Alternate Design Formulae for a Full Structural Weld Overlay Repair

This paper describes a new set of design formulae for a Full Structural Weld Overlay. The formulae presented herein are derived using similar assumptions as were used to develop the net section collapse formulae contained in Appendix C of the ASME B&PV Code, Section XI; however, they are developed specifically for a WOL geometry. By considering the WOL geometry during derivation of the plastic collapse load, a set of WOL design formulae are obtained which contain the WOL thickness as a solution variable. For WOL design this formulation is inherently easier and more efficient to use than adapting the part through wall flaw formulation contained in Appendix C. Sample WOL designs are presented in which both the new and existing formulae are used. The results obtained demonstrate that the new formulae produce a WOL thickness consistent with that calculated by properly using the existing method contained in Appendix C.