A modeling framework is established to describe running ductile fracture in vintage API grade X52 offshore pipelines. For the structural model, the plasticity and ductile fracture properties were characterized by various laboratory scale tests. Tensile tests up to strain rates of 1000 1/s were performed to calibrate the strain rate dependent plasticity model. Using notched tensile specimens with a wide range of stress states, a hybrid experimental-numerical procedure was performed to determine the parameters of a ductile fracture (FL) model. The material model was successfully verified against the instrumented Battelle Drop-Weight Tear (BDWT) test results. The decompression of the CO2-rich gas mixture was described by the GERG-2008 equation of state and implemented as an idealized pressure decay model to reduce the computational cost. Finally, the established modeling framework provides a valuable tool for investigating and evaluating ductile fracture propagation and arrest behavior in the vintage offshore pipelines.
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Themes: Ductile Fracture Under Complex Loading
ESTIMATING PLASTICITY AND DUCTILE DAMAGE MODEL PARAMETERS FOR S355-S690 STEEL FROM MILL TEST CERTIFICATE DATA
Accurate finite-element simulation of the fracture of metals requires the calibration of plasticity and fracture modelling parameters based on mechanical tests on the material. Depending on the complexity of the model, each different material that is modelled requires a number of non-standard tests followed by a calibration process. This paper derives relationships between mill test certificate data and the plasticity and damage model parameters for S355-S690 steel in order to enable the quick application of generally representative plasticity and damage models to these steels without the need for repeated manual calibration of each material. The relationships are obtained by regression analysis between a database of 2597 mill test certificate results (of tensile and Charpy tests) and a parametric finite element study in which the parameters of a Hollomon-type stress-strain model and the Modified Mohr-Coulomb damage model were varied.
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PREDICTING DUCTILE FRACTURE DURING TORSION TESTING USING ELLIPSOIDAL VOID MODEL AND ANALYTICAL MODEL
Research on ductile fracture under high stress triaxiality has been performed considerably, whereas research on ductile fracture under low stress triaxiality has not been performed sufficiently. In this paper, torsion testing of a bar which is prestrained by drawing is performed using a torsion testing machine, and ductile fracture during torsion testing is predicted using an ellipsoidal void model and an analytical model.
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EFFECT OF HPT PROCESSING ON FRACTURE BEHAVIOUR OF MARAGING STEELS
Maraging steels are a class of precipitation hardened steels wherein different micro-mechanisms of deformation such as planar slip, interaction with coherent/incoherent precipitates, and reverted austenite affecct the overall mechanical behavior of the material. High-pressure-torsion (HPT) processing introduces a large density of dislocations that form sub-grain boundaries within the refined nano-scale structure, leading to changes in precipitate morphology compared to hot-rolled maraging steels. The impact of such nanostructuring on the deformation and fracture micro-mechanisms is being reported for the first time using in-situ characterization techniques along with transmission electron microscopy and atom probe tomography analysis, in this study. Digital image correlation has been used to quantify the full field strain maps in regions of severe strain localization as well as to determine the fracture toughness through critical crack tip opening displacements.
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THE FOURTH SANDIA FRACTURE CHALLENGE – PREDICTING PUNCTURE IN A METAL STRUCTURE [Keynote]
The fourth Sandia Fracture Challenge (SFC4) investigated the puncture of aluminum structures through comparing various computational predictions to physical experiments. Five teams, internal to Sandia National Laboratories, submitted predictions with mixed success. Qualitatively, many teams were able to predict the deformation and failure modes at the critical velocity for puncture, but the extent of damage was underpredicted by all. Quantitatively, predictions for critical velocity varied widely, though were in the correct order of magnitude. The SFC4 highlighted difficulties in modeling damage and fracture in shear-dominated loading cases.
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PREDICTING DUCTILE FRACTURE FOR MIXED MODE OF LOADING USING THE MODIFIED MOHR-COULOMB CRITERION
Reliable and robust fracture prediction tools are necessary for designing and analyzing critical engineering structures. This paper uses a phenomenological damage model to study the fracture response of a pressure vessel steel under complex loading conditions. Details of the experiments and numerical procedures are provided for calibrating and validating the proposed framework for predicting ductile fracture.
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COUPLED CRYSTAL PLASTICITY PHASE-FIELD MODEL FOR DUCTILE FRACTURE IN POLYCRYSTALLINE MICROSTRUCTURES
A wavelet-enriched adaptive hierarchical, coupled crystal plasticity – phase-field finite element model is developed in this work to simulate crack propagation in complex polycrystalline microstructures. The model accommodates initial material anisotropy and crack tension-compression asymmetry through orthogonal decomposition of stored elastic strain energy into tensile and compressive counterparts. The crack evolution is driven by stored elastic and defect energies, resulting from slip and hardening of crystallographic slips systems. A FE model is used to simulate the fracture process in a statistically equivalent representative volume element reconstructed from electron backscattered diffraction scans of experimental microstructures. Multiple numerical simulations with the model exhibits microstructurally sensitive crack propagation characteristics.
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A UNIFIED NONLINEAR XFEM-CZM BASED METHODOLOGY TO DEAL WITH DUCTILE FRACTURE
The numerical treatment of the whole process of ductile fracture remains a challenging task, particularly when FEM is employed. The main issue regards pathologically mesh dependence of the numerical results, not only in the softening regime but also in the stages of strain localization and further crack propagation. In the literature, non-local approaches are adopted to mitigate these effects but they require a calibrated length scale and mesh refinement, thus being time consuming. This work focuses on the numerical treatment of ductile fracture in metal materials via a three-dimensional unified methodology that combines (i) the GTN model to describe diffuse damage using the standard FEM, the (ii) XFEM to represent the crack and (iii) the coupling of the XFEM with a cohesive zone model to account for the intermediate localization phase. We rely upon the Updated Lagrangian formulation to include large strains and rotations. The methodology, implemented in Abaqus commercial code as a user finite element (UEL), is capable of reproducing numerically the overall response of structures until rupture.
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VOID SIZE, SHAPE, AND ORIENTATION EFFECTS UNDER INTENSE SHEARING ACROSS SCALES
The present work demonstrates how gradient strengthening at the micron scale affects the macroscopic strain at coalescence under intense shearing conditions. The coalescence mechanism relies on severe flattening, rotation, and elongation of the voids causing severe heterogeneous plastic strain to develop near the voids and in the ligament between voids. These gradients are associated with geometrically necessary dislocations, causing a delay in the coalescence process.
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ANALYSES OF DUCTILE FRACTURE USING HUNNY THEORY
We present a theory with a structure that enables analyses of ductile fracture under any type of loading. The theory builds on the standard concept of homogeneous yielding and further proceeds from the concept of unhomogeneous yielding on a (yield) system that depends on the spatial distribution of voids. Depending on the desired level of refinement in analysis, a given simulation employs one or more yield systems with the isotropic limit being reached for an infinite number. We illustrate the predictive capabilities of the theory by considering simulations of three-dimensional crack initiation and growth in a round notched bar, a shear specimen and a compression pin.
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