Residual stress prediction contributes to nuclear safety by enabling engineering estimates of component service lifetimes. Subcritical crack growth mechanisms, in particular, require residual stress assumptions in order to accurately model the degradation phenomena. In many cases encountered in nuclear power plant operations, the component geometry permits two-dimensional (i.e., axisymmetric) modeling. Two recent examples, however, required three-dimensional modeling for a complete understanding of the weld residual stress distribution in the component. This paper describes three-dimensional weld residual stress modeling for two cases: (1) branch connection welds off reactor coolant loop piping and (2) a mockup to demonstrate the effectiveness of the excavate and weld repair process.

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