Appraisal of PD6493:1991 fracture assessment procedures

PD6493:1991 fracture assessment have been performed for a range of large-scale fracture mechanics tests conducted at TWI in the past. These tests cover several material groups, including pressure vessel steels, pipeline steels, stainless steels and aluminium alloys, including parent material and weldments. Ninety-two wide plate and pressure vessel tests have been assessed, following Levels 1, 2 and 3 PD6493:1991 procedures. In total, over 400 assessments have been performed, examining many features of the fracture assessment procedure including toughness input, proof testing, residual stress assumptions and stress state (tension, bending and biaxial). In all cases the large scale tests have been assessed as one would actual structures: i.e., based on lower bound toughness values obtained from small scale fracture toughness specimens.

Some examples of multiple solutions in limiting flaw calculations using PD6493:1991 fracture mechanics analyses

The use of PC-based PD6493:1991 fracture assessment procedures has revealed that, under certain circumstances, flaws of different dimensions may be found as being limiting or critical for identical applied conditions. The main causes for multiple solutions are a steep applied stress gradient, residual stress relaxation and flaw re-characterisation. This work uses several case studies to illustrate some of the circumstances under which multiple solutions occurs.