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The purpose of the present study is to obtain insight into the formation, behaviour and magnitude of welding-induced residual stresses and distortions resulting from welding nozzles onto cylindrical pressure vessels. A hybrid methodology that comprises numerical analysis, experimental measurements and empirical calculations is used in the present study. The welding process induces a high thermal gradient on the material due to non-uniform temperature distribution; thereby causing the portion of the material that is exposed to high temperatures to expand. However, the relatively cooler material portion that is away from the weld pool resists such expansion, thereby subjecting the structure to stresses and distortions around the fusion zone (FZ) and the heat-affected zone (HAZ). Over the last two decades a number of studies have been done in an effort to predict the effect of welding-induced residual stresses on the integrity of welded structures. However, to this end, such studies have focussed on analysing residual stresses on bead-on-plate, plate-to-plate and [to a less extent] on pipe-to-pipe weld joints. Fewer studies have looked at nozzle-cylinder joints of pressure vessels as is the case in this study. The second chapter gives a detailed review of applicable literature. The constitutive model described in the third chapter includes a two-phase sequentially-coupled thermo-mechanical analysis, which incorporates metallurgical effects. The non-linear transient problem is solved using an axisymmetric 2D model with ‘element birth’ technique, developed on ABAQUS. The first phase comprises the thermal analysis based on Goldak’s moving heat source model that is used to determine temperature histories. The second phase is a sequel stress/strain analysis wherein the temperature fields are used as input loads. The results discussed in chapters three and four show that there is a high concentration of residual stresses close to the weld centre-line, and these die down as distance away from centre-line increases. It is also shown that the inside surface is under tensile stresses, while the outer surface is under compressive stress, whose magnitude approaches yield strength of the material. Axial deflections of up to 0.384mm and radial shrinkage of 0.0237mm are observed. Distortion decreases as distance away from weld centre-line increases. Minimum axial shrinkage, which is close to zero, is observed at the restrained end. The analytical results show adequate corroboration and agreement with the experimental measurements. A number of mitigation techniques are suggested in order to alleviate the impact of residual stress and distortions on fatigue performance of welded structures. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2012.

Tensional Vacuum Vessels (TVV) are vessels constructed such that the walls are placed in tension rather than in compression as is the case with conventional vacuum vessels. TVVs have the advantage of being cost-effective, light weight in construction, and potentially portable. Tensional vessels have already been designed with regard to submarine applications. However, the use of this principle with regard to vacuum applications is believed to be novel. TVVs have two interlinked thin walled shells instead of the traditional single thick wall of conventional design. These shells are placed in tension by pressurising the intermediate space. This thesis outlines the theory of tensional vessels and describes the performance of a number of experimental chambers developed during this investigation. The fundamental theory of the TVV is outlined and developed in more detail with regard to cylindrical vessels. These include vessels constructed from longitudinal and circumferential tubes. The basic theory for any TVV can be derived from the equilibrium condition. This states that the force due to the gauge pressure on the outer shell must be greater than or equal to the force due to the absolute pressure on the inner shell. If the inward force predominates implosion will occur. Materials science considerations are also taken into account. If the tension in the walls exceeds that required for yield, the vessel will deform. The use of novel tensile materials is also explored. TVVs are potentially inflatable and theory is developed with regard to the possibility of buoyant vessels. The first experiments were based on earlier work performed at this institution with cylindrical TVVs constructed from longitudinal tubes. The tubes employed were soft drink cans which were sealed together with putty. The work described in this thesis outlines the development of larger versions and the instabilities which developed are noted. High vacuum experiments performed through the inclusion of a guard vessel are then described. This is followed by a further description of experiments performed with this basic tensional wall design in an attempt to gain a better understanding of its properties. These vessels were smaller and were gas pressurised in order to allow for increased flexibility with regard to pressure and volume variation. It is found that the compressional elements of such vessels cannot be ignored. A series of cylindrical TVVs with the walls constructed from circumferential tubes is then described, including high vacuum experiments, also performed through the inclusion of a guard vessel. The initial experiments were small in scale and made use of small bicycle tyres as the TVV walls. Larger vessels were then built, the walls being constructed from car tyres. These vessels are also inflatable and more stable than those constructed from longitudinal tubes. Also, the compressional elements do not play as great a role in these vessels. A fully tensional cylindrical vessel is then described which includes tensional end plates. Experiments performed with large bowls as the end plates are outlined. The theory of the deformation of a circular plate is also given including finite element analysis. Finally, a further novel vacuum vessel design is proposed. This is the spinning vacuum vessel. Proof of principle experiments are performed on a small scale vessel (a soft drink can with its interior reinforced with putty) which yields promising results. / Thesis (M.Sc.)-University of Natal, 1999.

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