A theoretical model of an expanded tube-to-tubesheet joint is developed and examined with the objective to determine the residual stresses in the transition zone, which lies between the expanded and unexpanded regions of the tube. Owing to their effect on the development of stress corrosion cracks, the residual tensile stresses on the surfaces of the tube are of particular interest. A mathematical model that can predict these residual stresses is developed. Results of the model show that the maximum tensile residual stresses are axial and occur on the inside diameter of the expanded tube. It is shown in a parameter study that, for expansions that ensure a leak-tight joint, the maximum residual tensile axial stress on the inside surface of the tube reaches 80–95 percent of the yield stress of the tube, regardless of the geometrical and material parameters of the tube and tubesheet.

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