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Accurate Effective Stress Measures: Predicting Creep Life for 3D Stresses Using 2D and 1D Creep Rupture Simulations and Data

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Abstract

Operating structural components experience complex loading conditions resulting in 3D stress states. Current design practice estimates multiaxial creep rupture life by mapping a general state of stress to a uniaxial creep rupture correlation using effective stress measures. The data supporting the development of effective stress measures are nearly always only uniaxial and biaxial, as 3D creep rupture tests are not widely available. This limitation means current effective stress measures must extrapolate from 2D to 3D stress states, potentially introducing extrapolation error. In this work, we use a physics-based, crystal plasticity finite element model to simulate uniaxial, biaxial, and triaxial creep rupture. We use the virtual dataset to assess the accuracy of current and novel effective stress measures in extrapolating from 2D to 3D stresses and also explore how the predictive accuracy of the effective stress measures might change if experimental 3D rupture data was available. We confirm these conclusions, based on simulation data, against multiaxial creep rupture experimental data for several materials, drawn from the literature. The results of the virtual experiments show that calibrating effective stress measures using triaxial test data would significantly improve accuracy and that some effective stress measures are more accurate than others, particularly for highly triaxial stress states. Results obtained using experimental data confirm the numerical findings and suggest that a unified effective stress measure should include an explicit dependence on the first stress invariant, the maximum tensile principal stress, and the von Mises stress.

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Notes

  1. Henceforth, we refer to a triaxial stress state as any stress tensor with all three principal values with non-negligible magnitudes.

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Acknowledgements

The research was sponsored by the US Department of Energy, under Contract No. DEAC02-06CH11357 with Argonne National Laboratory, managed and operated by UChicago Argonne LLC and Contract No. DE-AC07-05ID14517 with Idaho National Laboratory, managed and operated by Battelle Energy Alliance. Programmatic direction was provided by the Office of Nuclear Reactor Deployment of the Office of Nuclear Energy. The authors gratefully acknowledge the support provided by Sue Lesica, Federal Manager, Advanced Materials, Advanced Reactor Technologies (ART) Program, Diana Li, Federal Manager, Microreactor Program, and John H. Jackson of Idaho National Laboratory, National Technical Director, Microreactor Program.

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Authors and Affiliations

  1. Applied Materials Division, Argonne National Laboratory, Lemont, USA

    Andrea Rovinelli & Mark C. Messner

  2. Massachusetts Institute of Technology, Cambridge, USA

    David M. Parks

  3. Idaho National Laboratory, Idaho Falls, USA

    Ting-Leung Sham

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  1. Andrea Rovinelli
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Correspondence to Andrea Rovinelli.

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Rovinelli, A., Messner, M.C., Parks, D.M. et al. Accurate Effective Stress Measures: Predicting Creep Life for 3D Stresses Using 2D and 1D Creep Rupture Simulations and Data. Integr Mater Manuf Innov 10, 627–643 (2021). https://doi.org/10.1007/s40192-021-00228-1

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