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

IF 6.6 1区工程技术 Q1 ENGINEERING, CIVIL Thin-Walled Structures Pub Date : 2025-08-01 Epub Date: 2025-04-18 DOI:10.1016/j.tws.2025.113343

Zetao Jin , Pingsha Dong , Shaopin Song

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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.

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一种改进的薄壁管件环焊缝封闭残余应力估计方法

为了对压力容器和管道部件进行基于断裂力学的结构完整性（或适用性）评估，需要可靠的残余应力估计。封闭形式估计方法的最新发展显示出避免复杂的逐案热机械有限元模拟的巨大潜力。然而，对于薄壁管道，最近的研究表明，现有的方法产生不一致的残余应力估计。本文提出了一种改进的闭式残差估计方法，该方法将：(1)在解析估计最高温度分布时考虑有限壁厚对散热的影响；(2)通过薄壳理论支持的热-机械耦合公式对塑性区边界进行解析估计。通过详细的基于时程的热力学有限元模型验证了改进的方法，并通过两个演示案例突出了其改进。该方法为薄壁管件残余应力估计提供了一种物理上一致且有效的解析解。

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来源期刊

Thin-Walled Structures 工程技术-工程：土木

CiteScore

9.60

自引率

20.30%

发文量

801

审稿时长

66 days

期刊介绍： Thin-walled structures comprises an important and growing proportion of engineering construction with areas of application becoming increasingly diverse, ranging from aircraft, bridges, ships and oil rigs to storage vessels, industrial buildings and warehouses. Many factors, including cost and weight economy, new materials and processes and the growth of powerful methods of analysis have contributed to this growth, and led to the need for a journal which concentrates specifically on structures in which problems arise due to the thinness of the walls. This field includes cold– formed sections, plate and shell structures, reinforced plastics structures and aluminium structures, and is of importance in many branches of engineering. The primary criterion for consideration of papers in Thin–Walled Structures is that they must be concerned with thin–walled structures or the basic problems inherent in thin–walled structures. Provided this criterion is satisfied no restriction is placed on the type of construction, material or field of application. Papers on theory, experiment, design, etc., are published and it is expected that many papers will contain aspects of all three.