RESIDUAL STRESS DISTRIBUTIONS FOR MULTI-PASS WELDS IN PRESSURE VESSEL AND PIPING COMPONENTS

Panagiotis Michaleris Technical Division Edison Welding Institute 1100 Kinnear Road Columbus, OH 43212

ABSTRACT A welding simulation methodology is implemented and experimentally validated to predict residual stresses on multi-pass welds. The simulation involves performing thermo-elasto-plastic analyses using a consistent element activation approach in the mechanical analysis. A compendium of residual stress distributions in common pressure vessel and piping components is generated by using the multi-pass finite element methodology. Residual stresses are computed for circumferential girth welds on thin- and thick-walled pipes with various radius to thickness ratios. Both single- and double-V weld joints are investigated. Additional analyses are performed to evaluate seam welds and the effects of end restraint and hydrotest. 1.0 Introduction Although extensive data is available for residual stress distributions in common pressure vessel and piping geometries, generalizations and comparisons for geometry and process effects are difficult due to the non-uniformity in the materials and the method that the residual stress is determined (Scaramangas, 1984). Early efforts to evaluate residual stress in piping components involve imposing on a cylinder the residual stress profile generated by a similar weld in a plate by using shell theory (Vaidyanathan, 1973; Fujita, 1979). A difficulty of implementing such techniques is obtaining an estimate or measurement of residual stress for an equivalent weld in a plate. Furthermore, in multi-pass welds, the development of residual stress is coupled with the increasing structural resistance of the shell as the weld is deposited. Additional passes tend to impose axial compression over the residual stress pattern of the initial passes. Therefore, the applicability of these techniques is limited to thin-walled pipes with a few passes. Computational approaches developed over the last 15 years include elasto-plastic welding simulations. Most notable is the work of Rybicki (1979) involving an analytical thermal model which serves as input to a

mechanical model. The limitation of these models is the use of approximate analytical solutions for the thermal history. Such approximations overpredict the temperature in the weld region and ignore the effects of the latent heat of fusion. Furthermore, the mechanical models lump multiple weld passes into one, resulting in a fundamentally different weld being modelled than the one of interest. More recent computational approaches for welding residual stress involve the use of interface elements between the filler and base metal (Bertram, 1991, Das, 1993) to simulate the filler metal deposition. Shim and his coworkers (1992) use the software ABAQUS to simulate multiple pass welds. In their approach, after the completion of each pass, the elements of the next pass are stretched to fit the deformed geometry. This approach may introduce errors and convergence difficulties since each pass is not activated at a zero initial stress state. In this work, the improved heat input models used on plates (Goldak, 1984; Tekriwal, 1992; Das, 1993; and Michaleris, 1995) are applied to the weld modelling of pipes. Furthermore, a consistent element activation technique is implemented in the multi-pass mechanical analyses. Coincident nodes and multi-point constraints are used to introduce the filler metal in an undeformed configuration. The computational methodology is validated by comparing the computed results against thermocouple and residual stress measurements performed on test components. A compendium residual stress distributions is generated for common pressure vessel and piping geometries. Through-thickness residual stress plots are generated to facilitate future fracture assessments. Finally, the effect of pipe wall thickness, pipe radius to wall thickness ratio, weld joint design (e.g., single- and double-V), hydrotest, end restraint, and weld joint type (i.e., seam or girth weld) on the residual stress distribution are investigated.

2.0 Welding Simulation 2.1 Computational Approach Two-dimensional (2-D) thermo-mechanical welding simulations are performed to determine the residual stress. The welding simulations follow the work of previous investigators (Goldak, 1984; Chakravarti, 1986; Tekriwal, 1992). Two-dimensional nonlinear transient heat flow finite element analyses are performed in the plane perpendicular to the welding direction. The heat generated by the welding process is modeled with a "double ellipsoid" heat source model (Goldak, 1984) for each fillet, where a power density moving along with the torch is used. Radiation and convection boundary conditions are assigned to all free surfaces. Quasi static mechanical finite element analyses follow the heat transfer analyses and use the computed temperature history as loading. Elastic-plastic material response is assumed with kinematic work hardening. Solid- state phase transformations are not considered. The welding simulations are performed using the commercial code ABAQUS. Axisymmetric analyses are performed for girth welds, while generalized plane strain analyses are performed for seam welds. The MODEL CHANGE option of ABAQUS is used to simulate multi-pass welding (ABAQUS, 1994, Shim, 1992). The elements at the pass interfaces are assigned double coincident nodes. During the first weld pass, all elements corresponding to the following passes are removed from the model. These elements are held at zero displacement until the deposition of the pass is simulated. The displacement difference at the pass interface between the current and previous pass is then accommodated through the use of multi-point constraints (ABAQUS, 1994). This method ensures that all elements are activated in a zero stress state at the beginning of each weld pass and that the errors introduced by stretching the elements to fit the deformed geometry produced by the previous passes are avoided. 2.2 Model Verification Residual stresses are estimated for multi-pass circumferential girth welds for two pipe wall thicknesses. Corresponding temperature and residual stress measurements are used to validate the computational procedure. 2.2.1 Thin pipe (t = 0.25-in.) A pipe section made of X65 steel is welded and analyzed. The pipe wall thickness is 0.25-in. and the outside diameter (OD) 16-in. Figure 1 illustrates finite element model consisting of 2174 nodes and 1905 elements (DCAX4, axisymmetric four-noded heat conduction elements for the thermal analysis and CAX4 axisymmetric four-noded elements for the mechanical analysis). The welding is completed in three passes (Table 1) with fluxed core arc welding (FCAW) using a grind of the root pass. FCAW is used in this test due to its low cost, and because it represents a severe test on the 2D assumption due to the low welding speeds. Figure 2 compares the computed and measured temperature history at seven locations during and after the first pass. Excellent agreement is observed between the computed and measured temperatures. Residual stress measurements are obtained by the blind hole drilling (BHD) method. Figures 3 and 4 compare the computed and measured axial and hoop residual stress at the inside diameter (ID), respectively. Good agreement is observed considering the limitations of the BHD

Table 1. Welding Conditions of 0.25-in. Thick Pipe. Pass Volts Amps Travel speed (in./min) Heat Input (kJ/in.)

25

95

6.85

20.8

25

143

10.16

21.1

25

149

6.61

33.8

technique, namely, averaging the stress over a 8 mm radius and an error of 4 ksi. 2.2.2 Thick pipe (t = 1.3-in.) A girth weld is analyzed on pipe section made of X60. The pipe wall thickness is 1.3-in. and the OD 26-in. Figure 5 illustrates the corresponding finite element model consisting of 2850 nodes and 1884 elements (DCAX4 axisymmetric four-noded heat conduction elements for the thermal analysis, and CAX4 axisymmetric four-noded elements for the mechanical analysis). Welding is completed in 18 passes (Table 2) with submerged-arc welding (SAW). The pipe geometry and welding process is selected to match the pipe tested in Kim (1994). Residual stress measurements are obtained by the X-Ray and BHD Table 2. Welding Conditions of 1.3-in. Thick Pipe with a Single-V Weld. Pass Volts Amps Travel speed (in./min) 20 Heat Input (kJ/in.) 43.3

1-18

27

535

methods (Kim, 1994). Figures 6 and 7 compare computed and measured residual stresses on the ID in the axial hoop direction, respectively. Good agreement is observed. 3.0 Compendium of Residual Stress Distributions A compendium of residual stress distributions is generated for common pressure vessel and piping geometries. The analysis matrix is listed in Table 3. Both circumferential girth and seam welds are analyzed. For the girth welds, two wall pipe thicknesses are examined; namely, _-in. and 1.3-in., combined with three radius to thickness ratios, i.e., 10, 25, and 50. Both single- and double-V weld joints are analyzed. The effect of hydrotest and end restraint are also investigated for the extremes of the matrix. For the seam welds, double-V weld joints in 1.3-

in. wall thickness are investigated for radius to thickness ratios of 10 and 50. The effect of hydrotest on seam weld residual stresses is also investigated. All pipes are considered to be made of ASTM A516 Grade 70 steel. Table 3. Analysis Matrix of Residual Stress Compendium. Weld Type r/t t

_-in.

1.3-in.

10 Girth 25

SV

SV,DV, HT,ER DV

higher in thin wall pipes (Figs. 10 and 11). In general, in thin pipes the axial residual stress at the ID is tensile and of very high magnitude (up to 90% of yield). In thick pipes, the magnitude decreases (up to 70% of yield). These results are consistent with those of Rybicki (1979). As seen in Figs. 8 and 10, in thin pipes with a small number of passes, the axial residual stress at the weld region corresponds to a bending type profile through the thickness. This bending develops in response to the hoop shrinkage caused by the weld metal solidification, as illustrated in Fig. 13. However, in thick pipes with a high number of passes (Figs. 9 and 11), the distribution of axial residual stress changes significantly as a consequence of the axial shrinkage generated by the high number of passes (see Fig. 14). This shrinkage develops an axial tension at the OD. Therefore, to maintain equilibrium in pipes with free ends, the axial residual stress at the ID reduces in the magnitude. 3.2 Radius to Thickness Ratio Effect The axial residual stress at the ID reduces in magnitude in thin pipes as the radius to thickness ratio increases (Figs. 8 and 10). The results are consistent to those of Vaidyanathan (1973). Little variation in the residual stress is observed in thick pipes (Fig. 11). 3.3 Weld Joint Effect In thin pipes, the magnitude of the axial residual stress at the ID is smaller in single-V than double-V pipes (Figs. 8 and 10). The trend is attributed to the axial shrinkage created by the larger number of passes in the single-V weld (8 pass) than in the double-V weld (2 pass), which shifts the tension to the exterior of the pipe as described in Section 3.1. No significant weld joint effect is observed in thick pipes where the number of passes is large for both the single-V (10 pass) and double-V (18 pass) welds (Figs. 7 and 9). 3.4 Hydrotest Effect The hydrotest reduces significantly the axial residual stress at the ID in thin pipes (50-75% reduction in Figs. 8 and 10). In thick pipes, the reduction at the ID is smaller (30-50% reduction in Figs. 9 and 11). The effect is more significant in the double-V welds (Fig. 11). The reduction is attributed to the relief of the hoop shrinkage by the hydrotest. As seen in Fig. 13, a reduction of the hoop shrinkage will decrease the magnitude of the bending type component of the axial residual stress. Figure 12 illustrates the effect of hydrotest on the transverse (hoop) residual stresses in seam welds. As seen in the figure, the effect is negligible. This is attributed to the different mechanisms present in the development of transverse residual stresses (axial in girth welds, hoop in seam welds). In girth welds, the bending component of the transverse residual stress is generated by the hoop shrinkage, which is reduced by the hydrotest as it is of yield level. However, in seam welds, the transverse residual stress is generated only by transverse shrinkage of the weld metal, which is unaffected by the hydrotest, since it is of low magnitude. 3.5 End Restraint Effect Welds made on thin pipes with the ends restrained produce slightly higher axial residual stresses (20-50% increase) than when the pipes are welded without restraint. In the thick pipes with multi-pass welds, the effect of restraint is substantial in the geometries studied. The axial stresses in the thick pipes are of yield level under restrained conditions. The restrained thick pipes modelled here represent an extreme condition

SV,DV

50

SV,DV, HT,ER

DV

Seam

10

DV, HT

50

DV, HT

SV = Single-V DV = Double-V HT = Hydro Test ER = End Restraint

The hydrotest pressure is determined per ASME Section VIII. For an operating temperature of up to 650F, the hydrotest pressure is 1.5 times the maximum allowable pressure. Assuming no weld defects, the hydrotest pressure for a pipe radius to wall thickness ratio (r/t) of 50 is 0.519 ksi. For an r/t of 10, the hydrotest pressure is 2.475 ksi. Figure 8 illustrates the through thickness axial (transverse to the welding direction) residual stress on girth welds of single-V thin pipes (_-in.). The plots are generated at the location of the peak axial stress on the ID. Similarly, Figs. 9 through 11 illustrate axial residual stress on single-V thick, double-V thin, and double-V thick girth welds, respectively. Figure 12 illustrates hoop (transverse to the welding direction) seam double-V thick welds. In the following sections, the effects of pipe wall thickness (t), pipe radius to wall thickness ratio (r/t), weld joint design, hydrotest, end restraint, and weld joint type are investigated by comparing these through-thickness axial stress profiles. 3.1 Thickness Effect For r/t=10, the pipe wall thickness has negligible effect on the axial residual stress at the ID (Figs. 8 and 9). However, for an r/t of 25 and 50 with the same joint type (double-V), the axial residual stress at the ID is

where the length of pipe is relatively short compared to the pipe diameter (L= 58-in. for the thin pipe and L= 38-in. for the thick pipe). Moreover, as illustrated in Fig. 14, in thick pipes with a high number of weld passes, the transverse shrinkage generated by the high number of passes produces a very high tension when the ends are restrained. 3.6 Girth vs. Seam Comparing the transverse (axial) residual stress on girth welds (Fig. 11) to the transverse (hoop) residual stress on seam welds for thick double-V pipes (Fig. 12), the transverse stress on the seam welds is significantly smaller (50-70%) on the ID than for the girth welds. 4.0 Summary and Conclusions A finite element procedure is implemented and validated to evaluate residual stresses in multi-pass welds of pressure vessel and piping components. Using this procedure, a compendium of residual stress distributions is generated for circumferential girth welds and for longitudinal seam welds. Conclusions drawn from these investigations are as follows: The pipe wall thickness has negligible effect for an r/t of 10. However, for an r/t of 25 and 50 with the same joint type (double-V), the axial residual stress at the ID is higher in thin wall pipes. The axial residual stress at the ID reduces in magnitude in thin pipes as the radius to thickness ratio increases. Little variation in the residual stress is observed in thick pipes. In thin pipes, the magnitude of the axial residual stress at the ID is smaller in single- than double-V pipes. In girth welds, the hydrotest reduces the axial (transverse) residual stress at the ID. The reduction is higher in thin pipes than in thick pipes. The hydrotest has negligible effect on the transverse residual stress of seam welds. The axial residual stress in girth welds of short length thick pipes with restraint ends are of yield magnitude through thickness.

Elasto-Plastic Analysis (4th Report)," J.S.N.A. Japan, 146: 164-174, Dec. 1979. Goldak, J., Chakravarti, A., and Bibby, M., "A New Finite Element Model for Welding Heat Sources," Metallurgical Transactions B, 15B:299-305, Jun. 1984. Kim, D. S. and Smith, J. D., "Residual Stress Measurements of Tension Leg Platform Tendon Welds," 1994 OMAE- Volume III, Materials Engineering, ASME 1994. Rybicki, E. F. and Stonisifer, R. B., "Computation of Residual Stresses due to Multipass Welds in Piping Systems," Journal of Pressure Vessel Technology, Transactions of the ASME, 101: 149-154, May 1979. Scaramangas, A., Residual Stresses in Girth Butt Welded Pipes, Ph.D. Dissertation, University of Cambridge, UK, May 1984. Shim, Y., Feng, Z., Lee, S., Kim, D.S., Jaeger, J., Paparitan, J. C., and Tsai, C. L., "Determination of Residual Stress in Thick-Section Weldments," Welding Journal, Vol. 71, pp. 305s-312s, 1992. Teckriwal, P. and Mazumder, J., Transient and Residual Thermal Strain-Stress Analysis of GMAW, Journal of Engineering Materials and Technology, Transactions of the ASME, 113:336-343, Jul. 1991. Vaidyanathan, S., Todaro, A. D., and Finniew, I., "Residual Stresses Due to Circumferential Welds," Journal of Engineering Materials and Technology, Transactions of the ASME, 233-237, 1973.

Acknowledgement This work was funded by the Edison Welding Institute and the Materials Properties Council. References ABAQUS/Standard Example Problems Manual, Example 3.3.15, Hibbitt, Karlsson & Sorensen, Inc., 1994. Bertram, L. A. and Ortega, A. R., "Automated Thermomechanical Modeling of Welds Using Interface Elements for 3D Metal Deposition," Manuscript for Proceedings of ABAQUS User's Conference, Oxford: Hibbitt Karlsson and Sorensen, Inc., 1991. Das, S., Upadhya, G. Chandra, Kleinosky, M. J., and Tims, M. L., "Finite Element Modeling of a Single-pass GMA Weldment," in Piwonka, T. S., Voller, V., and Katgerman, L., (eds.), Modeling of Casting, Welding and Advanced Solidification Processes VI, 593-600, Palm Coast FL, 1993. Fujita, Y., Nomoto, T., and Hasegawa, H., "Method of Thermal Elasto-Plastic Analysis (4th Report)," J.S.N.A. Japan, 146: 164-174, Dec. 1979. Fujita, Y., Nomoto, T., and Hasegawa, H., "Method of Thermal