Fatiguelifeassessmentbyhaagensen 131206022435 Phpapp01

Utmattingsberegninger for stlkonstruksjoner
ihht NORSOK og Eurokode 3
Fatigue life assessment

Tirsdag 13 desember 2011
Professor P J Haagensen
Norges teknisk-naturvitenskapelige universitet
Fakultet for ingenirvitenskap og teknologi
Institutt for konstruksjonsteknikk
Trondheim
per.haagensen@ntnu.no
Fatigue design of welded structures - Norsok and Eurocode 3
2011
P J Haagensen
Fatigue life assessment
Topics
Approaches to fatigue life estimation
1. Nominal stress
2. Hot spot stress
3. Notch stress
4. Fracture mechanichs
Loads and stress calculations
Damage accumulation
Comparisons of standards
2011
P J Haagensen
Fatigue life assessment.

Fatigue life predictions analysis should be
performed according to standards in order to avoid
uncertainties regarding assumptions for loads and
component capacity.
2011
P J Haagensen
Fatigue life assessment approaches

- S-N curves, nominal stress
- S-N curves, hot spot stress
- S-N curves, notch stress
- Crack growth curves
(da/dN - K diagram
2011
P J Haagensen
Loading data load spectra
Cumulative load spectra obtained by stress range counting

(rainflow) is converted to histogram to give stress ranges Sr vs.
number of cycles ni per stress interval
5
2011
P J Haagensen
Narrow band vs. broad band load time

histories:
Narrow band
PSD
Stress
Time
Frequency
Stress
PSD
Broad band
Time
Frequency
PSD = Power Spectrum Density
2011
P J Haagensen
Stress range bin #
Fatigue damage
accumulation
Number of stress range

occurrences, ni
Number of cycles
to failure, Nfi
Experimental
Design
S-N curve
Damage at stress level Sri :

di
ni
Ni
Log n, Log N
Cumulative damage at fracture

(Miner-Palmgren rule:
D
i 1
ni
1.0
Ni
If damage due to loads in spectrum = DT (during time T )

then:
Fatigue life L = T/DT
2011
P J Haagensen
Uncertainties in calculated fatigue life are

caused by: 1. Uncertainties in load spectra
2. Uncertainties in S-N curves - extrapolation

3. Uncertainties in Miner-Palmgren damage
summation rule (sequence effects)
Fatigue tests with representative loadtime histories show

k
that the damage sum D = ni
i=1
Ni
at failure varies typically in the range 0.1 < D < 10

Some tests indicate that D decreases with increasing
irregularity, i.e. more than one peak in the power density
spectrum (PSD)
IIW design guidance recommends D 0.5 instead of 1.0 at failure
DNV: D where is the usage factor. 0.5 < <0.1 depending on
inspectability and consequences of failure.
8
2011
P J Haagensen
Sequence effects gives variations in MinerPalmgren damage sum
Crack length
Overloads in tension
blunt the crack tip and
introduce compressive
stresses that slow
down crack growth
Cycles
2011
P J Haagensen
Uncertainties in extrapolation of S-N curves

A major source of uncertainty is related to the extrapolation of
the S-N curve below the constant amplitude fatigue limit. In
most current codes, e.g. Norsok, DNV and IIW the knee point
is now at N =107 cycles. However, an increasing amount of test
data indicate that the knee point should be at N =108, or a
straight line extrapolation should be used.
Dahle, 1994
10
Fisher, 1993
2011
P J Haagensen
Extrapolation of S-N curves

New test data indicate that the knee point should be at N =108, or a
straight line extrapolation should be used.
107
108
107
EXXON data, OMAE 2003
Sonsino, Maddox & Haagensen

IIW 2004
11
2011
P J Haagensen
Fatigue life calculation nominal stress method
1.
2.
3.
3.
4.
12
Choose weld class

Calculate nominal stress range
Correct stress range for thickness effect and misalignment
?
Determine cycles to failure from S-N curve
Use Miner rule to calculate damage and life
2011
P J Haagensen

What loads and stresses to consider?
All types of fluctuating load acting on the component and the
resulting stresses at potential sites for fatigue have to be
considered. Stresses or stress intensity factors then have to be
determined according to the fatigue assessment procedure
applied.
The actions originate from live loads, dead weights, snow, wind,
waves, pressure, accelerations, dynamic response etc. Actions
due to transient temperature changes should be considered.
Improper knowledge of fatigue actions is one of the major sources
of fatigue problems.
Tensile residual stresses due to welding decrease the fatigue
resistance, however, the influence of residual weld stresses is
already included in the fatigue resistance data given in S-N curves
13
2011
P J Haagensen
Separation of stress components
The membrane stress mem is equal to the average stress calculated

through the thickness of the plate. It is constant through the thickness.
The shell bending stress bend is linearly distributed through the
thickness of the plate. It is found by drawing a straight line through the
point O where the membrane stress intersects the mid-plane of the plate.
The gradient of the shell bending stress is chosen such that the
remaining non-linearly distributed component is in equilibrium.
The non-linear stress peak nlp is the remaining component of the stress.
14
2011
P J Haagensen
Nominal stress calculations

Nominal stress is the stress calculated in the sectional area
under consideration, disregarding the local stress raising effects
of the welded joint, but including the stress raising effects of the
macro-geometric shape of the component in the vicinity of the
joint, such as e.g. large cut-outs. Overall elastic behaviour is
assumed.
15
2011
P J Haagensen
Nominal stress calculations

Effects of macrogeometric features of the component as well
as stress fields in the vicinity of concentrated loads must be
included in the nominal stress:
16
2011
P J Haagensen
Local effects occur in the vicinity of concentrated loads or

reaction forces. Significant shell bending stress may also be
generated, as in curling of a flange, or distortion of a box section.
17
2011
P J Haagensen
Effects of misalignment (eccentricity

The secondary bending stress caused by axial or angular misalignment
must be considered if the misalignment exceeds the amount which is
already covered by fatigue resistance S-N curves for the structural detail.
This is done by the application of an additional stress concentration factor
(SCF). Intentional misalignment (e.g. allowable misalignment specified in
the design stage) is considered when assessing the stress by multiplying
by SCF.
18
2011
P J Haagensen
Calculation of nominal stress

In simple components the nominal stress can be determined
using elementary theories of structural mechanics based on
linear-elastic behaviour.
In other cases, finite element method (FEM) modelling may be used.
This is primarily the case in:
a) complicated statically over-determined (redundant) structures
b) structural components incorporating macro-geometric
discontinuities, for which no analytical solutions are available
Using FEM, meshing can be simple and coarse. However, care must
be taken to ensure that all stress raising effects of the structural
detail of the welded joint are excluded when calculating the
modified (local) nominal stress.
19
2011
P J Haagensen
Modification of basic S-N curves

The basic S-N curves may need to be modified for the following
influencing factors:
Misalignment, axial and angular

Effects of stress relief
Plate thickness, for t > 25 mm
Effects of corrosion
Temperature
Effects of high and low stresses in the spectrum
Material: Different S-N curves for steel, aluminium,
titanium
20
2011
P J Haagensen
10
Effects of misalignment (DNV & Norsok 004)

In the test data on which the design cures are based, some axial
misaligment (eccentricity) 0 is included as follows:
Butt welds: 0 = 0.1t (10% of plate thickness)

The effect of axial misaligment for butt welds e0 is accounted for
by applying a stress concentration factor SCF:
SCF = 1-
3 m - 0
t
where m is the measured eccentricity
21
2011
P J Haagensen
Cruciform joints
Axial misalignment included in S-N curves:
e0 = 0.5t (15% of plate thickness)
where
= (m + t) is the total eccentricity.
0 = 0.3t is misalignment inherent in the
S-N data for cruciform joints
ti = thickness of the considered plate
(i = 1, 2)
li = length of considered plate (i = 1, 2)
22
2011
P J Haagensen
11
Effect of thickness (DNV & Norsok)

For plate thickness t > 25 mm the thickness correction is included in the
equation for the S-N curve
The thickness exponent k is listed as follows:
23
2011
P J Haagensen
Thickness effects in welded

connections:
S / S0 (t / t0 ) k
Exponent k depends on weld class:
0.1< n <0.4 (IIW design guidance)
0 < n <0.25 (0.3 for tubular joints with high SCFs
0.25 for bolts) (DNV-RP-C203)
24
2011
P J Haagensen
12
Biaxial loading
IIW recommendations:
1. Use the equivalent normal stress range is less than 10% of the equivalent
shear stress range, or if the damage sum due to shear stress range is
lower than 10% of that due to normal stress range, the effect of shear
stress may be neclected.
2. If the normal and shear stress vary simultaneously in phase, or if the
plane of maximum principal stress is not changed significantly, the
maximum principal stress range should be used.
25
2011
P J Haagensen
IIW verification procedures for combined normal and

shear stress using S-N curves
26
2011
P J Haagensen
13
Norsok 004, NS 3472 and DNV RP-C203

Weld classes - 1 unwelded components
27
2011
P J Haagensen
DNV RP-C203 Weld classes example welded components
28
2011
P J Haagensen
14
DNV RP-C203- Aug. 2005

S-N curves welded structures in air
29
2011
P J Haagensen

S-N curves welded structures in air -details
30
2011
P J Haagensen
15
1.
2.
3.
3.
4.
31
Choose weld class

Calculate nominal stress range
Correct stress range for thickness effect and ?misalignment
Determine cycles to failure from S-N curve
Use Miner rule to calculate damage and life
2011
P J Haagensen
DNV RP-C203
S-N curve for high strength steel unwelded material
YS > 500 Mpa, machined surface with R a < 3.2 m
FAT 235 MPa
S-N curve
32
2011
P J Haagensen
16

New S-N curve small diameter umbilical pipes
in super duplex steel
Equations for S-N curve:
33
2011
P J Haagensen
The hot spot stress method

The hot spot stress is a local stress at the weld toe, taking
into account the overall geometry of the joint, except the
shape of the weld. It is therefore sometimes called the
structural or geometrical stress.
It is used when it is difficult to define a nominal stress, e.g. in
complicated plate structures.
Originally (in the 60s), the stress was measured at a single spot. In
the AWS/API at a distance of 1/8 (3.2mm) from the weld toe, while
Haibach recommended 2mm.
In recent versions the stress at the weld toe is extrapolated from two or
three points near the weld toe. The method is included in DNVs RP-C203,
also and IIW (International Institute of Welding)
34
2011
P J Haagensen
17
Definition of the hot spot stress (DNV)
The hot spot stress is a linear extrapolation at distances 0.5t an 1.5t from
the weld toe.
In the IIW guidance the to points are at 0.4 and 1.0t. The stress at these
two points are obtained from FE analysis or from strain gauge
measurements.
35
2011
P J Haagensen
Failure locations in welded joints
The structural hot spot stress method is normally applicable to surface cracks
only, but it is also possible to define a stress in a weld, e.g. by stress linearisation
over the weld throat or weld leg. Examples: Fillet weld subjected to local bending,
e.g. one-sided welds or welds around cover plates subjected to lateral loads
(Fricke et al.,2006)
36
2011
P J Haagensen
18
Types of hot spot stress

The stresses obtained in FE analyses must include any
misalignments or by an appropriate stress concentration factor,
SCF.
Two or three types of hot spot stress are usully defined:
37
2011
P J Haagensen
FE modeling - hot spot stress

The stresses obtained in FE analyses must include any
misalignments or an appropriate stress concentration factor, SCF.
Shell or solid elements are used in the FE meshing depending on
the shape and size of the structure
38
2011
P J Haagensen
19
FE stress analysis ship structure
39
39
Utmatting
- grunnlag
Oslo, 8.
nov. 2010
Fatigue
design
of welded structures
- Norsok
and Eurocode 3
P
J Haagensen
2011
P J Haagensen
Meshing rules and determination of hot spot stress

The IIW and DNV fatigue design rules give detailed advice regarding
meshing and determination of the hot spot stress
Recommended meshing and extrapolation
Reference points for different

types of meshing
At the extrapolation procedures for structural hot spot
stress of type b, a wall thickness
correction exponent of n=0.1 shall be applied.
40
2011
P J Haagensen
20
Calculation of hot spot stress

Since the stresses obtained in FE analyses depend strongly on the
type of element and the mesh that are used, detailed guidance is
given in the design rules. The degree of bending influences life.
The DNV RP C-203 correction:
A single hot spot S-N curve is used by DNV (in air). This is the Tcurve = the D-curve = the FAT 90 curve. This is the S-N curve for a
good butt weld, welded from both sides.
In IIW the FAT 90 curve is used for load carrying welds and FAT 100
for non-load carrying welds.
41
2011
P J Haagensen
The hot spot stress method tubular joints

The hot spot stress method is used for tubular structures, and
parametric equations are given for stress concentration factors
(SCFs) for simple joint configurations. The hot spot stress to be
used when entering the S-N curve is given by:
HS SCF nom
An example of SCFs for a simple tubular joint:
42
2011
P J Haagensen
21
Example of FE analysis
- out of plane loading of brace
43
2011
P J Haagensen
S-N curves to use with the hot spot stress
In air: Use the T-curve (= the D-curve)

44
2011
P J Haagensen
22
Effective notch stress method

The effective notch stress is the total stress at the root
of a notch, obtained assuming linear-elastic material
behaviour. For structural steels an effective notch root
radius of r = 1 mm in the FE analysis gives consistent
results. For fatigue assessment, the effective notch
stress is compared with a common fatigue resistance
curve.)The method is valid for plate thickness t> 5 mm
The FAT 225 (m=3) S-N curve is to be used in this
method. For t < 5 mm a radius o
The method is included in DNVs revised RP-C203, April 2010
For t < 5 mm a radius of 0.05 has been proposed

(Sonsino 2002) with an S-N curve with FAT 630
45
2011
P J Haagensen
Effective notch stress method

An effective notch radius of 1 mm is assumed in the FE
analysis
Main advantages:
Only one S-N curve is required, the FAT 225 curve.
Can be used to assess fatigue life for root cracks
46
2011
P J Haagensen
23
Example of stress analysis of cover plate

which can fail from the weld toe or the root
47
2011
P J Haagensen
Example from 2D FE analysis

50 mm long plate
142 MPa
225 MPa
50 mm
Ref. Stress
= 100 MPa
Small risk of root cracking
48
2011
P J Haagensen
24
Comparison with nominal stress method

Effective notch
stress S-N curve
FAT 225
225
51 mm long plate gives the F curve
L = 51 mm
49
2011
P J Haagensen
Alternative local stress methods

In recent years several local stress based methods have
been proposed as follows:
Battelle/Dong mesh insensitive method (Dong, et al. 2000)
Xiao and Yamada 1 mm method (2004)
Notch stress intensity factor approach (Lazzarin et al. 2006)
50
2011
P J Haagensen
25
The Battelle/Dong method

In this method the through-thickness stress distribution
is used to obtain an equivalent stress surface stress SS
based on equilibrium of nodal forces and moments.
A large number of test data can from many types of test

specimens be correlated on the basis of SS in a single
master curve.
51
2011
P J Haagensen
Master S-N curve according to Dong (2003)
52
2011
P J Haagensen
26
The Xiao-Yamada method

Xiao and Yamada found that the influence of various
sharpness of the notch practically disapears at at dept
of 1 mm, and proposed to use this as a structural stress
SS .
A large number of test data can from many types of test

specimens be correlated on the basis of SS in a single
master curve.
53
2011
P J Haagensen
Stress distribution at the surface and in the

depth direction (Xiao and Yamada)
54
2011
P J Haagensen
27
Test data correlated on the stress at 1 mm

below the surface
The data indicate that the FAT100 curve can be used for design.
55
2011
P J Haagensen
The fracture mechanics method

- describing the behaviour of cracked components
Useful for:
Calculating residual strength
Calculting remaining life spent in crack growth
under cyclic loading
56
2011
P J Haagensen
28
Stresses at the crack tip
57
2011
P J Haagensen
Stresses at the crack tip

X
cos 1 sin sin 3

2
2
2
2r
cos 1 sin sin 3

2
2
2
2r
XY
cos sin cos 3

2
2
2
2r
for = 0 i.e. in the plane directly ahead of the crack the

trigonometric function = 1
When r 0 all stresses infinity
Use K as a loading parameter
58
2011
P J Haagensen
29
The Stress Intensity Factor K (SIF)

The stress intensity factor K is a scaling factor
for the stress field at the crack tip, i.e. all
stresses are proportional to K
K Y a
= global stress
Y = geometry factor
a = crack depth,
or crack half length
for interior crack
59
2a
2011
P J Haagensen
The critical value of the stress intensity

factor is the fracture toughness of the
material, i.e. fracture occurs when
KIC
The fracture toughness KIC can be used to:

a) determine failure stress, when the crack size is known
b) determine critical crack size, when the stress is known
60
2011
P J Haagensen
30
Fracture mechanics - fatigue

When the speed at which a crack grows is
known, then the fatigue life can be
estimated if the stress intensity factor is
known for the particular load the part is
subjected to.
The crack growth rate can be determined in

tests on standardized specimens (ASTM, BS).
61
2011
P J Haagensen
Testing to determine crack growth rate
62
2011
P J Haagensen
31
Influence of R Ratio on crack growth

R=0
R=0.5
R=-1
0
-1
Largest Influence near the

threshold
Decreasing threshold with
increasing R ratio.
63
2011
P J Haagensen
Integrating the crack growth law

gives the fatigue life N
da / dN C (K ) m
af
da
N
C (K )m
ai
af
ai
Y = const.
K=Y a
Assume that
da
C Y a
a1fm / 2 ai1m / 2
C Y
(1 m / 2)
(m 2)
By inputting values of ai and af:
N C0 m
Or:
Stress
range,
1
m
log N log C m log S
Log C0
This is the equation for an S-N curve with slope - 1/m

64
2011
P J Haagensen
32
Relationship between the crack growth

diagram and the S-N curve
log
log
da
dN
KmaxKc
m
1
Paris:
da
= C(K)m
dN
Kth
Fatigue limit:
65
Fatigue limit
m
o= f(Kth, ai)
log K
log N
K th = YE a
2011
K th
ai
P J Haagensen
Example 1 Crack growth prediction

Crack in a Finite Width Plate
K= (sec(a/W))
Smin=0, Smax=50 MPa,
W=100 mm
t=10 mm
ai=4 mm
2ai
Material 355 YS
Yield =370 MPa, KIC= 55 MPam
Crack Growth Data

C=1.37x10-14
m=3.3
66
2011
P J Haagensen
33
Example 1
Crack length development
50
45
Crack Length a (mm)
40
35
da/dN=C Km
a= (C Km) dN
30
25
20
15
10
5
0
0.0E+00
2.0E+06
4.0E+06
6.0E+06
8.0E+06
Cycles
Fatigue life ?
67
2011
P J Haagensen
500
450
400
350
300
250
200
150
100
50
0
Yield Strength = 355 MPa
Lig =
68
50
45
40
35
30
25
20
15
10
5
0
F
W - 2ai t
10
20
30
40
Crack Length (mm)
50
Failure occurs by
plastic collapse when
Lig =355 MPa =YS
Critical Crack Length = ~ 42 mm
K (MPa m 1/2 )
Ligament (MPa)
Example 1 Failure mode
2011
P J Haagensen
34
Structural implications
Slow growth up to 10 mm, fast growth beyond 20 mm
Actions:
Establish failure criteria, apply safety factor (SF)
to the critical crack length (ac) i.e. 42 mm / SF of
2.0; which gives allowable crack length = 21
mm
Establish inspection and maintenance
schedules up to the allowable crack length.
When the crack length (a) reaches 21 mm:
Remove component from service
69
2011
P J Haagensen
Fracture mechanics - summary

Advantages:
Applicable to any type of structure with life
dominated by crack growth
FEM, BEM or formulas can be used to determine SIF
Prediction of tolerable crack sizes in structure
Provide maintenance and inspection intervals
Disadvantages:
Requires detailed information of structure geometry
Cycles to failure dependent on initial flaw geometry
Implementation at the design stage difficult
Determining SIFs can be involved and require special
numerical techniques
70
2011
P J Haagensen
35
The BS 7910
standard
71
2011
P J Haagensen
The critical value of the stress intensity

factor for brittle materials is the fracture
toughness of the material, i.e. fracture
occurs when
K KIC
The critical value of the crack tip opening
displacement (CTOD = ) is C i.e. ductile
fracture occurs for when
C
72
2011
P J Haagensen
36
Guidance assessing the risk for unstable

fracture:
Methods for calculating stresses, external

and interior (or residual stresses)
Calculation of SIFs for defect in question
Materials data
Use Level 1 or 2 fracture assessment
73
2011
P J Haagensen
Guidance needed for fatigue crack

growth calculations:
Methods for calculating stresses, external
and interior (residual stresses)
Calculation of SIFs
Materials data (crack growth curves)
Objectives
Acceptable flaw sizes
Remaining life
Inspection planning length of inspection periods
74
2011
P J Haagensen
37
Stress calculations BS 7910
75
2011
P J Haagensen
Crack growth data - schematic
76
2011
P J Haagensen
38
Crack growth data - schematic

Environmental effects
77
2011
P J Haagensen
Crack growth data, BS 7910
78
2011
P J Haagensen
39
Crack growth data constants, BS 7910
79
2011
P J Haagensen
2011
P J Haagensen
SIF
calculations
80
40
Quality category S-N curves
81
2011
P J Haagensen
Symmary Fracture mechanics
BS 7910 gives comprehensive guidance for assessing

the criticality of cracks or crack-like defects in welded
structures with respect to fracture and fatigue
The assessment can be made at different levels of
complexity
The effects of environment can be included in the
assessments
82
2011
P J Haagensen
41

Fatiguelifeassessmentbyhaagensen 131206022435 Phpapp01

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Fatiguelifeassessmentbyhaagensen 131206022435 Phpapp01

Uploaded by

Copyright:

Available Formats

Utmattingsberegninger for stlkonstruksjoner

ihht NORSOK og Eurokode 3

Fatigue life assessment

Fatigue design of welded structures - Norsok and Eurocode 3

Fatigue life assessment

Fatigue design of welded structures - Norsok and Eurocode 3

Fatigue life assessment.

Fatigue design of welded structures - Norsok and Eurocode 3

Fatigue life assessment approaches

Fatigue design of welded structures - Norsok and Eurocode 3

Loading data load spectra

Cumulative load spectra obtained by stress range counting

Fatigue design of welded structures - Norsok and Eurocode 3

Narrow band vs. broad band load time

PSD = Power Spectrum Density

Fatigue design of welded structures - Norsok and Eurocode 3

Stress range bin #

Number of stress range

Damage at stress level Sri :

Cumulative damage at fracture

If damage due to loads in spectrum = DT (during time T )

Fatigue design of welded structures - Norsok and Eurocode 3

Uncertainties in calculated fatigue life are

2. Uncertainties in S-N curves - extrapolation

Fatigue tests with representative loadtime histories show

at failure varies typically in the range 0.1 < D < 10

Fatigue design of welded structures - Norsok and Eurocode 3

Sequence effects gives variations in MinerPalmgren damage sum

Fatigue design of welded structures - Norsok and Eurocode 3

Uncertainties in extrapolation of S-N curves

Fatigue design of welded structures - Norsok and Eurocode 3

Extrapolation of S-N curves

EXXON data, OMAE 2003

Sonsino, Maddox & Haagensen

Fatigue design of welded structures - Norsok and Eurocode 3

Fatigue life calculation nominal stress method

Choose weld class

Fatigue design of welded structures - Norsok and Eurocode 3

Fatigue life calculation nominal stress method

Fatigue design of welded structures - Norsok and Eurocode 3

Separation of stress components

The membrane stress mem is equal to the average stress calculated

Fatigue design of welded structures - Norsok and Eurocode 3

Nominal stress calculations

Fatigue design of welded structures - Norsok and Eurocode 3

Nominal stress calculations

Fatigue design of welded structures - Norsok and Eurocode 3

Local effects occur in the vicinity of concentrated loads or

Fatigue design of welded structures - Norsok and Eurocode 3

Effects of misalignment (eccentricity

Fatigue design of welded structures - Norsok and Eurocode 3

Calculation of nominal stress

Fatigue design of welded structures - Norsok and Eurocode 3

Modification of basic S-N curves

Misalignment, axial and angular

Fatigue design of welded structures - Norsok and Eurocode 3

Effects of misalignment (DNV & Norsok 004)

Butt welds: 0 = 0.1t (10% of plate thickness)

where m is the measured eccentricity

Fatigue design of welded structures - Norsok and Eurocode 3

Fatigue design of welded structures - Norsok and Eurocode 3

Effect of thickness (DNV & Norsok)

The thickness exponent k is listed as follows: