Two types of specimen for crack tip opening angle (CTOA) measurement have been investigated for pipeline applications, i.e., the modified double cantilever beam (MDCB) (at NIST) and the drop-weight tear test (DWTT) specimen (at CANMET). Results of effects of specimen types, thicknesses and loading rates on CTOA are summarized and discussed. The main observations include: (i) For both MDCB and DWTT specimens tested at quasi-static loading rate, crack front tunnelling (i.e., with a deep triangular crack-tip shape) was present in high-strength steels; (ii) For DWTT specimens, CTOA values measured optically at the surface were significantly higher than those from the simplified single-specimen method (S-SSM) and those measured at mid-thickness [on sections cut using electric discharge machining (EDM)]; and (iii) CTOA values from surface measurement of MDCB specimens were comparable to those derived from S-SSM of DWTT specimens, but the surface values of DWTT were higher than those of MDCB specimens.

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The need to evaluate the significance of flaws in welded pipelines for gas transportation requires the knowledge of the material resistance to ductile tearing. In particular, the fracture resistance of pipe girth welds should be evaluated since they may potentially be critical for structural integrity. Standard toughness Three Point Bending tests (SENB) are too conservative since they are more constrained than actual pipeline. In this case, the adoption of a reduced notch depth, which is considered to reproduce well actual stress-strain conditions at the crack tip of a weld flaw, increases critical toughness values when compared to standard specimen configuration. Alternative solutions may be applied, even if not yet included in toughness standards. In particular, the Single Edge Notch Tensile (SENT) test is a possible solution reducing conservatism. A matter of concern for toughness characterization of weld joint is also represented by the notch orientation, since the weld microstructure is inhomogeneous in nature. The L–R oriented specimen (notch at the pipe inner surface) typically shows CTOD values strongly lower than the ones of L–T oriented specimens (through thickness notch) for both weld metal and heat affected zone. All these issues are discussed within this paper, while an advanced approach is presented to determine the resistance curve by using a single SENT specimen with the compliance method for crack growth evaluation. A relationship between the specimen elastic compliance and actual crack growth was determined through Finite Element Analysis and a Fracture Mechanics model. Such a relationship is presented and compared to other solutions available in scientific literature.

A B S T R A C T Arc welding typically generates residual tensile stresses in welded joints, leading to deteriorated fatigue performance of these joints. Volume expansion of the weld metal at high temperatures followed by contraction during cooling induces a local tensile residual stress state. A new type of welding wire capable of inducing a local compressive residual stress state by means of controlled martensitic transformation at relatively low temperatures has been studied, and the effects of the transformation temperature and residual stresses on fatigue strength are discussed. In this study, several LTTW (Low Transformation-Temperature Welding) wires have been developed and investigated to better characterize the effect of phase transformation on residual stress management in welded joints. Non-load-carrying cruciform fillet welded joints were prepared for measurement of residual stresses and fatigue testing. The measurement of the residual stresses of the three designed wires reveals a compressive residual stress near the weld toe. The fatigue properties of the new wires are enhanced compared to a commercially available wire.Keywords fatigue; residual stress; welded joints; weld metal phase transformations. N O M E N C L A T U R Eb 0 = width of the residual stress in tension or in compression e α = thermal expansion coefficient of ferrite e γ = thermal expansion coefficient of austenite h = leg length along the principal member h p = leg length along the transverse member t 1 = thickness of the principal member t 2 = thickness of the transverse member K t = stress concentration factor N = number of cycles to failure R = stress ratio S = stress level T 0 = thermodynamic equilibrium temperature T Ff = ferrite transformation finish temperature T Fs = ferrite transformation start temperature T Mf = martensite transformation finish temperature T Ms = austenite-to-martensite transformation start temperature x = distance from the weld toe T m = undercooling austenite-to-martensite transformation range temperature Correspondence: Ph. P. Darcis.

A non-associated/associated flow rule coupled with an anisotropic/isotropic quadratic yield function is presented to describe the mechanical responses of two distinct X65 pipeline steels. The first as a product of the cold-rolling forming (UOE) process also known as seam weld pipes and the second as a result of high temperature piercing process called seamless tube manufacturing. The experimental settings consist of a wide range of sample types, whose geometric characteristics represent different state of stresses and loading modes. For low to intermediate stress triaxiality levels, flat specimens are extracted at different material orientations along with notched round bar samples for high stress triaxialities. The results indicate that despite the existing differences in plasticity between materials due to anisotropy induced processes, material failure can be characterized by an isotropic weighting function based on the Modified Mohr-Coulomb (MMC) criterion. The non-associated flow rule allows for inclusion of strain directional dependence in the definition of equivalent plastic strain by means of scalar anisotropy (Lankford) coefficients and thus keeping the original capabilities of the MMC model.

This study presents fatigue data for six different pipeline steels, with strengths ranging from Grade B to X100. A fatigue crack growth test for full thickness pipeline samples was developed using a Middle Tension (MT) type specimen. The six steels showed similar fatigue crack growth rate (da/dN) behavior. There were only minor differences among the steels for the threshold values and most of the stable crack growth regime. Larger differences were observed in the final stages of crack growth and fatigue failure. The effect of compressive residual stresses at the outer surface of the pipeline was also examined. A Failure Assessment Diagram technique was used to evaluate the potential failures modes of the six pipeline steels, containing, as an example, an internal surface, semi-elliptic, axially oriented flaw. Mixed-mode failure was predicted for all of the steels.

The toughness and plasticity of steel generally decreases with increasing testing rate. The crack tip opening angle (CTOA) was measured on two types of commercial pipeline steels API-X65 and API-X100, at a range of displacement rates to characterize rate effects. The testing was conducted at quasi-static and dynamic rates. The crosshead displacements in our test matrix ranged from 0.002 mm/s in the quasi-static mode to approximately 8000 mm/s in the dynamic mode. The quasi-static tests were conducted in a servo-hydraulic uniaxial test machine using Modified Double Cantilever Beam (MDCB) specimens. The dynamic experiments were made on a similar servo-hydraulic uniaxial test machine using the same type of specimen and with the addition of a disc spring setup for the fastest rate. The results of these tests indicate that the rate effect has negligible influence on the CTOA values measured for these materials for the reported rates. The CTOA values measured for the two materials show a small but convincing difference. The resistance to fracture was found to be higher for the X65 steel, as indicated by a higher CTOA and lower crack growth velocity. This paper presents results on the influence of displacement rates from quasi-static to dynamic for the X65 and X100 grade pipeline steels, and discusses a method for optimizing the reduction of the CTOA data.

A B S T R A C T Crack tip opening angle (CTOA) is becoming one of the most accepted methods for characterizing fully plastic fracture. It provides a measure of the resistance to fracture for a material in cases where there is a large degree of stable-tearing crack extension during the fracture process. Our current pipeline research uses the CTOA test as an alternative, or addition, to the CTOD (crack tip opening displacement) and the fracture energy characterization provided by the J-integral approach. A test technique was developed for measurement of CTOA that uses a modified double cantilever beam (MDCB) specimen. A digital camera and image analysis software were used to record the progression of the crack tip and to estimate the CTOA. In this article, CTOA data on crack growth orientations perpendicular to pipeline girth welds are presented. The CTOA for X100 high strength bainitic gas pipeline steel is reported. Two different specimen gauge sections, 3 mm and 8 mm, were used and the effect of the specimen thickness on the CTOA is discussed.The results show a change in the CTOA as the crack grows into the heat affected zone (HAZ). A slight improvement in the fracture resistance is measured, and through the weld, a slight decrease in fracture resistance is observed.a 0 = fatigue pre-crack length COD = crack opening displacement CTOA = crack tip opening angle CTOA c = critical crack tip opening angle CTOD = crack tip opening displacement e u = uniform elongation e f = failure elongation E = Young's modulus HAZ = heat affected zone K = stress intensity factor Q = crack extension to achieve stable CTOA c r = distance behind the crack tip R = fatigue pre-crack loading ratio TR = thickness reduction W = specimen width δ 5 = crack opening displacement δ i = distance between two points located in the crack profile K = stress intensity factor range σ 0.2 = yield stress σ UTS = ultimate tensile strength * Contribution of an agency of the U.S. government, not subject to copyright.Correspondence: Philippe Darcis.