Fatigue life predictions for welded boiler water walls

IF 3 2区工程技术 Q2 ENGINEERING, MECHANICAL

International Journal of Pressure Vessels and Piping Pub Date : 2024-09-21 DOI:10.1016/j.ijpvp.2024.105328

Suvan Dev Choudhury, Waris Nawaz Khan, Leijun Li

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引用次数: 0

Abstract

Boiler water walls experience in-phase thermo-mechanical loading during start-ups and shut-downs, leading to low cycle fatigue (LCF) failure. This study aims at establishing an FEA-based failure prediction method for estimating the fatigue performance and service life of the welded water walls. The developed model is validated for predicting failure in the defect-free uniaxial fatigue specimens. Stress-mechanical strain hysteresis loops and accumulated inelastic strain energy density per cycle parameters are extracted from fatigue tests at 0.4%, 0.6%, and 0.7% strains. A combination of cyclic plasticity and continuous damage mechanics (CDM) theory is utilized to predict fatigue crack initiation sites and estimate the specimen fatigue life. Accumulated damage has been calculated for the life cycle of each specimen. FEA model predicted failure and service life agrees well with the experimental results. The established failure analysis parameters are then transferred from the specimen level to the water wall component level, thereby estimating the service life of defect-free water walls at 750 cycles.

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焊接锅炉水墙的疲劳寿命预测

锅炉水墙在启动和停机过程中会承受同相热机械载荷，从而导致低循环疲劳（LCF）失效。本研究旨在建立一种基于有限元分析的失效预测方法，用于估算焊接水墙的疲劳性能和使用寿命。所开发的模型对预测无缺陷单轴疲劳试样的失效进行了验证。从 0.4%、0.6% 和 0.7% 应变的疲劳试验中提取了应力-机械应变滞后环和每周期累积非弹性应变能量密度参数。循环塑性和连续损伤力学（CDM）理论相结合，用于预测疲劳裂纹起始点和估算试样疲劳寿命。每个试样的寿命周期都计算了累积损伤。有限元分析模型预测的失效和使用寿命与实验结果非常吻合。然后，将已建立的失效分析参数从试样层面转移到水墙组件层面，从而估算出无缺陷水墙在 750 个循环周期下的使用寿命。

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来源期刊

International Journal of Pressure Vessels and Piping 工程技术-工程：机械

CiteScore

5.30

自引率

13.30%

发文量

208

审稿时长

17 months

期刊介绍： Pressure vessel engineering technology is of importance in many branches of industry. This journal publishes the latest research results and related information on all its associated aspects, with particular emphasis on the structural integrity assessment, maintenance and life extension of pressurised process engineering plants. The anticipated coverage of the International Journal of Pressure Vessels and Piping ranges from simple mass-produced pressure vessels to large custom-built vessels and tanks. Pressure vessels technology is a developing field, and contributions on the following topics will therefore be welcome: • Pressure vessel engineering • Structural integrity assessment • Design methods • Codes and standards • Fabrication and welding • Materials properties requirements • Inspection and quality management • Maintenance and life extension • Ageing and environmental effects • Life management Of particular importance are papers covering aspects of significant practical application which could lead to major improvements in economy, reliability and useful life. While most accepted papers represent the results of original applied research, critical reviews of topical interest by world-leading experts will also appear from time to time. International Journal of Pressure Vessels and Piping is indispensable reading for engineering professionals involved in the energy, petrochemicals, process plant, transport, aerospace and related industries; for manufacturers of pressure vessels and ancillary equipment; and for academics pursuing research in these areas.