The study and testing of the structural behavior of a failed pipe with a spiral weld seam was conducted. Our study and testing was part of a larger failure investigation to determine the influence of residual stress for initiation of hydrogen stress cracking. Finite element and structural testing methods were used to guide the study for determination of residual stresses. All properties used in our study were measured per ASTM A-370. The validation of the finite element model of the pipe was conducted against the test results per ASTM E-837-89. The difference in predicted and measured residual stresses was 3% at the ID of the structure. Due to the small differences in the results from analysis and testing, no correlation was required, and the test-validated finite element model was used to predict the total stresses due to the manufacturing processes and operational loads. Based on the validation results, one can conclude that the finite element technique is accurate for predicting residual welding stresses. The finite element technique, however, is far less time -consuming and thus less expensive method than mechanical testing for determining the residual stresses.

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