The knowledge of residual stresses introduced in the tubes of heat exchangers during their expansion in the tubesheet holes is important because of their effect on the structural integrity of components. This paper presents a simplified theoretical method to calculate the maximum residual stresses introduced in the transition zone of expanded tube-to-tubesheet joint. The higher positive values of tensile residual stresses and their corresponding axial locations are determined by using a standard deviation analysis. The validation of the proposed equations was accomplished by comparing their results to those obtained by the finite element method for some arbitrary cases. An upper limit has been imposed on the expansion pressure level, depending on the combination of the geometrical and material parameters that are involved in the design of the tube-to-tubesheet joints.

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