Simulation of the welding process of steel tube joints made of S355 and S690

Welding is an important joining method for the work with metals. During the welding process, the material is heated and deforms plastically which leads a change in microstructure in the heat affected zone, to complex residual stress distributions, and distortions. The residual stresses can have a major impact, among other phenomena, on the fatigue resistance of a welded structure. The aim of this work was to develop a model with the finite element software Abaqus for the simulation of a welding process for butt welded tubes and the calculation of the resulting welding residual stress field. The residual stress field depends on several input parameters, like the geometry, the heat input, the welding speed, the material data, and the number of weld passes. The chosen dimensions of the tubes are realistic for tubular steel bridge constructions. Since, no experimental welding procedures were conducted, the welding parameters like the heat input and the welding speed were estimated in order to obtain a realistic temperature distribution in the weld and the heat affected zone. The assignment asked to place a main focus on the influence of the material data and the number of weld passes. Within the framework of this work, tensile tests at three different temperatures were conducted in order to find the deformational behavior of the two different steel grades S355 and S690. The results show generally good agreement with the data given by the European Standard for the structural fire design of steel structures [11], that is noted Eurocode 3 (EC3) in the course of this work. According to the test results, the yield strength at room temperature are underestimated by the Eurocode 3. Based on the experiments and the data given in the Eurocode 3, the influence of the mechanical properties were studied in several Abaqus models. For the description of the temperature dependent material behavior, a bilinear stress-strain curve was implemented. The resulting stress distributions show a similar trend, but the offset values between the stress curves of two models are dependent on the position in circumferential direction and the distance in axial direction. During the literature study, different welding simulation programs were compared. With specific welding simulation programs, mostly two-dimensional models can be realised. A major advantage of these programs is, that phase transformations can easily be considered and therefore a more realistic material model can be implemented provided that the temperature dependant behavior of the different microstructural phases are known. The influence of the number of weld passes was studied by comparing a single- and a multi-pass model with the material data from the Eurocode 3. The total heat input and the welding speed was the same for all the models. The tendency of the resulting stress distributions varied greatly and therefore implies that a multi-pass model cannot be approximated by a single-pass model.

Investigations and numerical modeling of mechanical properties of tempered martensitic steel Eurofer97 at various loading rates, temperatures and after spallation irradiation

Serafin Knitel

The reduced activation tempered martensitic steel Eurofer97 is a reference steel for a structural applica-tions in fusion reactors. The first-wall and blanket materials will be subjected to high thermal and neutron fluxes and will experience very complex, time-dependent mechanical loading. Owing to impinging neutrons in materials, points defects and gasesous impurities (hydrogen and helium) are created and accummulated in the form of small defect clusters in the microstructure altering the mechanical properties. Notably, fracture toughness decreases as strength increases. Eurofer97, being a body centered cubic alloy, presents a ductile-to-brittle transition temperature T0 that shifts to higher temperatures after irradiation. The main objective was to study the loading rate and irradiation effects on plastic flow and fracture properties of Eurofer97. Tensile and fracture tests were performed at temperatures in the transition region, at low and high loading rates on unirradiated material. Tensile properties of irradiated material were assessed after irradiation in the Swiss neutron spallation source SINQ to a dose of about 11 dpa and helium content of 500 appm at about 250 Â°C. The information gathered from the mechanical tests was used either as input in finite element models of fracture specimens, or as benchmark data to calibrate and verify the predictions of the models. Fractographic observations were also conducted. The tensile tests on unirradiated Eurofer97 showed a strong temperature dependence and strain rate sensitivity of the stress at low temperature, consistent with a mechanism of nucleation and propagation of double kink on screw dislocation. At high loading rate, the strain rate hardening was partially compensated by thermal softening due to quasi-adiabatic heating. The tensile properties after irradiation showed strong irradiation hardening (increase of the yield stress) accompanied by a drastic decrease of uniform elongation. The constitutive behavior at large strains, representative of those at crack tip, was obtained with an inverse method, based on finite element (FE) models of tensile specimens, developed to derive the true stress-strain curves from the load-displacement ones. These curves were used as input for the FE models of fracture specimens. Comparative fractographic observations on unirradiated and irradiated specimens did not reveal any strong effect of irradiation or helium on fracture mechanism, which remains transgranular cleavage. This observation indicates that higher helium concentration than 500 appm is necessary to initiate intergranular cleavage by helium bubble precipitation on grain boundaries. Dynamic fracture tests were performed on unirradiated Eurofer97. A shift of about 10 Â°C of T0 by one order of magnitude in loading rate was determined, which was in good agreement with results obtained on different ferritic steels. Static fracture toughness tests were also performed on disk compact tension specimens that can be accommodated in irradiation tubes of SINQ. Different FE models of fracture specimens were developed to include strain-rate sensitivity of flow stress, heating resulting from the plastic work in the fracture process zone and loading rate. The structure of the stress field at the crack tip was studied and the temperature dependence of a lower bound to toughness data in the transition was reconstructed using a calibrated criterion of local approach to brittle fracture.

EPFL2018

Time-Dependent Response of Ultra High Performance Fibre Reinforced Concrete (UHPFRC) under Low to High Tensile Stresses

Agnieszka Ewa Switek

Ultra High Performance Fibre Reinforced Concretes (UHPFRC) are characterised by high mechanical performance, extremely low permeability and tensile strain hardening. For structural applications, in composite structures they are very well adapted for reinforcement and protection of existing concrete members. Cast in-situ, they undergo under restraint development of tensile eigenstresses at early age, which can lead in some specific cases of applications to localised macrocracking of a new layer and loss of protective function. On the other hand their tensile viscoelastic potential helps mitigate these stresses. The objective of this study was to investigate the tensile viscoelastic properties of UHPFRC at early ages and long-term in creep and relaxation tests. A large experimental campaign with tensile creep and relaxation tests was performed, with load levels ranging from 30 to 90% of the tensile strength, including creep and relaxation tests during the strain hardening phase, at two different loading ages of 3 and 7 days. Three main testing setups were used: TSTM (Temperature Stress Testing Machine), creep rigs and closed-loop servo-hydraulic testing machine with additional Acoustic Emission detection. The influence of early age evolution in mechanical response and underlying mechanisms governing this response were discussed. Linear viscoelastic models were used to analyse and to highlight on the basis of the experimental results the non-linear behavior depending on solicitation level and loading sequence. The non-linear threshold for viscoelastic response was estimated for the material loaded at 3 and 7 days. The early age mechanical response at 3 days was proportional to the load level in the instantaneous part for three stress levels tested 30, 60 and 90% of the tensile strength, and showed non-linear creep from 60% on. It was observed that for a very low stress level of 13% the creep deformation was decreasing. Relaxation tests with compensation of simultaneously monitored shrinkage deformation were performed, and showed a viscoelastic potential similar to the one observed for creep for the low load level of 30%. Incremental creep and relaxation tests were successfully performed for 3 days age specimens. For higher stress levels, the viscoelastic response from creep tests was more pronounced than in relaxation tests, which was highlighted by analysis with linear viscoelastic models. The creep response at 7 days showed that the threshold for non-linear viscoelasticity is close to 9 MPa (81% of the tensile strength) load level. The Acoustic Emission non-destructive testing method was used to get insight on the physical mechanisms involved in viscoelastic deformations. A strong correlation between AE number of events and the deformation was found, also the amplitude and energy of AE events was found to be of the same order during the instantaneous and delayed deformations. UHPFRC loaded at 7 days age in incremental test showed linear behavior until very high stress level corresponding to the hardening domain. The non-linear and tertiary creep was obtained during the last loading step, for 12 and 11 MPa respectively, which occurred in the hardening domain. The Acoustic Emission monitoring confirmed very close correlation between non-linear creep and AE cumulative number of events induced by microcracking. In order to precisely detect non-linear phenomena in incremental test, analysis with linear viscoelastic models was performed. Comparison between creep and relaxation test results showed that non-linear viscoelastic phenomena were more actively involved in creep tests. The outcomes of this research, bridging the material science and structural engineering, provide useful data to foster applications in new and existing structures, making the best use of the tensile viscoelastic potential of UHPFRC.

EPFL2011

Development and characterisation of a new ODS ferritic steel for fusion reactor application

Nadine Baluc, Zbigniew Oksiuta

This paper describes the microstructure, tensile properties and Charpy impact resistance of a reduced activation oxide dispersion strengthened ferritic steel Fe-14Cr-2W-0.3Ti-0.3Y(2)O(3) produced by mechanical alloying of a pre-alloyed, gas atomised steel powder with Y2O3 particles, compaction by hot extrusion at 1100 degrees C, hot rolling at 700 degrees C and heat treatment at 1050 degrees C for 1 h. At room temperature the material exhibits a high ultimate tensile strength of about 1420 MPa and high yield strength of about 1340 MPa in the transverse direction. In the longitudinal direction the values are about 10% lower, due to the anisotropy of the microstructure (elongated grains in the rolling direction). At 750 degrees C the material still exhibits relatively high yield strengths of about 325 MPa and 305 MPa in the longitudinal and transverse directions, respectively. The material exhibits reasonable uniform and total elongation values over the temperature range 23-750 degrees C, in both transverse and longitudinal directions. The material exhibits weak Charpy impact properties in the transverse direction. Charpy impact properties are slightly better in the longitudinal direction, with upper shelf energy of about 4.2 J and a ductile-to-brittle transition temperature of about 8.8 degrees C. (C) 2009 Elsevier B.V. All rights reserved.