An experimental study on the key fretting variables for flexible marine risers

This paper presents an experimental investigation into the effects of contact conformity, contact pressure and displacement amplitude on the gross-slip fretting behaviour grease-lubricated cylinder-on-flat contacts in the context of flexible marine riser pressure armour wire, and compares behaviour with that observed in unlubricated conditions. Characterisation of friction and wear is critical to fretting fatigue life prediction in flexible risers since friction directly controls trailing-edge fretting stresses and hence fatigue crack initiation, on the one hand, and on the other hand, directly affects wear via relative tangential slip (displacement). Wear can have a beneficial or detrimental effect on fatigue crack initiation and propagation, depending on relative slip and slip regime. It is shown that friction and wear are higher for dry conditions than for grease-lubricated conditions. For grease-lubricated conditions, behaviour is determined by whether grease can be retained in the contact (as opposed to being extruded out). Retention (or replenishment) of grease in the contact results in low rates of wear and low coefficients of friction; these conditions are favoured by fretting displacements above a critical value, by low contact conformity, and by low applied loads

High temperature, low cycle fatigue characterization of P91 weld and heat affected zone material

The high temperature low cycle fatigue behavior of P91 weld metal (WM) and weld joints (cross-weld) is presented. Strain-controlled tests have been carried out at 400 °C and 500 °C. The cyclic behavior of the weld material (WM) and cross-weld (CW) specimens are compared with previously published base material (BM) tests. The weld material is shown to give a significantly harder and stiffer stress–strain response than both the base material and the cross-weld material. The cross-weld tests exhibited a cyclic stress–strain response, which was similar to that of the base material. All specimen types exhibited cyclic softening but the degree of softening exhibited by the cross-weld specimens was lower than that of the base material and all-weld tests. Finite element models of the base metal, weld metal and cross-weld test specimens are developed and employed for identification of the cyclic viscoplasticity material parameters. Heat affected zone (HAZ) cracking was observed for the cross-weld tests

A combined wear-fatigue design methodology for fretting in the pressure armour layer of flexible marine risers

This paper presents a combined experimental and computational methodology for fretting wear-fatigue prediction of pressure armour wire in flexible marine risers. Fretting wear, friction and fatigue parameters of pressure armour material have been characterised experimentally. A combined fretting wear-fatigue finite element model has been developed using an adaptive meshing technique and the effect of bending-induced tangential slip has been characterised. It has been shown that a surface damage parameter combined with a multiaxial fatigue parameter can accurately predict the beneficial effect of fretting wear on fatigue predictions. This provides a computationally efficient design tool for fretting in the pressure armour layer of flexible marine risers

Elastic-plastic generalised load-displacement prediction for tubular joints

Available from British Library Document Supply Centre-DSC:DXN026882 / BLDSC - British Library Document Supply CentreSIGLEGBUnited Kingdo

Investigation of an iterative sub-structure method for elastic and elastic-plastic framework analysis

This paper investigates the viability of an iterative sub-structure method for elastic and elastic-plastic framework analysis. The motivation is the prohibitive model sizes required for brick element analyses of large, three-dimensional frameworks, which require detailed non-linear material and geometry response at the joints but only linear behaviour in between. The rationale adopted is to investigate the viability of the approach for some simple plane frameworks, which can be easily validated against global brick element models. Future work will address extension to more realistic three-dimensional space frames

A global-local fretting analysis methodology and design study for the pressure armour layer of dynamic flexible marine risers

In this paper, a global-local fretting design methodology for the pressure armour layer of flexible marine risers is outlined. This includes global dynamic riser analysis, geometrical and analytical sub-models and local nub-groove contact finite element analysis. Furthermore, a fretting test rig is developed and utilised to quantify coefficient of friction and wear coefficient under representative nub-groove loading conditions. The combination of the global-local computational methodology and experimental characterisation of pressure armour wire material allows for the development of running condition fretting maps. This identifies design criteria for critical riser global curvatures that are associated with minimum number of cycles to failure. The design methodology presented in this paper is applied to a realistic riser design study, using extreme sea-state loading conditions. In this case study, the predicted pressure armour fretting fatigue lives are found to be in the same range as the plain fatigue lives of the tensile armour layer

Cyclic plasticity and low cycle fatigue damage characterisation of thermally simulated X100Q heat affected zone

This paper presents the cyclic plasticity and low cycle fatigue (LCF) damage characterisation of thermally simulated heat affected zone (HAZ) for API 5L X100Q weldments. Microstructures representative of the HAZ for two cooling rates are generated using a Gleeble thermomechanical simulator for manufacture of strain-controlled cyclic plasticity test specimens. The simulated HAZ specimens are subjected to a strain controlled test programme which examines the cyclic effects of strain-range and the tensile response at room temperature. A modified version of the Chaboche rate independent plasticity model, which accounts for early stage damage is implemented to characterise the cyclic plasticity response, including isotropic and kinematic hardening effects. The constitutive parameters are fitted to experimental data using an optimisation procedure developed within a MATLAB code. The measured response of the simulated HAZ specimens is compared to that of the X100Q parent material (PM), and the simulated HAZ is shown to share the early stage fatigue damage behaviour of the PM, but exhibits significantly a higher yield and cyclic strength

Helium permeability of polymer materials as liners for composite overwrapped pressure vessels

Polymers have been identified as replacement materials for metallic liners in composite overwrapped pressure vessels (COPVs) for future space launchers. PEEK, Nylon, and PVDF plastics formed from base powder grades have been permeability tested to determine their susceptibility to the diffusion of helium through flatwise panel cross sections. Permeability, diffusion, and solubility coefficients have been obtained for each material with PVDF and PA11 grades showing the lowest permeability coefficients and hence the best barrier properties to permeation. Crystallinity percentages and internal air void contents in the polymer samples have also been used to assess the differences in permeability between materials with an analysis of void dispersion effects given through X-ray CT scanning techniques. The measured permeability coefficients have been used to assess the ability of all materials tested to act as a functional polymer liner in a standard COPV with final leak rates predicted based on liner thicknesses and weights. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016, 133, 43675

Fatigue life of pitch- and stall-regulated composite tidal turbine blades

Tidal turbine blades are subject to harsh loading and environmental conditions, including large thrust and torsional loadings, relative to wind turbine blades, due to the high density of seawater, among other factors. The complex combination of these loadings, as well as water ingress and associated composite laminate saturation, have significant implications for blade design, affecting overall device design, stability, scalability, energy production and cost-effectiveness. This study investigates the effect of seawater ingress on composite material properties, and the associated design and life expectancy of tidal turbine blades in operating conditions. The fatigue properties of dry and water-saturated glass fibre reinforced laminates are experimentally evaluated and incorporated into tidal blade design. The fatigue lives of pitch- and stall-regulated tidal turbine blades are found to be altered by seawater immersion. Water-saturation is shown to reduce blade life about 3 years for stall-regulated blades and by about 1–2 years for pitch-regulated blades. The effect of water ingress can be compensated by increased laminate thickness. The tidal turbine blade design methodology presented here can be used for evaluation of blade life expectancy and tidal device energy production

Influence of composite fatigue properties on marine tidal turbine blade design

The structural design of marine tidal turbine blades is governed by the hydrodynamic shape of the aerofoil, extreme loadings and composite material mechanical properties. The design of the aerofoil, chord and twist distribution along the blade is generated to optimise turbine performance over its life time. Structural design gives the optimal layout of composite laminae such that ultimate strength and buckling resistance requirements are satisfied. Most structural design approaches consider only extreme static loads, with a lack of dynamic load-based fatigue design for tidal blades. Approaches for tidal turbine blade design based on dry and immersed composite material fatigue life are studied