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Numerical simulation of similar and dissimilar welds of martensitic

steels and Nickel alloys


D. Hggenberg, P. Buhl, T. Klein, A. Klenk
Materialprfungsanstalt Universitt Stuttgart (MPA), Pfaffenwaldring 32, 70569 Stuttgart,
Germany
39th MPA-Seminar
October 8th and 9th, 2013 in Stuttgart

Abstract
In components of power or process plants operating at high temperatures weldments often
become the weakest links due to the specific characteristics of the weld or heat affected
zones. In design and life assessment this is considered by weld strength factors reducing the
allowable stresses. For common materials material and temperature specific factors are
available. These factors are usually obtained by evaluation of crossweld creep tests. Thus,
they are applicable for creep loading and describe the weld strength of a fully loaded and at
least in the long term range approximately homogeneous stress distribution. However, this
often does not reflect the real situation in components.
Numerical simulations considering the specific properties of heat affected zones in ferritic
and martensitic steels are able to predict the stress and strain situation and the stress
redistribution more accurate. In this paper assessments of martensitic welds in piping
systems using numerical simulation are described.
The demand for efficiency increase in fossil fired plants which lead to the development of
700C-technology, causes the necessity of the application of Nickel alloys in at least parts of
boiler and turbine components. This implies also the necessity of dissimilar welds in such
components. In the paper similar assessments for dissimilar welds are shown allowing
conclusions regarding stress redistributions and explanation of failure mechanisms.

Introduction / Motivation

Welded joints in piping systems are subjected to complex loading conditions. On the one
hand the development of the damage depends on the primary stresses, which act permanent
like the internal pressure and weight of the system. On the other hand there are secondary
stresses, which influence the redistribution of the stresses. These stresses occur due to
restraint of the thermal expansion in components with inhomogeneous temperature
distributions. A welded joint consists of the heat affected zone, the base and weld material.
Due to the different material properties within the weld and its specific loading conditions it is
very difficult to evaluate the most critical location and to describe stress redistribution during
operation.
The design of components in the current regulations DIN EN 12952-3 and DIN EN 13445-3
is carried out with equations for linear elastic material behavior. For components, where
irreversible deformations occur due to plastic deformation or creep strain accumulation the
use of these regulations lead to conservative results because the redistribution of stresses
and the reduction of local stress peaks are usually not considered. Even the treatment of
additional forces, bending and torsion moments of the piping system which influence the size
and direction of maximum principal stresses is not clearly handled by these regulations.
Therefore nonlinear viscoplastic simulations can be carried out to calculate the redistribution
of the stresses and the accumulation of inelastic strains in components with welded joints
with regard to its different material properties.

Comparison of technical rules for lifetime assessement of components


for elevated temperatures

Table 1 shows an overview of the procedures of the standards and regulations which are
used for design or lifetime evaluation: DIN EN 13480-3 [1], FDBR [2], AD2000 [3] and TRD
[4], with regard to the calculation of welded joints in pressurized components.
Regulation

DIN EN13480-3

FDBR

eff

AD2000

TRD

allow

Additional
reduction of
allow

-20%

-20%

Table 1: Overview of the procedures of different regulations

The effective and the allowable stress are treated identical in the regulations DIN EN
13480-3 and FDBR. The allowable stress in AD2000 is equal to DIN EN 13480-3 and FDBR.
TRD includes differences in the determination of the allowable stresses for 200.000 h of
creep. There is used a denominator of 1 and in the other regulations it has a value of 1,25.
The calculation of the effective stress is different in the TRD and AD2000.
All these procedures make use of equivalent stress formulations but do not consider effects
of multiaxial stress states on the material or component behavior. The influence of primary
and secondary stresses in welded joints is not handled in a consistent manner. Due to this
reason a comparative assessment using these procedures and a detailed inelastic
calculation is of interest.

3
3.1

Numerical Investigations for welds in pipework


Welded joint with a high bending moment

For comparion with the results obtained using standard regulations, an inelastic finite
element simulation of a pipe section with a detailed modeled welded joint was performed.
The pipe section has the material properties of the martensitic steel P92 and is subjected to
internal pressure and bending moment. The level of the bending moment was defined
according to the FDBR regulation with the aim to get an ineligible load factor in the welded
joint. The critical value of the bending moment amounts to MB=6,1*108 Nmm. Furthermore
the internal pressure and the temperature were assumed to be 85 bar respectively 618C for
the whole simulation for a service period of 200.000 h. At the determined temperature the
time dependent material behavior of the P92 base material was modeled by a modification of
the incremental Graham Walles creep law which is given by equation (1) and (2).

d


10 A1
m1 10 A2

dt
1 D
1 D
n1

3
dD
AD1

10
dt
q

nD1

n2

m2

3
mD1
AD 2

10

q

(1)
nD2

mD 2

(2)

Equation (1) is the modified Graham-Walles creep law whereby it is possible to describe the
primary, secondary and with the damage parameter D the tertiary creep effects. The damage
parameter D is calculated with equation (2) and depends on the multiaxiality factor q. The
parameter AD1, nD1, mD1, AD2, nD2, mD2, A1, n1, m1, A2, n2 and m2 are material
dependent parameter that are fitted with uniaxial creep tests.
For modeling purposes the welded joint was divided into four areas representing the
intercritical, the fine and the coarse grained zone and the weld metal as shown in figure 1.
The different creep behavior of these areas was determined with uniaxial creep tests of
specimens with simulated microstructure (weld simulation using Gleeble test). The resulting
creep curves were the basis of the approximation of the Graham-Walles parameter for each
area. The same material properties as the base material were assigned to the welde metal.
The creep curves of the different areas are shown in figure 2.
Using an user defined material (UMAT) the implementation of the time dependent material
behavior of material P92 in a finite element calculation was performed.

Figure 1: finite element model of a pipe section with a detailed modeled heat affected zones (HAZ)

Figure 2: Creep curves of the three areas of the HAZ and WM at a stress of 80 MPa

For geometrical modeling two reference points in cylindrical coordinates were defined. The
first reference point was used for the application of the bending moment and the second to
fix the model. Both reference points were coupled with kinematic couplings and one degree
of freedom in radial direction was coupled to the free surfaces of the pipe section. By
choosing these boundary conditions expansion of the pipe as a result of the internal pressure
is possible.
With the described model a stress and a strain controlled simulation were performed. In the
stress controlled simulation all loads were treated like primary loads and in the strain
controlled simulation all loads with the exception of the internal pressure were treated like
secondary loads.
In figure 3 the stress and creep strain distribution in the weld region is shown in detail. The
top of the contour plot represents the inner side of the pipe wall, the bottom of the picture
shows the outer side of the pipe wall. In the upper row of the figure the equivalent Mises
stress after loading and after 200.000 h of creep is depicted, in the lower row the equivalent
creep strain after 200.000 h of creep is shown. For the 200.000 h state a distinction has been
made between the stress controlled and the strain controlled case.
After the first loading step the equivalent Mises stress on the inner side of the pipe is slightly
higher than on the outer side. Since both weld metal and heat affected zones have been
modeled using identical elastic material parameters, they cannot yet be distinguished in the
contour plot in this state. After 200.000 h the influence of the weld on the stress distribution
becomes apparent in both stress and strain controlled case, the maximum equivalent
stresses are encountered in HAZ 1, the minimal equivalent stresses can be found in HAZ 3.
Again in both cases (stress and strain controlled) the highest creep strains appear in HAZ3
on the inner side of wall.

Figure 3: Contourplots of the equivalent stress and creep strain in the weld for the stress and strain
controlled loadcase

Figure 4 shows evaluations of the equivalent Mises stress and creep strain along a path from
inner to outer pipe surface in HAZ3 for stress and strain controlled loading case.
Stress controlled :

Strain controlled:

Figure 4: Path evaluation for equivalent Mises stress and creep strain from inner to outer surface along
the HAZ 3

The finite-element-simulations have been evaluated with respect to time and the equivalent
stresses and creep strains are given in figure 5.

Figure 5: Temporal courses of the equivalent Mises stresses and creep strains evaluated at the respective
maximum for the stress and strain controlled simulation

The development over time clearly shows that the stress controlled case yields significantly
higher stresses and strains than the strain controlled case. In addition, the Mises equivalent
stress obtained by analytical formula valid for linear elastic thickwalled pipes is plotted in the
diagram. The path evaluation of the HAZ3 shows a maximum accumulated creep strain close
to inner surface.
In order to assess the results of the FE-simulations, values taken from different locations
(base metal: BM, heat affected zone: HAZ1 and HAZ3) at several time points are compared
to the 100,000-creep strength of P92 base metal at 618 C.
Normalized

0h

5.000 h

200.000 h

stress

HAZ1

HAZ3

BM

HAZ1

HAZ3

BM

HAZ1

HAZ3

BM

Mises

0.93

0.93

0.93

0.70

0.47

0.58

0.70

0.45

0.58

Axial

0.23

0.23

0.23

0.30

0.29

0.30

0.30

0.31

0.31

Table 2: Comparison of the finite element results with 100,000 h-creep strength acc. to VdTV und ECCC

In the regulations AD2000 and TRD the bending moment is not considered in the effective
stress calculation. The comparison of the evaluation of local values of effective and axial
(perpendicular to the weld) stress shows that after short relaxation periods the stresses in the
critical zones especially in the intercritical heat affected zone are small. It is also visible that
the axial stress which is the critical one since it is perpendicular to the weld is significantly
smaller than the effective stress. This is in coincidence with the estimated strains (see Fig.
4).

Dissimilar welded joints

3.2

The 700C power plants currently under development will utilize Ni-base alloys such as
Alloy 617. Due to technical and economic reasons CrMoV-steels will be used for components
or parts of components which are subjected to temperatures < 650 C. Therefore dissimilar
joining of Ni-base alloys and Cr-steels is necessary in these plants.
The following investigation focuses on welds between Alloy 617 and a 2Cr-steel. Figure 6
shows the creep-rupture strength at 550 C. In creep tests two competing failure
mechanisms are observed:

Failure in the fusion line (FL) between ferritic/martensitic steel and nickel based weld
metal. The crack usually occurs on the outer surface.
Failure in the heat affected zone (HAZ) of ferritic/martensitic steel.
The crack usually occurs in the specimen center.

Figure 6: Creep-rupture strength of 2Cr/A617-welds at 550C [5]

Several research projects, [6]-[10], have identified the intercritical heat affected zone (HAZ3)
as the weakest link in welded components under service conditions. The heat input during
the welding procedure affects the microstructure of this zone [6].
Inelastic analysis is able to obtain detailed information on the deformation and failure
behavior of welds. Figure 6 shows contour plots of an axisymmetric finite-element analysis at
different time points. The increase in stress in the Ni-base weld metal near the fusion line
and (due to the lower creep resistance) the concentration of creep strain in the intercritical
HAZ3 can be seen.
In Figure 7 the development of stress and creep strain over time is shown for two different
loads. The time to rupture in the experiment is marked respectively. In case of the lower load
(92 MPa) the creep strain rate in the HAZ is so small that the axial stress in the weld metal
becomes predominant and as a consequence crack growth completely takes place in the
fusion line. The higher load (125 MPa) leads to higher stresses in the weld metal and higher
creep rates in the heat affected zone. Thus, the two competing damage mechanisms in weld

metal and HAZ become nearly equally important. On the one hand the higher creep rate
promotes failure in the HAZ. On the other hand the maximum principal stress in the fusion
line increases, even compared to the equivalent stress, which still leads to cracks in the
fusion line.

Figure 7: Regions of highest stress and strain in a creep-rupture specimen (FEM-simulation)

250

200

Mises stress / MPa

Mises stress / MPa

200

150
Mises (below surface)
Mises (center)
axial stress (below surface)
axial stress (center)

100

50

150

100

Mises (below surface)


Mises (center)
axial stress (below surface)
axial stress (center)

50

SV1Z19, 550C, 125 MPa

SV1Z20, 550C, 92 MPa


0
0

2000

4000

6000

time / h

4000

6000

8000

10000

12000

2,0

equivalent creep strain / %

equivalent creep strain / %

2000

time / h

2,0

1,5

1,0

0,5

HAZ3: intercritical zone

1,5

1,0

0,5

HAZ3: intercritical zone

SV1Z19, 550C, 125 MPa

SV1Z20, 550C, 92 MPa

0,0

0,0
0

2000
time / h

4000

6000

2000

4000

6000

8000

10000

12000

time / h

Figure 8: Development of stresses in fusion line and strain in HAZ over time of 2Cr/A617-welds at 550C
(FEM-simulation)

The different stress distributions in weld metal and HAZ are illustrated in figure 8. The
highest values of maximum principal stress in the weld metal are found at the outer surface,
while the mostly stressed region in the HAZ is near the center, which corresponds to the
crack positions found in the specimens.

weld metal_Mises
weld metal_SMax
HAZ3_Mises
HAZ3_SMax

SV1Z20, 550C, 92 MPa

stress / MPa

stress / MPa

300
280
260
240
220
200
180
160
140
120
100
80
60
40
20

300
280
260
240
220
200
180
160
140
120
100
80
60
40
20

SV1Z19, 550C, 125 MPa

radius [mm]

weld metal_Mises
weld metal_SMax
HAZ3_Mises
HAZ3_SMax

radius [mm]

Figure 9: Stress distributions in weld metal and HAZ at time to rupture (FEM-simulation)

To summarise, the following findings have been presented:

Creep tests of dissimilar welds have shown significant creep strength reduction
Two competing damage mechanisms have been identified
Numerical simulation of crossweld specimens gave evidence to the development of
different damage mechanisms by correlation to the development of stresses and
strains

Since the numerical calculations can explain the damage occurring in specimens similar
calculations for components can be used to make predictions on the failure behavior of
components.
LITERATURE
1.
2.
3.
4.
5.

6.
7.

8.

9.
10.

Metallic industrial piping Part 3: Design and calculation; German version EN


13480-3:2012, Beuth Verlag, Berlin
FDBR-Taschenbuch Rohrleitungstechnik 1: Planung und Berechnung, Gnter
Wossog, Vulkan, 2005
AD2000 Regelwerk Taschenbuch Ausgabe 2009, Verband der TV e.V., Berlin
TRD - Technische Regeln fr Dampfkessel mit den Vereinbarungen der Verbnde:
Taschenbuch-Ausgabe 1998/2, Heymann
T. Klein, C. Feuillette and A. Klenk: Verhalten von optimierten Werkstoffen und
Werkstoffverbunden fr 700-720C-Dampfturbinenbauteile, Teilvorhaben MPA
Stuttgart zu Verbundvorhaben COORETEC DT3, 2010
K. Maile et al.: Zeitstandverhalten von P91-Schweiverbindungen,
19. Vortragsveranstaltung AGW/AGHT, Dsseldorf, 1996
R. U. Husemann, et al.: Langzeiteigenschaften von Schweiverbindungen
moderner Sthle fr Dampferzeuger, 23. Vortragsveranstaltung AGW/AGHT,
Dsseldorf, 2000
K. Maile et al.: Behavior of similar welds in T24 Tubes and E911 pipes, 3rd HIDA
and Integrity Conference, Integrity of High Temperature Repair Welds, OeirasLisabon, Portugal, 16-18 September, 2002, pp. 69/80.
M. Bauer et al.: Evaluation of cross weld creep strength of 9-11% Cr steels,
Proceedings Int. Conf. on Plant Life Extension, Cambridge, 16-18 April 2004
M. Bauer, A. Klenk, K. Maile and E. Roos: Numerical Investigations On
Optimisation Of Weld Creep Performance In Martensitic Steel, 8 th Seminar of
Mathematical Modelling of Weld Phenomena, Seggau, 2008

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