This paper presents the results of a structural integrity assessment of a large-scale test undertaken as part of the EU programme STYLE on a repair welded pipe containing a circumferential through-thickness crack. The pipe was manufactured from two Esshete 1250 stainless steel pipes joined by a girth weld containing a deep repair. A through-thickness circumferential pre-crack was introduced to the centre of the repair prior to testing in four-point bend. The assessment used a finite element model created in Abaqus, with the weld residual stress introduced by an iterative technique. Linear elastic fracture mechanics was used to evaluate the stress intensity factor KI for the defect and elastic-plastic analyses were performed to characterise the crack driving force J along the crack front. The predicted crack mouth opening displacement as a function of load was compared with the test results and the derived variation in J used to predict crack initiation and growth. The results predicted the global behaviour of the test to within approximately 7% at final load, and the position of maximum crack growth. However, the final extent of crack extension is under-predicted. Reasons for this underprediction are suggested.

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