Work

An improved closed-form residual stress estimation method for girth welds in thin-walled pipe components

Year: 2025

Type: article

Abstract: A reliable residual stress estimation is required for performing fracture mechanics-based structural integrity (or fitness-for-service) evaluations of pressure vessels and pipe components. Recent developments in closed-form estimation methods have shown significant potential for avoiding complex, case-by-case thermo-mechanical finite element simulations. However, for thin-walled pipes, recent studies have shown that existing methods yield inconsistent residual stress estimations. This study presents an improved closed-form residual estimation method by incorporating: (1) finite wall thickness effects on heat dissipation in the analytical estimation of maximum temperature distribution, and (2) an analytical estimation of the plastic zone boundary through a thermo-mechanically coupled formulation enabled by thin-shell theory. The improved method is validated against detailed time-history-based thermo-mechanical finite element models, with two demonstration cases highlighting its improvements. The presented method offers a physically consistent and efficient analytical solution for residual stress estimation in thin-walled pipe components.

Source: Thin-Walled Structures

DOI: 10.1016/j.tws.2025.113343

Authors: Zetao Jin, Pingsha Dong, Shaopin Song

Institution: University of Michigan

Language: English

Topic: Welding Techniques and Residual Stresses

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

Open Access status: hybrid

Estimated APC paid: $4,440

Funder: Welding Research Council