A comparative study between conventional

and elevated temperature creep autofrettage

the place
Yevgen Gorash and Volodymyr Okorokov of useful
Department of Mechanical & Aerospace Engineering, University of Strathclyde, Glasgow G1 1XJ, UK learning
Emails: yevgen.gorash@strath.ac.uk & volodymyr.okorokov@strath.ac.uk

Abstract Purpose [1] Weir has been providing Techniques

This poster presents a comparative study
between conventional hydraulic and
elevated temperature autofrettage. For
modelling of both methods advanced
plasticity and creep material models are
used. The main governing equations for
the models are presented as well. A
beneficial influence of compressive
residual stresses induced by both
methods is demonstrated on a
benchmark problem of cross-bored
block. The effectiveness and applicability
of the two methods are estimated by
conduction of compressive residual
stress analysis and crack arrest
modelling. Numerical simulation of the
cyclic plasticity and creep problems are
carried out by means of FEM in ANSYS
Wo r k b e n c h w i t h F O R T R A N u s e r -
programmable subroutines for material
model incorporating custom equations.
innovative pump solutions across
This work is a part of the PhD project aiming to develop a comprehensive qualitative & quantitative the globe for almost 150 years. Induction of compressive residual stresses in high
understanding of the effect of compressive residual stresses on the corrosion-fatigue life of structural steels pressure components is a useful practise of increasing the
used for the pumps designed by Weir Group for a long service life in aggressive operating environments. fatigue life in both air and corrosion environment. There
are different residual stress inducing techniques which
Application [1] are based on a plastic/creep overload of a material. In this
study a conventional autofrettage at normal temperature
is compared to hot isostatic pressing (HIPing).
Developed residual stress modelling techniques are to be applied to the whole range of Weir
high-pressure pumps that are designed to handle abrasive and corrosive slurries, dirty water
and process mixtures. Leading worlds mining companies choose the Warman range of
centrifugal slurry pumps. Through SPM, Weir is the number one supplier of plunger pumps
to the shale energy industry for hydraulic fracturing. The range of GEHO diaphragm pumps
Conventional Autofrettage
are built to handle the most abrasive, corrosive & high temperature slurries, sludges & tailings.
SPM The main idea of autofrettage is application of high
QEM3000 pressure to the internal surface of a high pressure
Objectives [1] Warman component in order to induce plastic strain of required
GEHO MDC values. With unloading the elastic layers of a component
Development of theoretical and numerical approaches for accurate modelling of residual stresses after AF; TZPM start shrinking the plastically deformed layers thereby
Development of corrosion fatigue assessment methodology for accurate prediction of the corrosion fatigue inducing compressive stresses. The depth of the residual
life under the compressive residual stresses; stress layers up to a half of the wall thickness has made
Conduction of an extensive experimental program for quantifying the effect of induced compressive
autofrettage efficiently applicable in a huge variety of
residual stresses on the corrosion fatigue life; industrial applications, particularly pumping processes.
Application of the developed methodology of compressive residual stress modelling to Weir pumps.

HIPing Creep Autofrettage

Constitutive model for cyclic plasticity at RT [2,3] Cross-bored block specimen [5] Hot isostatic pressing (HIPing) is a manufacturing process,
commonly used to reduce the porosity of metals and increase
This study uses a constitutive model of cyclic plasticity which is based 3
f = S - X : S - X - R - s0 ,( )( ) the density of many ceramic materials. This improves the

pressure
on the von Mises yield criterion. The yield surface is implemented as
2 material's mechanical properties and workability.
where The HIP process subjects a component to both elevated
S deviatoric stress tensor; X back stress tensor; R isotropic hardening variable; 0 initial size of elastic domain. temperature and isostatic gas pressure in a high pressure
p containment vessel. The pressurizing gas most widely used
The memory surface is where plastic strain tensor; and q the
introduced as follows F= ( - )( - )- q,
p p
centre and the radius of the memory surface.
heat heat is argon. An inert gas is used, so that the material does not
chemically react. The chamber is heated, causing the
pressure inside the vessel to increase. Many systems use
treated
q& = p - p - 2q d Z p& p& = p - p
A new set of internal
variables is introduced as: [ ] ( )
and [ ]d (Z ) p& , pressure metal pressure
associated gas pumping to achieve the necessary pressure
level. Pressure is applied to the material from all directions
where q& stand for the rate of strain amplitude that is attained in the previous step and p & stand for the part (hence the term "isostatic").
rate of accumulated plastic strain that is attained during all straining up to the end of the previous step. The pressures of an inert gas usually range from 7,350 psi
(50.7 MPa) to 15,000 psi (100 MPa) and the temperature -
Dirac delta function heat heat
1 2 p from range from 900 F (482 C) to 2,400 F (1,320 C)
the argument of which is Z =
p - p - sign(eeq - eeq )(eeq - eeq ) with eeq =
p p p
p
p
: ,p
depending on the type of material. When components are
2 3 treated with HIP, the simultaneous application of heat and

pressure
defined as follows:
where is pressure eliminates internal voids and microporosity through
q = q (t - t ), p = p (t - t ), p = p (t - t ) and e eq = e eq (t - t ), an infinitesimal time delay.
p p
a combination of plastic deformation, creep, and diffusion

The strain range dependence is then . 2 Simulation of high pressure vessel

introduced into the constants in the
isotropic and kinematic hardening rules:
bonding. This process improves fatigue resistance of the
component through induction of compressive stress.
R& = b (Q - R ) p& and X i = ci g i e& - g i X i p& ,
3 autofrettage
where Q, ci and i are functions of the introduced internal variables.
Creep curves for the structural steel SM50A at 550 C [4]
0.02

C1 s t e C2 C3 +1 - C4 / T
0.0175 e =
cr
+ C5 s C6 te - C7 /T
C3 + 1
0.015
Combined Time Hardening
Creep strain, mm/mm

creep data - 49 MPa

creep model
0.0125 creep data - 73.6 MPa
creep data - 98 MPa
0.01 creep data - 122.6 MPa
creep model - 49 MPa
creep model - 73.6 MPa
0.0075
creep model - 98 MPa
creep model - 122.6 MPa
0.005

0.0025 Time, minutes

0
0 25 50 75 100 125 150 175 200 225 250

Comparison of compressive residual stress fields over the volume Comparison of compressive residual stresses along the bore
-90.9
-83.9
conventional -90.9
-83.8
HT creep 20
-76.8
-69.8 autofrettage -76.7
-69.6 autofrettage High temperature creep autofrettage Conventional hydraulic autofrettage 2
-62.8 -62.6
-55.7 -55.5 0
-48.7 -48.4
-41.6 -41.3
Compressive stress, MPa

-34.6 -34.3
Path length, mm
-27.6 -27.2
-20.5 -20.1 -20
-13.5 -13.0
-6.42 -5.97
0.63 1.11

-40

-60

-80

1
-100
0 5 10 15 20 25 30 35 40

Stress intensity calculations for conventional & creep autofrettage [6,7] Conclusions References
25 Creep AF has advantages over [1] Weir Minerals Netherlands & University of Strathclyde (2015) "Advanced Pump Engineering for Severe
conventional hydraulic AF in the low Applications (APESA)." H2020 Euro. Industrial Doctorate project, ref. 643159: www.apesaproject.eu.
Stress Intencity Range, MPa*m^0.5

Convent. AF, Service P = 10 MPa pressure AF range. This is because [2] Okorokov, V., Comlekci, T., MacKenzie, D., van Rijswick, R. & Gorash, Y. (2017) "Implementation of
the material does not have yield stress plasticity model for a steel with mixed cyclic softening and hardening and its application to fatigue
20 Convent. AF, Service P = 15 MPa during creep deformation, so that assessments." FATIGUE 2017 (3-5 July 2017, Cambridge, UK), EIS, pp. 72-81.
HT Creep AF, Service P = 13 MPa creep strains are developed at any [3] Okorokov, V. & Gorash, Y. (2017) "A comparative study between conventional and elevated temperature
level of stress. The results show that creep autofrettage." ICSI 2017: Proc. of 2nd Int. Conf. on Structural Integrity (4-7 Sept. 2017, Madeira,
15 HT Creep AF, Service P = 19 MPa creep AF can induce a high magnitude Portugal), ESIS (in press).
Fatigue crack growth threshold of compressive residual stresses by [4] Kodur, V.K.R., Dwaikat, M.M.S. (2010) Effect of high temperature creep on the fire response of restrained
applying pressure of values similar to steel beams. Materials & Structures 43(10): 13271341.
10 working conditions. Creep AF can
also provide a deeper level of [5] Badr, E., Sorem, J., Tipton, S. (2000) "Evaluation of the autofrettage effect on fatigue lives of steel blocks
compressive residual stresses with a with crossbores using a statistical and a strain-based method." J. of Testing and Evaluation 28(3): 181188.
high magnitude of these stresses [6] Taylor, D. (2007) The Theory of Critical Distances: A New Perspective in Fracture Mechanics. Elsevier
5 even far away from the stress Science Ltd, Oxford.
concentration. This allows a longer [7] Anderson, T.L. (2005) Fracture Mechanics: Fundamentals and Applications. 3rd ed., CRC Press, Boca
Crack Length, mm crack to be arrested in the pressure Raton, FL.
0 part under a higher service pressure [8] Okorokov, V., Morgantini, M., Gorash, Y., Comlekci, T., MacKenzie, D. & van Rijswick, R. (2017)
0 1 2 3 4 5 6 7 8 9 10 11 12 compared to conventional AF. FatigueDesign 2017 (29-30 Nov. 2017, Senlis, France), CETIM (in press).

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