A new monitoring system for piping systems in fossil fired power plants

A CEC-funded project has been performed to tackle the problem of producing an advanced Life Monitoring System (LMS) which would calculate the creep and fatigue damage experienced by high temperature pipework components. Four areas were identified where existing Life Monitoring System technology could be improved:

1. 1. the inclusion of creep relaxation

2. 2. the inclusion of external loads on components

3. 3. a more accurate method of calculating thermal stresses due to temperature transients

4. 4. the inclusion of high cycle fatigue terms.

The creep relaxation problem was solved using stress reduction factors in an analytical in-elastic stress calculation. The stress reduction factors were produced for a number of common geometries and materials by means of non-linear finite element analysis. External loads were catered for by producing influence coefficients from in-elastic analysis of the particular piping system and using them to calculate bending moments at critical positions on the pipework from load and displacement measurements made at the convenient points at the pipework. The thermal stress problem was solved by producing a completely new solution based on Green's Function and Fast Fourier transforms. This allowed the thermal stress in a complex component to be calculated from simple non-intrusive thermocouple measurements made on the outside of the component. The high-cycle fatigue problem was dealt with precalculating the fatigue damage associated with standard transients and adding this damage to cumulative total when a transient occurred.

The site testing provided good practical experience and showed up problems which would not otherwise have been detected.     

Growth Stresses in the Oxide Scales on TiAl Alloys at 800 and 900°C

In the oxidation of TiAl alloys, the role of scale-growth stresses formed during oxidation has, thus far, been unknown. In the present paper the oxide-growth stresses were investigated by the deflection-test method in monofacial oxidation (DTMO) accompanied by acoustic-emission measurements. On unmodified surfaces the growth stresses are compressive and reach levels of around –100 MPa. At the same time, significant acoustic emission occurs indicating that even under isothermal conditions, stresses are relieved by a scale-cracking mechanism. For oxide scales on TiAl surfaces, which had been ion implanted with chlorine before oxidation, a very thin protective alumina layer is formed which, however, develops growth stresses in the range of several GPa, accompanied by intensive acoustic emission. In all stress–time curves, a dynamic situation is observed. This consists of phases of stress relief by scale microcracking and phases of stresses increase due to crack healing and further oxide growth. As a result, the level of stress as a function of oxidation time, is characterized by an oscillating course.     

Simulation of Strength Distribution in Ground Ceramics by Incorporating Residual Stress Effect

Strength of ground ceramics may be affected by residual stress as well as surface flaws induced by grinding. Strength prediction for ground ceramics is convenient for mechanical design of ceramic components. In this article, a numerical procedure based on fracture mechanics was proposed to estimate strength distribution of ground ceramics by considering grinding-induced residual stress. Bending strength and residual stress of ground ceramics were measured for three grinding-conditions. By comparison of simulated results with experimental ones, it was revealed that strength characteristics in experiments were well simulated by using the proposed procedure.     

Eigenspannungen als Messgröße zur Qualitätssicherung

Residual stress as measured quantity in quality assurance The x‐ray method is used in the Volkswagen Automotive Group at different world‐wide locations as a standard procedure to determine residual stress. As an important measured quantity in the quality assurance residual stresses are specified in drawings of different components (e.g. gears, coil springs). Measurements are carried out during quality assurance, production, damage analyse, technical development department and design control of components from suppliers. An optimum efficiency can be achieved, if it exists a unique correlation between residual stress values and loading capacity of components, and if the processes to introduce residual stress can be optimized using residual stress measurements during the production.     

Life Calculations for Header – PGV-1000 Steam Generator Connector Weld Joints under NPP Service Conditions

The procedure for calculating the life of header – steam generator connector weld joints is proposed. It allows for running out the material plasticity reserve upon static cyclic elastoplastic loading as well as operating conditions, local stress concentrations, and residual stresses after welding.     

柔性冗余度机器人残余振动主动控制

研究柔性冗余度机器人的残余振动主动控制问题，设计了具有压电作动器与应变传感器的机敏杆件，建立了受控系统的状态空间表达式，采用独立模态空间控制理论设计LQR状态反馈控制器，并基于对偶原理设计了具有指定收敛特性的Luenberger全维状态观测器，最后，以平面3R柔性冗余度机器人为例进行了计算机仿真，结果表明，采用这种主动控制方法可以显著改善柔性冗余度机器人的动力学品质。     

Thermomechanical Models of Irreversible Finite Deformation of Anisotropic Solids

The proposed models for irreversible finite deformation of initially anisotropic solids are based on the hypothesis of the parameters of state, for which the authors have chosen a universal parameter (temperature) and a strain component, which is analogous to volume strains in an isotropic body and represents thermal strains of an unconstrained (stress-free) anisotropic solid. The application of this hypothesis allows the strain tensor to be resolved into a reversible and irreversible components. For irreversible processes of finite deformation of hardenable materials, the authors have proposed a deformation-type model, which makes it possible to describe a change in the type of anisotropy of initially anisotropic materials in the course of deformation. For the flow-theory-type model, the limiting state function, as given in the space of irreversible strains, allows for the experimentally observed plastic flow of anisotropic crystals under the action of hydrostatic pressure only.     

Residual Stress Simulation of Injection Molding

In this study, distribution and history of residual stresses in plaque-like geometries are simulated based on linear thermoviscoelastic model, which helps to understand the mechanics and evolution of the residual stresses in the injection molding process. The numerical calculation of direction, combined with the specified boundary conditions. Results show that the stress variation across the thickness exhibits a high surface tensile value changing to a compressive peak value close to the surface, with the core region experiencing a parabolic tensile peak. Residual stress distribution throughout the thickness is almost same along the flowpath and the final residual stresses value near the gate is lower than the value near the end of flowpath.     

Influence of Ni Interlayers on the Mechanical Properties of Ti6Al4V/(WC-Co) Friction Welds

Ni interlayers were introduced prior to dissimilar friction welding of Ti6Al4V base material to three cemented carbide substrates. The fracture strength of Ti6Al4V/(WC-6 wt% Co) welds were poor and were markedly improved when 20-µm thick Ni interlayers were introduced prior to dissimilar friction welding. These results were only produced when the (WC-6 wt% Co) cermet was electroplated prior to friction welding. When the Ti6Al4V alloy was electroplated prior to friction welding, fractured WC particles and cracking were observed in the (WC-Co) carbide substrate. The fracture strengths of Ti6Al4V/(WC-11 wt% Co) and Ti6Al4V/(WC-24 wt% Co) welds were not improved when 20-µm thick Ni interlayers were introduced prior to friction welding. During mechanical testing, the Ni layer retained at the dissimilar joint interface created a region of weakness.