Low alloy steel SA508 autogenously welded with Type 309L/308L austenitic stainless steel cladding is one of the common forms of the dissimilar metal weld joint (DMWJ) in the primary water of a pressurized water reactor (PWR). Accurate evaluation of the inhomogeneous mechanical propriety and crack growth driving force at the corresponding place on the DMWJ is important for integrity analyses of a PWR. In this study, the mechanical propriety of the DMWJ was obtained using a combined Vickers hardness test and the stress-hardness relationship. And, a finite element (FE) model for the DMWJ in a PWR with continuous transition mechanical propriety was built using a predefined temperature field method. Based on consideration of the heterogeneity mechanical properties on the DMWJ with the continuous transition mechanical propriety, the Mises stress distribution and J integral on the crack tip with different crack lengths was analyzed using elastoplastic FE analysis. As shown by the distribution profile of the Mises stress distribution and J integral on the crack tip, the inhomogeneous mechanical propriety distribution is found to significantly affect the crack driving force when the crack tip is close to the fusion boundary.

Environmentally assisted cracking (EAC) is essential in predicting light water reactors’ structural integrity and service life. Alloy 600 (equivalent to Inconel 600) has excellent corrosion resistance and is often used as a welding material in welded joints, but material properties of the alloy are heterogeneous in the welded zone due to the complex welding process. To investigate the EAC crack growth behavior of Alloy 600 for safe-end welded joints, the method taken in this paper concerns the probability prediction of the EAC crack growth rate. It considers the material heterogeneity, combining the film slip-dissolution/oxidation model, and the elastic-plastic finite element method. The strain rate at the crack tip is a unique factor to describe the mechanical state. Still, it is challenging to accurately predict it because of the complicated and heterogeneous material microstructure. In this study, the effects of material heterogeneity on the EAC crack growth behavior are statistically analyzed. The results show that the material heterogeneity of Alloy 600 can not be ignored because it affects the prediction accuracy of the crack growth rate. The randomness of yield strength has the most influence on the EAC growth rate, while Poisson’s ratio has the smallest.

The stress–strain conditions at the crack tip in dissimilar metal welded joints (DMWJ) are a critical factor influencing stress corrosion cracking (SCC) behavior. The processing technology and working environment of DMWJ lead to a randomly inhomogeneous distribution of material mechanical properties, making the crack tip mechanical field more complex. An inhomogeneous model was obtained using a combination of physical experiments and the elastic–plastic finite element method to understand the effect of this inhomogeneous distribution of mechanical properties on the direction of SCC growth and the growth rate in DMWJ and the impact of inhomogeneity on the SCC growth behavior was compared and analyzed. The findings demonstrate that Type I (opening mode) cracks are more likely to form due to the inhomogeneity of mechanical properties and are more likely to deflect toward the Alloy 52M region at the interface between Alloy 52M and 316L stainless steel. Additionally, the strain gradient at the crack tip increases with the degree of inhomogeneity, which has a bigger impact on the accuracy of SCC growth rate predictions.

The complicated driving force at the stress corrosion cracking (SCC) tip of the safe-end dissimilar metal-welded joints (DMWJs) in the pressurized water reactor (PWR) is mainly caused by the heterogeneous material mechanical properties. In this research, to accurately evaluate the crack driving force at the SCC in DMWJs, the stress-strain condition, stress triaxiality, and J-integral of the crack tip at different positions are analyzed based on the heterogeneous material properties model. The results indicate that the larger driving force will be provided for the I-type crack when the crack is in the SA508 zone and the interface between the 316L region and base metal. In addition, the heterogeneous material properties inhibit the J-integral of the crack in the 316L region, which has a promoting effect when the crack is in the SA508 zone and weld metal. It provides a new idea for analyzing driving force at the crack tip and safety evaluation of DMWJs in PWRs.

The welding residual stress is one of the main factors that lead to Stress Corrosion Cracking (SCC) in dissimilar metal welded (DMW) joints of the safe-end in nuclear power plants. Based on ABAQUS software, a thermal-elastic plastic finite element method is developed to simulate residual stress for DMW joints of the safe-end. Considering the randomness of material parameters of the welding metal, the neural network response surface method is applied to calculate the change of welding residual stress distribution. Meanwhile, to improve the efficiency of numerical analysis, MATLAB is employed in the secondary development for ABAQUS. With the help of existing experimental data, the effect of random parameters of the welding metal on the residual stress in DMW joints is simulated and analyzed in this study. The results show that the residual stress distribution of the DMW joints is significantly affected by the random parameters. Among the parameters, the randomness of Yield strength and Module of Elasticity has the most significant influence on the uncertainty of the distribution of welding residual stress.

The micro-mechanical state at the crack front is one of the key factors affecting the stress corrosion cracking (SCC) growth behavior. The mechanical heterogeneity and residual stress in the dissimilar metal welded joint (DMWJ) induce the micro-mechanical state at the crack front to become more complex. The sandwich model and dual-field model of the DMWJ with inner surface axial crack were established in this study. The stress and strain states at the crack front with different crack locations and lengths under the interaction of the mechanical property and the residual stress were investigated. The results show that a more accurate evaluation of stress and strain states can be obtained when using the dual-field model to describe the material mechanical property and residual stress of the DMWJ. The sandwich model overestimates the crack driving force including the stress and strain at the crack front. The tensile stress in the middle of shallow cracks is smaller than that at both ends, while the tensile stress in the middle of deep crack is larger than that at both ends. The variation trend of the tensile stress and normal strain at the crack apex is basically the same as that of the residual stress with the crack depth. However, there is almost no normal plastic strain in the initial stage of crack propagation due to the small residual stress in the initial stage.