ML20207H829
| ML20207H829 | |
| Person / Time | |
|---|---|
| Site: | FitzPatrick  |
| Issue date: | 05/31/1987 |
| From: | Briggs E, Wolfe G SOUTHWEST RESEARCH INSTITUTE |
| To: | |
| Shared Package | |
| ML20207H770 | List: |
| References | |
| NUDOCS 8808300048 | |
| Download: ML20207H829 (28) | |
Text
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EXPERIMENTAL DETERMINATION OF THE THROUGH WALL RESIDUAL STRESSES IN A 28 INCH 0.D. STAINLESS STEEL PIPE SECOND PIPE
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Prepared By Stephen C. Grigory r
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FINAL REPORT SwRI Project No. 06-8879 Prepared For i
STRUCTURAL INTEGRITY ASSOCIATES, INC.
3150 Almaden Expressway-Suite 226 San Jose, California 95118 i
May 1987 I
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SAN ANTONIO HOUSTON DO 5
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EXPERIMENTAL DETERMINATION OF THE THROUGH WALL RESIDUAL STRESSES IN A 28-INCH 0.D. STAINLESS STEEL PIPE SECOND PIPE l.
Prepared by Stephen C. Grigory A
rl FINAL REPORT u
SwRI Project No. 06-8879 a
Prepared for STRUCTURAL INTEGRITY ASSOCIATES, INC.
3150 Almaden Expressway - Suite 226 San Jose, California 95118 E
i May 1987 0
i R
Reviewed:
Approved:
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'GeMe L_ uni _ r, p o';7.w;,,,5br Edward M. Briggs, Director T
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'j Offshore Products dvelopment Structural and Mechanical Systems and Evaluation F
TABLE OF CONTENTS Eagg LIST OF FIGURES
................................................. 11 t
LIST OF TABLES
...............................................L.
111 I.
I NT RO DU CT I ON................................................. 1 II.
E X PE R I ME NT AL TEC HN I QU E....................................... 2
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A.
STRAIN GAGE INSTALLATION................................
2 B.
PARTING OUT AND LAYER REMOVAL METHOD....................
2 III.
EXPERIMENTAL RESULTS.........................................
6 A.
REQUIREMENTS............................................
6 L
B.
RES U L TS................................................. 6 C.
DISCUSSION OF BESULTS..................................
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1 LIST OF FIGURES
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1 FIGURE 1 PARTING OUT AND LAYER REMOVAL METHOD 3
FIGURE 2 STRAIN GAGE LOCATIONS 7
FIGURE 3 RESIDUAL STRESS - 28 INCH PIPE 12 5 DEGREE AZIMUTH INSIDE SURFACE
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FIGURE 4 RESIDUAL STRESS - 28 INCH PIPE 13 90 DEGREE AZIMUTH INSIDE SURFACE FIGURE 5 RESIDUAL STRESS - 28 INCH PIPE 14 0 DEGREE AZIMUTH INSIDE SURFACE FIGURE 6 RESIDUAL STRESS - 28 INCH PIPE 15 0 DEGREE AZIMUTH INSIDE SURFACE FIGURE 7 THROUGH WALL RESIDUAL STRESS 17 ROSETTE 1, 1.0 INCHES FROM CENTERLINE FIGURE 8 THROUGH WALL RESIDUAL STRESS 18 ROSETTE 4, 0.25 INCHES FROM CENTERLINE I
FIGURE 9 THROUGH WALL RESIDUAL STRESS 19 ROSETTE 5, 0.12 INCHES FROM CENTERLINE FIG' RE 10 THROUGH WALL RESIDUAL STRESS 20 ROSETTE 7, 0.25 INCHES FROM CENTERLINE d
FIGURE 11 THROUGH WALL RESIDUAL STRESS 21 1
ROSETTE 8, 0.50 INCHES FROM CENTERLINE FIGURE 12 THROUGH WALL RESIDUAL STRESS 22 ROSETTE 9, 0.75 INCHES FROM CENTERLINE FIGURE 13 THROUGH WALL RESIDUAL STRESS 23 ROSETTE 10, 1.0 INCHES FROM CENTERLINE 5
11 e
i LIST OF TABLES
!agg TABLE 1 RESIDUAL STRESS ON THE INSIDE SURFACE 8
AT THE 90 DEGREE AZIMUTH I
TABLE 2 RESIDUAL STRESS ON THE INSIDE SURFACE 9
AT THE 5 DEGREE AXIMUTH
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TABLE 3 RESIDUAL STr<ESS ON THE INSIDE SURFACE 10 AT THE O DEGREE AZIMUTH TABLE 4 RESIDUAL STRESS ON THE OUTSIDE SURFACE 11 AT THE O DEGREE AZIMUTH a
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I.
IKTRODUCTION l
Southwest Research Institute was contracted to determine the state of the weld of a section of 28 ihch diameter residual stresses in and near stainless steel pipe.
The weld had been subject to localized heating for the purpose of inducing residual stresses and to severe chemical treatment to test m
the effectiveness of the induced stresses.
A report dated November 1986
~
contained the results of the residual stress measurements of that pipe. This i
report contains the results of residual stress meaurements made on a second 28-inch diameter pipe tested in April of 1987.
This pipe had been subjected g
to localized heating only.
The through wall residual stress distribution was determined by the parting out and layering technique.
This is a destructive experimental
]
technique that requires cutting up the pipe into small pieces in a manner that 6
permits a mathmatical relationship between measured surface strains ar.d subsurface stresses.
Strain gages were installed at two azimuth positions ut the pipe approximately 90 degrees apart for the purposes of this analysis.
The residual stresses were found to be compressive on the inside surface from the center of the weld to one inch either side of the weld (the extent of the analysis).
On the outside surface the residual stresses were primarily tensile.
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II. EXPERIMENTAL TECHNIQUE A.
STRAIN GAGE INSTALLATION f~
Micro-Measurement three-gage strain rosettes, Stock No. EA-06-030YB-120, were used at all locations.
These rosettes have a 0.030-inch gage length, a a
120-ohm resistance, are temperature compensated for carbon steel, and the w
three grids are oriented in a Y pattern in 120' increments.
Rosettes were bonded to the pipe with Eastman 910 contact cement.
All mer.surements were made in an air conditioned laboratory several hours a
after macrining operations.
A reference bridge was used to zero the digital
~
L strain read-cuc instrument prior to taking each set of strain readings, and the instrument calibration was checked daily.
An initial set of strain gage readings was taken before any machining was performed on the pipe.
Readings were then taken after each of the machining operations described below.
The difference between each set of readings is the strain relieved by that machining operation.
J B.
PARTING OUT AND LAYER REMOVAL METHOD There are variations to the parting out and layer removal method that may be used, depending upon size and surface conditions of the structure being analyzed.
For a heavy pipe, such as the 28-inch diameter pipe supplied for this project.
SwRI chose to perform three distinct machining operations.
These are (1) parting out a beam type coupon, containing the array of strain gages, from the pipe, (2) splitting the beam coupon, and (3) removing layers from the two halves of the beam.
The operations are shown schematically in Figure 1 and are described in detail below.
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STEP 3 REMOVING LAYERS I
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FIGURE 1.
Parting Out and Layer Removal Method i
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1.
Parting Out After the rosettes are installed, coupons were then parted from the pipe by saw cutting with the pipe in the vertical position.
The initial cut I
was made several inches from the nearest row of rosettes to avoid. letting the residual stress produced by plastic deformation at the tip of the saw S. lade affect the results.
The sides of the coupons were then milled parallel,
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bringing the finisl width of the coupon to about two inches.
The line of rosettes was on the centerline of the coupon.
P 2.
Splitting The beam coupon was so. lit to separate the inside and outside surfaces O
as shown in the sketch below.
This operati?n was performed on a milling machine with a slitting saw.
Repeated shallow cuts were taken in order to reduce the residual stress created by the machining operation.
h Rosetten o.D. Surf aces El Aw r
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U Milled Edges 5
J The splitting operation is r.o-it. >ctly required.
The layer removal process 1
,j could be started on either the inside or outside surface. However, because of the curvature of the pipe and the irregular surface of the weld, it is felt that surface stresses at e mere accurately determined if the beam is spil"; and layer removal started beneath the surface.
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5-3.
Laver Removal Each half of the split beam coupon was subject to layer removal, as shown in the sketch below.
The surface opposite the rossettes was milled in t
fim.: cuts to reduce residual streyses produced by the machining.. Layers of O.025 inch to 0.050 inch were removed, depending upon the thickness of the bar (larger layers were remov(1 from thicker beams).
The layers are normally
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removed in cuts of 0.005 inch per pass and reduced to 0.001 inch per pass for the last five passes.
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r Milled Surface I.ayers 1, 2, 3...
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Roset Inside Surface E
E The beam was removed from the mill and taken to an air condition laboratory containing the readout instrument and allowed to stand for several hours before taking strain gage readings.
This procedure eliminated any error from temperature gradients created by aschining.
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III. EXPERIMENTAL RESULTS A.
REQUIREMENTS
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The article to be tested was a 7-foot long seccion of stainless steel pipe with a 28 inch outside diameter.
The wall thickness was about 1.20 inches.
The area of interest was the circumferential weld at the center of the pipe.
It was required to determine, at the weld, the through wall residual strees distribution at one asimuth position and the inside surface residual J
stresses at an azimuth position 90 degrees from the first. SwRI chose to
'l determine inside surface residual stresses at a third location 5 degrees from J
the first to provide some redundancy.
Only t'our strain gage locations were requested for insidr.
wrface measurements, Through wall residual stress distribution was to be determined at ten locations distributed no more than one inch either side of the weld.
D.
RESULTS 1.
Surface Residual Stresses i
The azimuth position of the through wall residual stress measurements is noted as zero degrees and the surface measurement only locations as 5 degrees and 90 degrees. The strait, gages were installed on either side of the weld as shown in Figure 2.
The residual strains and stresses computed from the experimental measurements are presented in Tables 1 and 2 for azimuth locations at 90 and at 5 degrees, respectively.
The computed data for the inside surface 9
measurements at the zero azimuth location are presented in Table 3 and the data for the outside surface are presented in Table 4.
These data are also
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presented graphically in Figures 3 through 6.
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4 CENTERLINE WELDMENT 5
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1 FIGURE 2.
STRAIN CACE LOCATIONS
4 1
Table 1 RESIDUAL STRESS ON THE INSIDE SURFACE AT THE 90 DEGREE AZIMUTH t,
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ROSETTE DIST El E2 SIG1 SIG2 PHI TAU SIGL SIGC inches u in/in u in/in ksi ksi deg ksi ksi ksi
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1
-0.25
-1887
-3442
-91.4 -125.5 8
17.1
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-124.9 2
-0.12
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-2261
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-86.1
-18 7
-73.4
-84.8 3
0
-1102
-1287
-46.6
-50.7
-20 2
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4 0.25
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Table 2 RESIDUAL STRESS ON THE INSIDE SURFACE AT THE 5 DEGREE A2IMUTH I
ROSETTE DIST El E2 SIG1 SIG2 PHI TAU SIGL SIGC inches u in/in u in/in ksi ksi deg ksi ksi ksi
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1
-0.25
-1230
-3419
-70.7
-118.6
-13 24 -116.3
-73 1
2
-0.12
-1490
-2915
-74
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-28 15.6
-81.1
-98.2 a
3 0
-2601
-3215 -111.7
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-31 6.7 -121.6 -115.2 u
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Table 3 RESIDUAL STRESS ON THE INSIDE SURFACE AT THE 0 DEGREE AZIMUTH ti ROSETTE DIST El E2 SIG1 SIG2 PHI TAU SIGL SIGC
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inches u in/in u in/in ksi ksi deg ksi kai ksi 1
-1
-1097
-2550
-58.32
-90.18
-36 15.93 -78.97 -69.53 2
-0.75
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-1989
-27.49
-64.93 1e 18.72 -30.34 -62.08 3
-0.5
-547
-1121
-27.67
-40.26 32 6.29 -31.13
-36.8 p
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-0.25
-328
-1644
-25.73
-54.56
-45 14.42 -40.21 -40.08 5
-0.12
-295
-2227
-30.16
-72.52 0
21.18 -30.16 -72.52 6
0
-1224
-4884
-84.21
-164.4
-10 40.12 -36.56 -160.5 7
0.25
-1004
-1495
-45.48
-56.25 19 5.38 -46.63
-55.1 8
0.5
-2145
-2843. -93.88 -105.65
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6 -104.4 -98.65 9
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13.65 -110.1 -100.9 10 1
-1222
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Table 4 RESIDUAL STRESS ON THE OUTSIDE SURFACE AT THE 0 DEGREE AZIMUTH ROSETTE DIST El E2 SIG1 SIG2 PHI TAU SIGL SIQC inches u in/in u in/in ksi ksi deg ksi ksi ks'i 1
-1 1035 574 37.8 27.7 40 5.05 33.68 31.81 2
-0.75 3
-0.5 4
-0.25 1094 211 36.26 16.89
-15 9.68 18.18 34.96 5
-0.12 1118
-744 28.04 -12.78
-16 P0.41 -9.83 25.09
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0.25 1150 89 36.86 13.6 14 11.63 14.89 35.57 l
8 0.5 1533 21 48.21 15.06 4 16.58 15.21 48.06 9
0.75 911
-1361 15.73 -34.06
-37 24.89 -2.54 -15.78 9
10 1
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RESIDUAL STRESS - 28 INCH PIPE 90 DEGREE AZIMUTH INSIDE SURFACE 50 40 -
30 -
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The distance measurement for surface stresses refers to the distance along the axis of the pipe from the center line of the we!.d to the point of measurement. El and E2 are the maximum and minimum principal strains. SIG1 and s
SIG2 are the maximum and minimum principal stresses. Th i angle:. PHI is the angle of the maximum principal stress with the axis of the pipe. SIGL and SIGC are the longitudinal and ciremferential stresses, respectively.
2.
Through Wall Residual Stress Distribution
.1 The through wall residual stress distribution was determined at ten r
locations at the zero degree azimuth position.
These data are shown graphically in Figures 7 through 13.
Outside surface rosettes 2, 3, and 6 u
were damaged so that through wall calculation could not be made at these locations.
C.
DISCUSSION OF RF3ULTS In general, the surface residual stress measurements are more accurately determined than subsurface residual stresses in the vicinity of high stress gradients, such as those found at a weld. The calculations of subsurface stress are based upon strength of material equations that assume that plane sections remain plane.
This is simply not the case in the complex stress field.
A more rigorous stress analysis, such as finite element analysis, of the experimental technique would produce a balanced through wall stress distribution in a pipe, only if input boundary conditions prevented the gaged I
surface from deflecting radially.
Otherwise, through wall stress distributions similar to those produced by our experimental techniques would be produced by the finite element analysis.
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6 FIGURE 11 THROUGH WALL RESIDUAL STRESS ROSETTE 8 0.5 INCHtES FROM CENTERLINE 50 40 -
30 -
20 -
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-100
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-120 -
-130 -
-140 -
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