Full Structural Weld Overlays (FSWOL) have been used successfully in the nuclear power industry for a number of years to mitigate and repair small (4) to medium (10) bore welded piping components susceptible to primary water stress corrosion cracking (PWSCC). Mitigation is provided by the creation of compressive residual stress on the inside surface of the pipe as layers of weld overlay are deposited over the outside surface of the pipe. ASME Code Case N-740-2 requires that these overlay designs provide adequate structural integrity considering the growth of postulated 75% through-wall inside surface flaws by PWSCC and cyclic fatigue. Application of this repair procedure to larger diameters components such as 30 inch reactor vessel nozzles is not practical due to the large amount of weld metal (overlay thickness) which would be required to satisfy the design requirements of a FSWOL and the associated demands on implementation schedule and exposure to radiation. An alternate procedure is currently being considered for these larger components which utilizes an Optimized Weld Overlay (OWOL) design based on a reduced thickness and smaller postulated flaw. In particular, ASME Code Case 754 specifies, in part, that 50% through-wall inside surface flaws be shown to be acceptable. Furthermore, an OWOL would continue to provide mitigation of materials susceptible to PWSCC by requiring that the thickness of the overlay be sufficient to induce compressive residual stress on the inside surface. This paper presents results of finite element analysis for an optimized weld overlay on a large bore (30) reactor vessel coolant nozzle dissimilar metal weld, with particular attention to the incremental development of residual stress with each layer of weld metal. Through numerical simulation of the complete fabrication history, including repair of the original dissimilar metal weld, hydrostatic testing, and completion of the nozzle safe end-to-pipe joint prior to implementation of the overlay, the pre-overlay state of stress is defined for use as the basis for evaluating the stress improvement provisions of the weld overlay process. Results are obtained for both kinematic and isotropic hardening rules to study the effect of these two extreme measures of material characterization on the development of residual stress. Additional results are presented to study the sensitivity of the welding simulations to material yield strength and mesh refinement. Predicted stresses are also compared to measured data from a full scale mockup of a large bore reactor vessel nozzle with an optimized weld overlay.

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