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Article

  • Title

    EFFECT OF PITTING CORROSION ON STRESS INTENSITY FACTORS OF SEMI-ELLIPTICAL SURFACE CRACKS ON THE OUTER WALL SURFACE OF A TUBULAR T-JOINT

  • Authors

    Rahbar-Ranji Ahmad
    Kaviani Amirhossein
    Iranmanesh Mehdi
    Dowlatabadi Alireza

  • Subject

    MACHINE BUILDING. PROCESS METALLURGY. MATERIALS SCIENCE

  • Year 2018
    Issue 2(55)
    UDC 539.3
    DOI 10.15276/opu.2.55.2018.01
    Pages 5-19
  • Abstract

    Fatigue and pitting corrosion are two important design considerations for strength assessment of steel structures of the offshore oil and gas industry. It is vital to evaluate the impact of corrosion on the fatigue life of corroded steel structures. Close examinations of the crack propagation life for fatigue-induced defects in the pipeline and tubular joint exposed to corrosion environment have posed serious challenges to engineering practice. The approach of linear elastic fracture mechanics (LEFM) can be used to analyze the growth of high-cycle fatigue crack, which typically occurs when the applied stresses are well below the yield stress. It is mostly accepted that the stress intensity factor (SIF) is calculated in the analysis and design of structures using LEFM. In the present study the effect of pitting corrosion on stress intensity factor along the crack front is investigated. Very few studies exist that employ the Finite element method (FEM) to estimate the stress intensity factor along the crack front in T-joint with and without pitting corrosion. In order to show the effect of pit on the fracture parameter, the pit-effect coefficient is defined as the difference between normalized stress intensity factors with and without pitting corrosion. A series of three-dimensional circular cone pit models together with a semi-elliptical surface crack in a tubular T-joint are simulated in ANSYS. In order to validate the model, the results of an un-corroded model are examined against the available results in the literature, and good agreements are observed. Three-dimensional finite element analyses are conducted in order to investigate the effects of depth, orientation, cross-sectional area and location of pitting corrosion. Thus the effects of the geometry and position of pitting corrosion, as well as the size of crack, are being analyzed. It is found that the location and geometry of pitting corrosion are the dominant parameters affecting the stress intensity factor. The pitting corrosion located in the direction of crack face and close to the surface crack has a significant influence on the stress intensity factor, whereas the pitting corrosion located in brace has a negative effect on the SIF.

     

  • Keywords Pitting corrosion, semi-elliptical crack, Finite element method, Stress intensity factor
  • Viewed: 124 Dowloaded: 8
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  • References

     

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    2. Yang S., Ni Y.L., Li C.Q. Weight function method to determine stress intensity factor for semi-elliptical crack with high aspect ratio in cylindrical vessels. Engineering Fracture Mechanics. 2013. № 109. P. 138–149. DOI: https//doi.org/10.1016/j.engfracmech.2013.05.014.
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    11. Qian X., Nguyen C.T., Petchdemaneengam Y., Ou Z., Swaddiwudhipong S., Marshall P. Fatigue performance of tubular X-joints with PJP+ welds: II—Numerical investigation. Journal of Constructional Steel Research. 2013. № 89. P. 252–261.
    12. Dao N.H., Sellami H. Stress intensity factors and fatigue growth of a surface crack in a drill pipe during rotary drilling operation. Engineering Fracture Mechanics. 2012. № 96. P. 626–640. DOI: https//doi.org/ 10.1016/j.engfracmech.2012.09.025.
    13. Nakai T., Matsushita H., Yamamoto N., editors. Pitting corrosion and its influence on local strength of hull structural members. ASME 2005 24th International Conference on Offshore Mechanics and Arctic Engineering, American Society of Mechanical Engineers. Greece. 2005. P. 25–35. DOI: https//doi.org/10.1115/OMAE2005-67025.
    14. Ji J., Zhang C., Kodikara J., Yang S.Q. Prediction of stress concentration factor of corrosion pits on buried pipes by least squares support vector machine. Engineering Failure Analysis. 2015. № 55. P. 131–138.
    15. Rahbar-Ranji A., Niamir N., Zarookian A. Ultimate strength of stiffened plates with pitting corrosion. International Journal of Naval Architecture and Ocean Engineering. 2015. № 7(3). P. 509–525. DOI: https//doi.org/10.1515/ijnaoe-2015-0037.
    16. Eslami-majd A., Rahbar-Ranji A. Blast response of corroded steel plates. Journal of Mechanical Science and Technology. 2014. № 28(5). P. 1683–1690. DOI: https//doi.org/10.1007/s12206-014-0313-1.
    17. Eslami-Majd A., Rahbar-Ranji A. Free vibration analysis of corroded steel plates. Journal of Mechanical Science and Technology. 2014. № 28(6). P. 2081–2088. DOI: https//doi.org/10.1007/s12206-013-1114-7
    18. Eslami-Majd A., Rahbar-Ranji A. Deformation behaviour of corroded plates subjected to blast loading. Journal of Ships and Offshore Structures. 2015. № 10(1). P. 79–93. DOI: https//doi.org/10.1080/ 17445302.2014.889371.
    19. Zhang Y., Huang Y., Zhang Q., Liu G. Ultimate strength of hull structural plate with pitting corrosion damnification under combined loading. Ocean Engineering. 2016. № 116. P. 273–285.
    20. Gandhi P., Murthy D.R., Raghava G., Rao A.M. Fatigue crack growth in stiffened steel tubular joints in seawater environment. Engineering Structures. 2000. № 22(10). P. 1390–1401.
    21. Xu S-h. Estimating the effects of corrosion pits on the fatigue life of steel plate based on the 3D profile. International Journal of Fatigue. 2015. № 72. P. 27–41. DOI: https//doi.org/10.1016/ j.ijfatigue.2014.11.003.
    22. Rokhlin S., Kim J.Y., Nagy H., Zoofan B. Effect of pitting corrosion on fatigue crack initiation and fatigue life. Engineering Fracture Mechanics. 1999. № 62(4). P. 425–444. DOI: https//doi.org/10.1016/S0013-7944(98)00101-5.
    23. Wang W., Zhou A., Robert D., Li C., editors. Assessment of stress intensity factors for cast iron pipes with pitting corrosion. International conference on Geo-mechanics, Geo-energy and Geo-resources. 3GDeep Group, Department of Civil Engineering. Monash University. 2016. P. 79–84.
    24. Nakai T., Matsushita H., Yamamoto N. Effect of pitting corrosion on local strength of hold frames of bulk carriers (2nd report)–lateral-distortional buckling and local face buckling. Marine Structures. 2004. № 17(8). P. 612–641.
    25. Jie Z., Li Y., Wei X. A study of fatigue crack growth from artificial corrosion pits at welded joints under complex stress fields. Fatigue & Fracture of Engineering Materials & Structures. 2017. № 40(9). P. 1364–1377. DOI: https//doi.org/10.1111/ffe.12577.

     

    1. Mahmoud, H.N, & Dexter, R.J. (2005). Propagation rate of large cracks in stiffened panels under tension loading. Marine Structures, 18(3), 265–288. DOI: https//doi.org/10.1016/j.marstruc.2005.09.001.
    2. Yang, S., Ni, Y.L., & Li, C.Q. (2013). Weight function method to determine stress intensity factor for semi-elliptical crack with high aspect ratio in cylindrical vessels. Engineering Fracture Mechanics, 109, 138–149. DOI: https//doi.org/10.1016/j.engfracmech.2013.05.014.
    3. Thévenet, D., Ghanameh, M.F., & Zeghloul, A. (2013). Fatigue strength assessment of tubular welded joints by an alternative structural stress approach. International Journal of Fatigue, 51, 74–82.
    4. Fathi, A., & Aghakouchak A. (2007). Prediction of fatigue crack growth rate in welded tubular joints using neural network. International journal of fatigue, 29(2), 261–275. DOI: https//doi.org/10.1016/ j.ijfatigue.2006.03.002.
    5. Lie, S.T., Li, G., & Cen, Z. (2000). Effect of brace wall thickness and weld size on stress intensity factors for welded tubular T-joints. Journal of Constructional Steel Research, 53(2), 167–182.
    6. Huang, X., & Hancock, J.W. (1988). The stress intensity factors of semi-elliptical cracks in a tubular welded T-joint under axial loading. Engineering Fracture Mechanics, 30(1), 25–35. DOI: https//doi.org/10.1016/0013-7944(88)90252-4.
    7. Ritchie, D., & Huijskens, H. (1989). Fracture mechanics based predictions of the effects of the size of tubular joint test specimens on their fatigue life. Proc. 8th Intn. Conference, Offshore Mechanics & Arctic Engng., Vol. 3. (pp.121–127).
    8. Olowokere, D., & Nwosu, D. (1997). Numerical studies on crack growth in a steel tubular T-joint. International journal of mechanical sciences, 39(7), 859–871. DOI: https//doi.org/10.1016/S0020-7403(96)00087-2.
    9. Nwosu, D., & Olowokere, D. (1995). Evaluation of stress intensity factors for steel tubular T-joints using line spring and shell elements. Engineering Failure Analysis, 2(1), 31–44. DOI: https//doi.org/10.1016/1350-6307(95)00005-B.
    10. Toribio, J., Matos, J., González, B., & Escuadra, J. (2014). Numerical modelling of cracking path in round bars subjected to cyclic tension and bending. International Journal of Fatigue, 58, 20–27. DOI: https//doi.org/ 10.1016/j.ijfatigue.2013.03.017.
    11. Qian, X., Nguyen, C.T., Petchdemaneengam, Y., Ou, Z., Swaddiwudhipong, S., & Marshall, P. (2013). Fatigue performance of tubular X-joints with PJP+ welds: II—Numerical investigation. Journal of Constructional Steel Research, 89, 252–261.
    12. Dao, N.H., & Sellami, H. (2012). Stress intensity factors and fatigue growth of a surface crack in a drill pipe during rotary drilling operation. Engineering Fracture Mechanics, 96, 626–640. DOI: https//doi.org/ 10.1016/j.engfracmech.2012.09.025.
    13. Nakai, T., Matsushita, H., & Yamamoto, N., editors. (2005). Pitting corrosion and its influence on local strength of hull structural members. ASME 2005 24th International Conference on Offshore Mechanics and Arctic Engineering, American Society of Mechanical Engineers. Greece. (pp.25–35) DOI: https//doi.org/10.1115/OMAE2005-67025
    14. Ji, J., Zhang, C., Kodikara, J., & Yang, S.Q. (2015). Prediction of stress concentration factor of corrosion pits on buried pipes by least squares support vector machine. Engineering Failure Analysis. 55, 131–138.
    15. Rahbar-Ranji, A., Niamir, N., & Zarookian, A. (2015). Ultimate strength of stiffened plates with pitting corrosion. International Journal of Naval Architecture and Ocean Engineering, 7(3), 509–525. DOI: https//doi.org/10.1515/ijnaoe-2015-0037.
    16. Eslami-majd, A., & Rahbar-Ranji, A. (2014). Blast response of corroded steel plates. Journal of Mechanical Science and Technology, 28(5), 1683–1690. DOI: https//doi.org/10.1007/s12206-014-0313-1.
    17. Eslami-Majd, A., & Rahbar-Ranji, A. (2014). Free vibration analysis of corroded steel plates. Journal of Mechanical Science and Technology, 28(6), 2081–2088. DOI: https//doi.org/10.1007/s12206-013-1114-7
    18. Eslami-Majd, A., & Rahbar-Ranji, A. (2015). Deformation behaviour of corroded plates subjected to blast loading. Journal of Ships and Offshore Structures, 10(1), 79–93. DOI: https//doi.org/10.1080/17445302.2014.889371.
    19. Zhang, Y., Huang, Y., Zhang, Q., & Liu, G. (2016). Ultimate strength of hull structural plate with pitting corrosion damnification under combined loading. Ocean Engineering, 116, 273–285.
    20. Gandhi, P., Murthy, D.R., Raghava, G., & Rao, A.M. (2000). Fatigue crack growth in stiffened steel tubular joints in seawater environment. Engineering Structures, 22(10), 1390–1401.
    21. Xu, S-h. (2015). Estimating the effects of corrosion pits on the fatigue life of steel plate based on the 3D profile. International Journal of Fatigue, 72, 27–41. DOI: https//doi.org/10.1016/ j.ijfatigue.2014.11.003.
    22. Rokhlin, S., Kim, J.Y., Nagy, H., & Zoofan, B. (1999). Effect of pitting corrosion on fatigue crack initiation and fatigue life. Engineering Fracture Mechanics, 62(4), 425–444. DOI: 10.1016/S0013-7944(98)00101-5.
    23. Wang, W., Zhou, A., Robert, D., & Li, C., editors. (2016). Assessment of stress intensity factors for cast iron pipes with pitting corrosion. International conference on Geo-mechanics, Geo-energy and Geo-resources. 3GDeep Group, Department of Civil Engineering. (pp.79–84). Monash University.
    24. Nakai, T., Matsushita, H., & Yamamoto, N. (2004). Effect of pitting corrosion on local strength of hold frames of bulk carriers (2nd report)—lateral-distortional buckling and local face buckling. Marine Structures, 17(8), 612–641.
    25. Jie, Z., Li, Y., & Wei, X. (2017). A study of fatigue crack growth from artificial corrosion pits at welded joints under complex stress fields. Fatigue & Fracture of Engineering Materials & Structures, Vol. 40(9), 1364–1377. DOI: https//doi.org/10.1111/ffe.12577.

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