹K值焊接残余应力与变形分析K Behavior for A Growing Longitudinal Surface Crack Parallel to Weld表面纵向扩展裂纹K值平行于焊缝焊接残余应力与变形分析K for A Growing Through-Wall Crack Parallel to Weld平行于焊缝厚度方向上的扩展裂纹K值焊接残余应力与变形分析Observations小结： Residual stresses in typical tank girth welds and seam welds were

22、characterized 在典型油罐中环焊和滚焊焊缝中残余应力的特点 Transverse residual stresses: “self-equilibrating” type 横向残余应力：自平衡类型 Longitudinal residual stresses: of typical double-V joint 纵向残余应力：典型双V接头 Residual stress induced stress intensities: 残余应力引起的应力强度 Longitudinal cracks: 纵向裂纹 Initially small surface cracks tends to g

23、row deeper first up to about 1/2t, then grow longer along the weld 初始表面小裂纹首先向深度扩展达到1/2t，然后沿焊缝继续扩展 If through-thickness cracks develop, SIF remains constant 如果裂纹沿厚度开裂，SIF保持常值 Transverse surface cracks 横向表面裂纹 Initially small surface cracks tends to grow faster in depth and become a through-wall crack

24、初始表面小裂纹向深度方向开裂的较快，然后形成贯穿整个厚度方向上的裂纹 Positive SIFs along crack front can be seen for potential crack growth up to 4-5 weld widths away 对于可能扩展到4 5倍焊缝宽度的裂纹，沿裂纹前端可以得到正的 SIFs焊接残余应力与变形分析Brittle Fracture in Beam to Column Connection in North Ridge Earthquake在North Ridge地震中梁柱连接处的脆性断裂n Brittle Fracture of wel

25、ded beam-to-column moment resisting frames 抗弯焊接梁柱框架的脆性断裂n All weld properties satisfy building code requirements 所有焊接性能满足建筑规范的要求焊接残余应力与变形分析Residual StressCharacterization High residual stress induced tri-axiality残余应力特点高残余应力引起的三维分布焊接残余应力与变形分析Residual Stress Tri-Axiality vs Plastic Deformation Capacit

26、y.三维残余应力与塑性变形能力焊接残余应力与变形分析Representative Welded Plate Specimen Results典型焊接板试件结果焊接残余应力与变形分析Fracture Mechanics Analysis Considering Residual Stress考虑残余应力的断裂力学分析焊接残余应力与变形分析A Superheater Header Repair Weld and Creep Damage Assessment过热箱补焊及蠕变损伤评估As-Welded焊态As-Welded Residual Stresses焊态残余应力Max. Creep Dama

27、ge = 1(after 600 hours Service) 最大蠕变损伤1 （服役600个小时）焊接残余应力与变形分析A Case Study on Local PWHT for Residual Stress Relieving - Superheater Header消除残余应力的局部热处理案例研究过热箱As-Welded Residual Stresses焊态残余应力Creep Damage duringLocal PWHT (ASME)局部热处理时蠕变损伤(ASME)Post Heat Treatment(Max.Nodal Damage=0.68) 热处理（最大节点损伤0.68）

28、焊接残余应力与变形分析Residual Stresses After An Alternative Stress Improvement Technique: “ Hot Compression”交变应力后的残余应力改进技术：“热压”焊接残余应力与变形分析Creep Damage Assessment蠕变损伤评估As-Welded焊态“Hot-Compression” Treatment热压处理焊接残余应力与变形分析Remarks小结： Residual stress contributions to K are quantified according to two dominated ty

29、pes 残余应力对K贡献的可以根据两种主要类型量化“Bending” type long range 弯曲大尺度范围“Self-equilibrating”- short range 自平衡小尺度范围 In general, displacement controlled K solutions are more appropriate 总的来说，位移控制K求解更恰当 A weld residual stress decomposition technique (3 parts) is proposed for K solution 对K求解提出了一种焊接残余应力分解技术 The effect

30、s of higher order self-equilibrating terms are negligible 高阶自平衡项的影响可以忽略 Dominant regimes（主要范围）焊接残余应力与变形分析Weld Sequence and Fixturing Optimization: Welding of Hydroformed Frames焊接顺序及夹具优化：液压架焊接焊接残余应力与变形分析Weld Sequence Effects on Final Distortion: Hydroformed Frames焊接顺序对变形的影响：液压架焊接Left Rail左架Right Rail

31、右架焊接残余应力与变形分析Combined Hydroforming and Welding Effects on Joint Property and Residual Stress State液压成形及焊接对接头属性及残余应力状态的影响焊接残余应力与变形分析In-Process Rolling Techniques to Mitigate Buckling Distortions减轻屈曲变形的加工滚压技术Welding Setup焊接建立（b)Temperature Distribution温度分布焊接残余应力与变形分析Effect of In-Process Rolling on Lon

32、gitudinal Residual Stress滚压对减缓纵向残余应力的作用焊接残余应力与变形分析Results结果焊接残余应力与变形分析Buckling Distortions in Lightweight Shipboard Panel轻量化船板屈曲变形Shop-Floor Photo船板照片LIDAR ScanLIDAR扫描焊接残余应力与变形分析LIDAR Characterization of Distortion Characteristics in Panel Design #1船板设计1变形特点的LIDAR描述n Out of plane distortion already

33、developed before and after tacking butt seam 定位对接焊之前和之后的 船板外变形n Wave lengths decreased after stiffener welds 焊接加强板后的屈曲波长的减小n The wave length isapproximately related panel aspect ratio and stiffener spacing 波长大小与板的形状、加 强版间距有关 焊接残余应力与变形分析What Drives The Out- of-Plane Distortions?什么引起了船板外变形？焊接残余应力与变形分析

34、Comparison of Measurements Between Two Panels -Design #3两个船板LIDAR测量的比较设计3n A similar trend to Design #1 与设计1相似n Insert plates raises local wave height 插入的板提高了局部屈曲波 的高度n Overall distortion characteristics: approximately same for same designs 整个结构的变形特点：相同 的设计变形相近 焊接残余应力与变形分析A Similar Trend Can be Obse

35、rved for Panel Design #3船板设计3观察到相似的变形趋势Significant Compressive Longitudinal Stress显著纵向应力Negligible TransverseResidual Stress忽略横向残余应力Additional features are due to insert and end plates插入板和端板的额外特征焊接残余应力与变形分析Buckling Distortions in Test Panel Design 3: Predicted versus Measured船板设计3的屈曲变形测试：仿真与测量比较FE E

36、stimation有限元评估LIDAR ScanLIDAR扫描Shop-Floor Photo船板照片焊接残余应力与变形分析Reversed Arching for Mitigating Buckling Distortion in Stiffened Panel减缓加筋板屈曲变形的反向变形方法焊接残余应力与变形分析Welding Assembly Sequence and “Reversed Arching” Technique Panel Design #2焊接装配顺序及反向变形技术船板设计2焊接残余应力与变形分析残余应力对疲劳的影响n Two part driving force 两部分

37、源动力 Applied stress and SCF characterization 施加的应力和SCF的特点 How to calculate consistent SCF? 如何计算协调SCF？ Residual stress 残余应力 Recent developments on consistent treatment of residual stresses in fatigue model 疲劳模型中残余应力的协调处理的最新发展 How to combine applied stress with residual stresses? 如何同时考虑施加的应力和残余应力？ The

38、key: residual stress effects on fatigue crack should be characterized as “displacement controlled” conditions 关键：残余应力对疲劳裂纹的影响被看作 “位移控制”条件。Residual stress effects on Fatigue焊接残余应力与变形分析The Two Major Issues in FE-Based Fatigue Evaluation Procedures Today目前基于有限元的疲劳评估方法的两个主要问题 How to eliminate mesh-sensi

39、tivity？如何消除网格敏感性？hich S-N curve to use?使用哪条S-N曲线？焊接残余应力与变形分析The Mesh-Insensitive Structural Stress Method and Master S-N Curve Approach网格不敏感结构应力法和主S-N曲线法nMesh-insensitive structural stress method 网格不明感结构应力法n Master S-N curve 主S-N曲线nAdopted by: 采纳： 2007 ASME Div 2 Code 2007 API-579/ASME FFS-1焊接残余应力与变

40、形分析目前焊接接头疲劳设计和残余应力效应的方面的规范及标准n Fatigue data of welded joints in general do not show significant mean stress or applied stress ratio effects 焊接接头的疲劳数据总体来说不能明显反映平均应力或所施加的应力比的影响n Use S-N data generated from a given mean load 使用给定平均载荷下的 S-N数据l Mean load - often using load controlled conditions 平均载荷经常使用载

41、荷控制条件 Derive a mean stress correction factor 获得平均应力修正系数 Use stress range with the mean stress correction factor to be conservative 为保守起见，使用考虑平均应力修正系数的应力范围 Some recommends using high mean stress S-N data without correction factor to be conservative 为保守起见，使用不考虑修正系数的高平均应力S-N曲线的一些建议Current Codes and Sta

42、ndards for Fatigue Design of Welded Joints and Residual Stress Effects焊接残余应力与变形分析Comparison of Fatigue Test Data with Different Stress Ratio or Mean Stress Effects: As-Welded不同应力比或平均应力影响的疲劳测试数据比较 ：焊态 焊接残余应力与变形分析Comparison of Fatigue Test Data with Different Stress Ratio or Mean Stress Effects: As We

43、lded vs Stress-Relieved不同应力比或平均应力影响的疲劳测试数据比较 ：焊态与应力释放焊接残余应力与变形分析Recent S-N Data from HHI Mean Stress Effects Simulating Residual stress Effects来自HHI最新S-N曲线平均应力效应模拟残余应力效应焊接残余应力与变形分析An Equivalent K Definition Incorporating Mean Stress Effects考虑平均应力效应的一个等效K定义 焊接残余应力与变形分析Two-Stage Growth Model Incorporating Loading Ratio Effects (R)考虑载荷比效应的两阶段扩展模型焊接残余应力与变形分析Crack Growth Rate Data裂纹扩展速率数据W/O R Effects有/无效应W/R Effects有效应焊接残余应力与变形分析焊接残余应力与变形分析焊接残余