The crack tip strain and stress condition are one of the main factors affecting stress corrosion cracking (SCC) behaviors in the dissimilar metal welded joint of the primary circuit in the pressurized water reactor. The mechanical property mismatch of base metal and weld metal can significantly affect the stress and strain condition around the crack tip. To understand the effect of different weld metals on strain and stress fields at SCC crack tips, the effects of strength mismatch, work hardening mismatch, and their synergy on the strain and stress field of SCC in the bi-material interface, including plastic zone, stress state, and corresponding J-integral, are investigated in small-scale yielding using the finite element method. The results show a significant effect of the strength mismatch and work hardening mismatch on the plastic zone and stress state in the weld metal and a negligible effect in the base metal. J-integral decreases with the single increase in either strength mismatch or work hardening mismatch. Either the increase in strength mismatch or work hardening mismatch will inhibit the other’s effect on the J-integral, and a synthetic mismatch factor can express this synergistic effect.

Stress corrosion cracking (SCC) is an important destruction form of materials such as stainless steel, nickel-based alloy and their welded components in nuclear reactor pressure vessels and pipes. The existing popular quantitative prediction models of SCC crack growth rate are mainly influenced by fracture toughness values K_Jc or J_c. In particular, the composite constraint, containing the in-plane constraints and out-of-plane constraints around the crack front, has a significant influence on the fracture toughness of structures in nuclear power plants. Since the plastic strain gradient is a characterization parameter of the quantitative prediction model for crack growth rate, it may be a characterization parameter of composite constraint. On the basis of the experimental data at a low temperature of alloy steel 22NiMoCr3-7 used in nuclear pressure vessels, the gradient of equivalent plastic strain D_PEEQ around the crack fronts at different constraint levels was calculated using the finite element method, which introduces a new non-dimensional constraint parameter D_p, to uniformly characterize the in-plane and out-of-plane constraint effects. Compared with constraint parameters A_PEEQ or A_p, the process of obtaining parameters D_PEEQ or D_p is much simpler and easier. In a wide range, a single correlation curve was drawn between parameter D_p and normalized fracture toughness values K_Jc/K_ref or J_c/J_ref of specimens at a low or high constraint level. Therefore, regardless of whether the constraint levels of the structures or standard specimens are low or high, constraint parameter D_p can be used to measure their fracture toughness. To build an evaluation method that has structural integrity and safety while containing the composite constraint effects, in addition to accurate theoretical interpretation, further verification experiments, numerical simulations and detailed discussions are still needed.

The material mechanical properties and crack propagation behavior of dissimilar metal welded joint (DMWJ) of pressurized water reactor (PWR) was investigated. In this research, the mechanical parameters of the cladding layer materials (304L-SA508) of the DMWJ in PWRs were obtained by the continuous indentation test. Simultaneously, the user-defined (USDFLD) subroutine in ABAQUS was used to establish the heterogeneous materials model of the welded joint. On this basis, the local crack propagation path of DMWJs has been discussed based on the extended finite element method (XFEM). The result indicated that the strength value at the fusion boundary line (FB line) is the largest, and the yield strength reaches 689 MPa. The yield stress values of the cladding metal (304 L) and base metal (SA508) are 371 MPa and 501 MPa, respectively. Affected by the material constraint effect of the DMWJ, the crack will propagate through the FB line when the initial crack is perpendicular to the FB line. And when the initial crack parallels the FB line, the crack will deviate from it. Meanwhile, the crack propagation length is smaller as the initial crack tip is closer to the FB line when the load condition is constant.