Implementation of ANL’s Mechanics Based Evolutionary Fatigue Modeling Through ABAQUS-WARP3D Based High-Performance Computing Framework
This report presents an update on the environmental fatigue research that is being conducted at Argonne National Laboratory in support of the Department of Energy’s Light Water Reactor Sustainability (LWRS) program. Argonne is developing a fully mechanistic fatigue evaluation approach without using empirical fatigue (S~N) curves. This approach is based on the fundamental concept of the time evolution of progressive fatigue damage rather than on the conventional S~N curve approaches using end-of-life data. In FY 2017, we performed extensive validation of this approach with respect to fatigue test data for 316 stainless steel [1]. This validation was performed for different loading cases, including constant, variable, and random amplitude. In the present FY 2018 semi-annual report, we present the further advances of Argonne’s environmental fatigue research work in the context for more practical applications. In this report, we discuss a methodology for fully mechanistic (i.e., not using S~N curves) fatigue life evaluation of reactor components subjected to realistic loading cycles, namely, design-basis loading cycles. The loading cycles include plant heat-up, full-power, and cool-down operations. As a test case, we considered a typical pressurized water reactor surge line, which is made of 316 SS. To perform the fatigue simulation for thousands of fatigue cycles in a computationally cost effective way, we modified our previous desktop-based finite element (FE) modeling approach to work in a high-performance computing (HPC) framework. For the HPC implementation, we developed a hybrid framework based on commercial FE software (ABAQUS), open-source FE software (WARP3D), and Argonne-developed evolutionary cyclic-plasticity modeling methods. We validated this HPC-based cycle-by-cycle damage model for the entire fatigue life of a Pressurized Water Reactor (PWR) surge line (SL) pipe with respect to assumed loading cycles. The simulated fatigue life was found to be 5855 cycles, which is 85% accurate as compared to the corresponding small-specimen-based experimental fatigue life (6914 cycles). Also, the simulated stress history captures the cyclic hardening and softening behavior of the material for entire fatigue cycles. The FE simulation of the PWR SL pipe was conducted in a reasonable time of 12.5 days. These results show the promise that a fully mechanistic (not using S~N curves) fatigue life evaluation of a safety-critical nuclear reactor component (or even other safety critical components like those in aircraft, aero-engines, etc.) is possible. We anticipate that this type of methodology will drastically reduce the uncertainly associated with conventional fatigue life estimates based on empirical S~N curves. We also proposed an FE model that is based on a hybrid full-component and single-element approach and that can readily be used by industry if HPC resources are not available. In this approach, a single-cycle FE simulation has to be performed first for the required loading cycle. Then, the resulting strain/stress profile at the hotspot (highest strain/stress location) is used as input strain/stress loading to the single-element FE model. The single-element FE model is run under multiple fatigue cycles as long as the failure criteria are achieved. The cycle number at failure gives the fatigue life of the component in question. This cost-effective framework does not require expensive HPC hardware and can be performed in a reasonable time by using a desktop computer. We demonstrated this approach with respect to PWR SL fatigue evaluation under two realistic design-basis loading cycles (simple and detailed). The associated results were validated with respect to test data obtained through fatigue testing of uniaxial specimens under the in-air condition at 300 °C. The approach is in the development stage and requires further improvement and validation.