Analysis of the effect of pre-crack curvature in Mini-C(T) specimen on fracture toughness evaluation

Shimodaira, Masaki; Ha, Yoosung; Takamizawa, Hisashi; Katsuyama, Jinya; Onizawa, Kunio

Proceedings of ASME 2023 Pressure Vessels and Piping Conference (PVP 2023) (Internet), 11 Pages, 2023/07

In the current structural integrity assessment of the reactor pressure vessel, the accurate reference temperature (T) based on the Master Curve method is necessary. The T can be estimated by using the Mini-C(T) fracture toughness specimen in accordance with ASTM E1921 and JEAC4216, which prescribe the pre-crack straightness criteria. A requirement in ASTM E1921 has been revised in a decade to increase the accuracy and reasonability, and the applicable crack curvature has been varied by applied codes. The pre-crack curvature of the Mini-C(T) specimen might have an impact on the T because of the variation of the plastic constraint. In this work, the effect of the crack curvature on the fracture toughness (K) evaluation using the Mini-C(T) specimen was quantitatively evaluated by using the finite element analysis (FEA) including the Weibull stress analysis, to discuss the difference in a requirement of the crack straightness in ASTM E1921 and JEAC4216. FEAs showed a possibility that the upper limit curvature would decrease the plastic constraint, and consequently obtain higher K in the Mini-C(T) specimen. Furthermore, if the upper limit curvature according to the ASTM E1921-21 was allowed, the T would be estimated as non-conservative based on the Weibull stress analysis. In contrast, the difference in (T) between the crack with upper limit curvature according to JEAC4216 and the ideal straight crack was not significant.

Development of stress intensity factor solution for surface crack at nozzle corner in reactor pressure vessel

Yamaguchi, Yoshihito; Takamizawa, Hisashi; Katsuyama, Jinya; Li, Y.

Proceedings of ASME 2023 Pressure Vessels and Piping Conference (PVP 2023) (Internet), 9 Pages, 2023/07

The stress intensity factor (SIF) for crack at nozzle corner is a key parameter in structural integrity assessment of nozzle in reactor pressure vessel (RPV). Although various SIF solutions for surface cracks at nozzle corners have been proposed, most of them are only focusing on the deepest point of the crack, and the information about geometric dimension of the nozzle corner is not clear. According to the previous fatigue test results regarding the surface crack at the nozzle corner, the amounts of crack growth at the surface points were larger than that at the deepest point of the crack. Such results imply that SIFs at the surface points may be higher than that at the deepest point. To increase the reliability of the structural integrity assessment, it is necessary to provide SIF solutions for both surface and deepest points. In this study, SIF solutions for two surface points and the deepest point of surface crack at nozzle corners are developed through finite element analyses and the solutions are provided corresponding to the geometric dimensions of nozzle corner and crack size.

Guideline on structural integrity assessment for reactor pressure vessel in domestic light water reactor based on probabilistic fracture mechanics

Lu, K.; Katsuyama, Jinya; Takamizawa, Hisashi; Li, Y.

JAEA-Research 2022-012, 39 Pages, 2023/02

JAEA-Research-2022-012.pdf:1.72MB

For reactor pressure vessels (RPVs) in the light water reactors, the fracture toughness decreases due to the neutron irradiation embrittlement with operating years. In Japan, to prevent RPVs from a nil-ductile fracture, deterministic fracture mechanics methods in accordance with the codes provided by the Japan Electric Association are performed for assessing the structural integrity of RPVs under the pressurized thermal shock (PTS) events by taking the neutron irradiation embrittlement into account. On the other hand, in recent years, probabilistic methodologies for PTS evaluation are introduced into regulations in the United States and some European countries. For example, in the United States, a PTS screening criterion related to the reference temperature based on the probabilistic method is stipulated. If the screening criterion is not satisfied, it is allowable to perform the evaluation based on the probabilistic method by calculating numerical index such as through-wall crack frequency (TWCF). In addition, the reduction of non-destructive examination extent or extension of examination intervals for RPV welds have been discussed based on the probabilistic method. Here, the probabilistic method is a structural integrity assessment method based on probabilistic fracture mechanics (PFM) which is rational in calculating the failure probability of components by considering uncertainties of various factors related to the aged degradation due to the long-term operation. Based on these backgrounds, we developed a PFM analysis code PASCAL and released a guideline on structural integrity assessment based on PFM by reflecting the latest knowledge and expertise in 2017. Here, the main analysis target was the RPV of pressurized water rector considering neutron irradiation embrittlement and PTS events in the structural integrity assessment of RPVs. The objective of the guideline is that persons who have knowledge on the fracture mechanics can carry out the PFM analyses and

Improvement of the return mapping algorithm based on the implicit function theorem with application to ductile fracture analysis using the GTN model

Mano, Akihiro; Imai, Ryuta*; Miyamoto, Yuhei*; Lu, K.; Katsuyama, Jinya; Li, Y.

International Journal of Pressure Vessels and Piping, 199, p.104700_1 - 104700_13, 2022/10

https://doi.org/10.1016/j.ijpvp.2022.104700

Elastic-plastic analyses based on finite element methods are widely applied to simulate the nonlinear behaviors of materials. When the analysis is conducted by an implicit method, the stress values are generally updated with a time increment by using the so-called return mapping algorithm. This algorithm requires solving simultaneous nonlinear equations related to a constitutive model. In the present paper, we proposed a general method to reduce the number of equations in the return mapping algorithm based on the implicit function theorem. In addition, the proposed method was applied to the Gurson-Tvergaard-Needleman (GTN) model that considers the influence of damage due to nucleation and growth of microscopic void in materials in the simulation of the nonlinear behaviors. By using the GTN model with the proposed method, an elastic-plastic analysis was performed by the implicit method for a 4-point bending test of pipe with a through-wall crack. The numerical solution of the variation of the load-load line displacement from the analysis agreed with experimental result. Thus, we concluded that the proposed method is useful for simulating nonlinear behaviors, including void nucleation and growth in materials.

Damage evaluations for BWR lower head in severe accident based on multi-physics simulations

Katsuyama, Jinya; Yamaguchi, Yoshihito; Nemoto, Yoshiyuki; Furuta, Takuya; Kaji, Yoshiyuki

Proceedings of ASME 2022 Pressure Vessels and Piping Conference (PVP 2022) (Internet), 9 Pages, 2022/07

Improvement of probabilistic fracture mechanics analysis code PASCAL-SP regarding stress corrosion cracking in nickel based alloy weld joint of piping system in boiling water reactor

Mano, Akihiro; Yamaguchi, Yoshihito; Katsuyama, Jinya; Li, Y.

Journal of Pressure Vessel Technology, 144(1), p.011506_1 - 011506_9, 2022/02

https://doi.org/10.1115/1.4052449

In the past few decades, the cracks because of stress corrosion cracking (SCC) have been detected in the dissimilar weld joints welded using nickel based alloy in piping system of boiling water reactors. Thus, the structural integrity assessment for such weld joints has become important. Nowadays, probabilistic fracture mechanics (PFM) analysis is recognized as a rational method for structural integrity assessment because it can consider inherent uncertainties of various influencing factors as probability distributions and quantitatively evaluate the failure probability of a cracked component. The Japan Atomic Energy Agency has developed a PFM analysis code PASCAL-SP for a probabilistic structural integrity assessment of weld joint in pipe in nuclear power plant. This study improves the analysis functions of PASCAL-SP for weld joint welded using nickel based alloy in boiling water reactor susceptible to SCC. As an analysis example of the improved version of PASCAL-SP, the failure probability of a weld joint is quantitatively evaluated. Furthermore, sensitivity analyses are conducted concerning the effect of leak detection and in-service inspection. From the analysis results, it is concluded that the improved version of PASCAL-SP is useful for structural integrity assessment.

Constraint effect on fracture behavior of underclad crack in reactor pressure vessel

Shimodaira, Masaki; Tobita, Toru; Takamizawa, Hisashi; Katsuyama, Jinya; Hanawa, Satoshi

Journal of Pressure Vessel Technology, 144(1), p.011304_1 - 011304_7, 2022/02

https://doi.org/10.1115/1.4051704

In the structural integrity assessment of a reactor pressure vessel (RPV), the fracture toughness (K) should be higher than the stress intensity factor at the crack tip of an under-clad crack (UCC), which is prescribed in JEAC4206-2016. However, differences in crack depth and existence of cladding between the postulated crack and fracture toughness test specimens would be affected to the plastic constraint state and K evaluation. In this study, we performed fracture toughness tests and finite element analyses (FEAs) to investigate the effect of cladding on K evaluation. FEA showed that the cladding decreased the plastic constraint in the UCC rather than the surface crack. Moreover, it was also found that the apparent K for the UCC was higher than that for the surface crack from tests and the local approach.

A Novel method to uniquely determine the parameters in Gurson-Tvergaard-Needleman model

Zhang, T.; Lu, K.; Mano, Akihiro; Yamaguchi, Yoshihito; Katsuyama, Jinya; Li, Y.

Fatigue & Fracture of Engineering Materials & Structures, 44(12), p.3399 - 3415, 2021/12

https://doi.org/10.1111/ffe.13568

The Gurson-Tvergaard-Needleman (GTN) model is considered a promising approach in failure prediction as it takes the micromechanical behavior of ductile metals into consideration and its function exhibits a relatively clear physical meaning. Although the GTN model has been widely investigated in the past decades, its engineering applications have scarcely progressed due to the difficulty in determining the eight strongly coupled parameters. Based on the physical background of GTN model, a set of methods was established to determine the parameters in the GTN model. The knowledge of continuum damage mechanics was used to experimentally determine the development of void volume fraction through the variation of effective Young's modulus in a uniaxial tensile test, and three parameters regarding void nucleation were analytically derived using a newly established method. Other parameters in the GTN model were also uniquely determined through a joint use of the chemical composition analysis (for the initial void volume fraction), the cell model analyses (for the two constitutive parameters), and the inverse finite element method (for the two failure parameters). The reliability of this novel parameter determination method was verified through the failure prediction of both cracked and uncracked specimens of carbon steel STPT410.

Assessment of residual stress for thick butt-welded plate of a reactor pressure vessel steel

Ha, Yoosung; Okano, Shigetaka*; Takamizawa, Hisashi; Katsuyama, Jinya; Mochizuki, Masahito*

Proceedings of ASME 2021 Pressure Vessels and Piping Conference (PVP 2021) (Internet), 6 Pages, 2021/07

Development of guideline on seismic fragility evaluation for aged piping

Yamaguchi, Yoshihito; Katsuyama, Jinya; Masaki, Koichi*; Li, Y.

Proceedings of ASME 2021 Pressure Vessels and Piping Conference (PVP 2021) (Internet), 9 Pages, 2021/07

The seismic probabilistic risk assessment is an important methodology to evaluate the seismic safety of nuclear power plants. In this assessment, the core damage frequency is evaluated from the seismic hazard, seismic fragilities, and accident sequence. Regarding the seismic fragility evaluation, the probabilistic fracture mechanics can be applied as a useful evaluation technique for aged piping systems with crack or wall thinning due to the age-related degradation mechanisms. In this study, to advance seismic probabilistic risk assessment methodology of nuclear power plants that have been in operation for a long time, a guideline on the seismic fragility evaluation of the typical aged piping systems of nuclear power plants has been developed considering the age-related degradation mechanisms. This paper provides an outline of the guideline and several examples of seismic fragility evaluation based on the guideline and utilizing the probabilistic fracture mechanics analysis code.