Creep fracture mechanics parameters for internal axial surface cracks in pressurized cylinders and creep crack growth analysis

In the present study, a low alloy Cr–Mo steel cylinder subjected to internal pressure at high temperature with a semi-elliptical crack located at the inner surface is considered. The creep crack driving force parameter C∗-integrals calculated by finite element (FE) method, are compared with results from previous studies, which indicates that empirical equations may be inaccurate under some conditions. A total of 96 cases for wide practical ranges of geometry and material parameters are performed to obtain systematic FE results of C∗-integral, which are tabulated and formulated in this paper. It is observed that the maximum C∗-integral may occur neither at the deepest point nor at the surface point when the aspect ratio is large enough and the value of C∗-integral is significantly sensitive to the crack depth ratio. Furthermore, based on the proposed equations for estimating C∗-integrals and a step-by-step analysis procedure, crack profile development, crack depth, crack length and remaining life prediction are obtained for surface cracks with various initial aspect ratios. It is found that when the crack depth ratio is increased, there is no obvious convergence of crack aspect ratio observed. The magnitude of half crack length increment is always minor compared with the crack depth increment. In addition, the remaining life is much more dependent on the surface crack depth than on the surface crack length.

► Existing empirical equations of C∗-integral for surface cracks may be inaccurate.
► Systematic FE results of C∗-integral from 96 cases are tabulated and formulated.
► Maximum C∗-integral may not occur at deepest/surface point if a/c is large enough.
► The value of C∗-integral is significantly sensitive to the crack depth ratio.
► Crack profile development, crack size and remaining life prediction are obtained.