test vtest v the “raymond” test - bay bridge info. test v...the first rsl ehe (the first rsl ehe...

TEST VTEST VTEST VTEST VTHETHETHE THE “RAYMOND”“RAYMOND”

LRA/RSL™ R&D Labs LRA/RSL™ R&D Labs

L i R dL i R d

RAYMOND RAYMOND TESTTEST

LRA/RSL™ R&D Labs11

Louis RaymondLouis RaymondPh.D., P.E.Ph.D., P.E.TESTTEST

The RSL MethodThe RSL Method

StepStep--modified slow strain rate methodmodified slow strain rate method

To measure the threshold for the onset of SCC and To measure the threshold for the onset of SCC and EHE/IHEEHE/IHE

Using small specimen in tension and bendingUsing small specimen in tension and bending

Rapid test method Rapid test method ppvs. long sustained vs. long sustained load methodload method

Adaptable to a Adaptable to a variety of specimen variety of specimen geometriesgeometries

2 LRA/RSL™ R&D Labs

geometriesgeometries

The RSL BackgroundThe RSL Background

Rising Step Load test method resulted in Rising Step Load test method resulted in ASTM F1624 ASTM F1624 “Standard Test Method for Measurement of Hydrogen“Standard Test Method for Measurement of HydrogenStandard Test Method for Measurement of Hydrogen Standard Test Method for Measurement of Hydrogen Embrittlement Threshold in Steel by the Incremental Embrittlement Threshold in Steel by the Incremental Step Loading Technique”Step Loading Technique”

The test method has been incorporated into The test method has been incorporated into –– ASTM F519ASTM F519–– ASTM F519ASTM F519

–– NASM 1312/5 NASM 1312/5

–– ASTM F2660ASTM F2660


Bolt Test Standards Incorporating Bolt Test Standards Incorporating RSL™ TechnologyRSL™ TechnologyRSL TechnologyRSL Technology

Accelerated Test Equipment for KIc & KIctod (ASTM E399/E1290) KIscc& KIctod (ASTM E399/E1290) KIscc (ASTM F1624); Rsb/Hsr (ASTM E812/F2078); for IHE/EHE process control (ASTM F519/F1940)control (ASTM F519/F1940); Coatings EHE (ASTM F2660); DTIc & DTIscc USN MSP & FTRP; fastener qualification (A490/AC193B/NASM1312-5) in tension and bending.g


Threshold for Onset of Threshold for Onset of Hydrogen Induced StressHydrogen Induced StressHydrogen Induced Stress Hydrogen Induced Stress Cracking (HE) Defined with the Cracking (HE) Defined with the Sustained Load Test Sustained Load Test


RSL™ Testing Protocol to RSL™ Testing Protocol to Measure the HE ThresholdMeasure the HE ThresholdMeasure the HE ThresholdMeasure the HE Threshold


Test VTest V

Objective: Measure threshold stress intensity load Objective: Measure threshold stress intensity load for the onset of hydrogen induced stress crackingfor the onset of hydrogen induced stress crackingfor the onset of hydrogen induced stress crackingfor the onset of hydrogen induced stress cracking

Verification and correlation of Test V with Test IVVerification and correlation of Test V with Test IV

Testing Testing fpcfpc fracture mechanics specimens for fracture mechanics specimens for comparison with the Townsend results of 1975comparison with the Townsend results of 1975

Evaluate:Evaluate:–– HardnessHardness–– MicrostructureMicrostructure–– ToughnessToughness


Test VTest V

Evaluate various factors that might influence crack Evaluate various factors that might influence crack initiation:initiation:initiation:initiation:

–– Thread root radiusThread root radius

–– Hardness gradientHardness gradientgg

–– Method of thread fabricationMethod of thread fabrication

–– MicrostructureMicrostructure

Evaluate the influence of the electrochemical potential Evaluate the influence of the electrochemical potential of the SAS rods coating on SCCof the SAS rods coating on SCCof the SAS rods coating on SCCof the SAS rods coating on SCC


RSL™ is an Accelerated Test RSL™ is an Accelerated Test to Measure HE Thresholdto Measure HE Thresholdto Measure HE Thresholdto Measure HE Threshold


ASTM F1624 Test ProtocolASTM F1624 Test Protocol

Fast fracture is performed to determine the Fast fracture is performed to determine the maximum loadmaximum loadmaximum loadmaximum load

The first RSL™ EHE (The first RSL™ EHE (Wet in 3.5% NaCl, Wet in 3.5% NaCl, --1.06 Vsce1.06 Vsce) ) test is based on the maximum load of the fasttest is based on the maximum load of the fasttest is based on the maximum load of the fast test is based on the maximum load of the fast fracture testfracture test

–– Step load specimen to failure in steps of 5% of max FFS loadStep load specimen to failure in steps of 5% of max FFS load

Next specimen is tested at a Next specimen is tested at a slower rateslower rate

Test additional specimens at slower rates until Test additional specimens at slower rates until es add o a spec e s a s o e a es ues add o a spec e s a s o e a es uthreshold determined is within threshold determined is within 5% of FFS5% of FFS load of load of previous test. (Invariant Threshold)previous test. (Invariant Threshold)


IHE follows same protocol but tested in airIHE follows same protocol but tested in air

ASTM F1624 Standard Test Method for ASTM F1624 Standard Test Method for Measurement of Hydrogen Embrittlement Measurement of Hydrogen Embrittlement Th h ld i St l b th I t l StTh h ld i St l b th I t l StThreshold in Steel by the Incremental Step Threshold in Steel by the Incremental Step Loading TechniqueLoading Technique


Threshold Stress for Environmentally Threshold Stress for Environmentally Induced Hydrogen EmbrittlementInduced Hydrogen Embrittlementy gy g


Small RSL™ Test Specimens Small RSL™ Test Specimens for Test Vfor Test Vfor Test Vfor Test V

Test CVN specimens:Test CVN specimens:

Fatigue PreFatigue Pre--cracked cracked ThreadedThreadedat gue eat gue e c ac edc ac ed


Small RSL™ Test Specimens Small RSL™ Test Specimens for Test Vfor Test Vfor Test Vfor Test V

At core, mid radius, outer At core, mid radius, outer diameter or thread rootdiameter or thread root

HRCHRC

KIc, KIKIc, KIρρc, KIc, KI--EHE, EHE, KIKIρρ--EHEEHE

Root radius, thread profileRoot radius, thread profile

SEM l i f f tSEM l i f f t SEM analysis of fracture SEM analysis of fracture surfacessurfaces


Test EquipmentTest Equipment

RSLRSL Tensile FrameTensile Frame


Test Apparatus Test Apparatus —— 4 Point Bend4 Point Bend


Test Apparatus Test Apparatus —— 4 Pt Bend4 Pt Bend

Rising Step Load Rising Step Load 44--pt Bend Testpt Bend Test

ASTM E1290

4 - Pt BendP P

0 4 W SEN(B)Environmental Chamber

SEN 4-pt Bend

0.4 W — SEN(B)P P


Load drop under displacement control used to measure crack initiation threshold, Kth, and monitor da/dt

17

Threaded Specimen in EHE TestThreaded Specimen in EHE Test


Test V Test V —— Rods TestedRods TestedSAS A354BD B lt T t V S li (B lt S l )SAS A354BD B lt T t V S li (B lt S l )

ID Structural ComponentNumber of

BoltsNominal Bolt Diameter [in]

Sustained Bolt Tension % Fu (UTS)

Threads (Cut or Rolled)

Test VISL Technique

1 Shear Key Anchor Bolts- Bottom (S1/S2) 96 3 0.70 Cut 2 Sh K A h B lt B tt (S3/S4) 96 3 0 70 C t

SAS A354BD Bolt Test V Sampling (Bolt Samples)SAS A354BD Bolt Test V Sampling (Bolt Samples)

2Shear Key Anchor Bolts- Bottom (S3/S4) 96 3 0.70 Cut Pier E2 Bearing Bolts- Bottom Housing (B1, B2, B3, B4) 96 3 0.70 Cut

3Shear Key Anchor Bolts—Top (S1/S2) 160 3 0.70 Cut 4 (spares)Shear Key Anchor Bolts—Top (S3/S4) 160 3 0.70 Cut 2 (spares)

4 Pier E2 Bearing Bolts—Top Housing (B1,B2,B3,B4) 224 2 0.70 Rolled 4 (spares)e ea g o ts op ous g ( , , 3, ) 0 0 o ed (spa es)5 Spherical Bearing Bushing Assembly Bolts 96 1 0.61 Cut 6 Bearing Retainer Ring Plate Assembly Bolts 336 1 0.40 Cut 7 PWS Strand Anchor Rods (Main Cable) 274 3-1/2 0.32 55 Cut/219 Rolled 4*8 Tower Saddle Tie Rods 25 4 0.68 Rolled 1 (spare)

9Tower Saddle Turned Rods (@ Splices) 100 3 0.45

Cut Tower Saddle Turned Rods (@ Splices) 8 3 0.10

10 Tower Saddle Grillage Bolts 90 3 0.10 Cut 11 Tower Outrigger 4 3 0.10 Cut 12 Tower Anchorage Anchor Bolts (75 Dia Anchor Bolts) 388 3 0 48 Cut 212 Tower Anchorage Anchor Bolts (75 Dia. Anchor Bolts) 388 3 0.48 Cut 213 Tower Anchorage Anchor Bolts (100 Dia. Anchor Bolts) 36 4 0.37 Cut 114 East Saddle Anchor Rods 32 2 0.10 Cut 15 East Saddle Tie Rods 18 3 0.20 Cut 16 Cable Bracket Anchor Rods 24 3 0.16 Rolled


17 Bikepath Anchor Bolts at Pier W2 43 1-1/4 0.10 Cut 18 E2 2013 Replacement Rods (CCO 312) 40 3 0.70 6* samples with rolled thread and cut thread * samples with rolled thread and cut thread

Specimens Cut from RodSpecimens Cut from Rod

Multiple specimens can be taken Multiple specimens can be taken out of a small 3out of a small 3--in piece of materialin piece of materialout of a small 3out of a small 3 in piece of materialin piece of material

Specimens can be taken at the Specimens can be taken at the mid radius, center or outermid radius, center or outermid radius, center or outer mid radius, center or outer diameter, including threadsdiameter, including threads

Specimens can be used toSpecimens can be used toSpecimens can be used to Specimens can be used to characterize material properties characterize material properties like KIc and KIlike KIc and KI--EHE or geometrical EHE or geometrical properties such as KIproperties such as KIρρ c andc andproperties such as KIproperties such as KIρρ--c and c and KIKIρρ--EHEEHE

Extra specimens allow forExtra specimens allow for


Extra specimens allow for Extra specimens allow for verification of test resultsverification of test results

Specimen Quantities per RodSpecimen Quantities per Rod

Rod Diameter Center

(C)Mid-Radius

(MR)

Outside Diameter Threaded

(Th) TOTALSDiameter (in.) (C) (MR) Diameter

(OD) (Th) TOTALS

2 1 6* 0 6* 73 1 6 6 6 193 1 6 6 6 19

3.5 1 7 7 8 234 1 10 10 10 31

*Only 6 MR or 6 Th can be removed from 1 slug*Only 6 MR or 6 Th can be removed from 1 slug


Processing DataProcessing Data

Small Threaded Specimens Small Threaded Specimens cut from 2"D, 3"D, 3.5"D, cut from 2"D, 3"D, 3.5"D, 4"D Threaded Anchor Rod4"D Threaded Anchor Rod

Load drop MeasureLoad drop MeasureKIKI--ρρ--EHE EHE Threshold Stress Threshold Stress Intensity Factor of Intensity Factor of specimen for onset ofspecimen for onset ofspecimen for onset of specimen for onset of Environmentally Induced Environmentally Induced Stress Corrosion CrackingStress Corrosion Cracking


RSL™ Testing Protocol to RSL™ Testing Protocol to Measure the ThresholdMeasure the ThresholdMeasure the ThresholdMeasure the Threshold

KIscc


Raymond Test Raymond Test —— Test V Test V

Fracture Mechanics is the Bridge

EHEthreshold

EHEthresholdthreshold

LOADon

thresholdLOAD

ononThreadedSpecimen

ThreadedRod


RSL™ Testing Protocol to RSL™ Testing Protocol to Measure the Threshold LoadMeasure the Threshold LoadMeasure the Threshold LoadMeasure the Threshold Load

AnalysisAnalysisB d F t M h i f f tB d F t M h i f f tBased on Fracture Mechanics of fastenersBased on Fracture Mechanics of fasteners

KK of threaded SEN(Bend) of threaded SEN(Bend) = = KK of threaded rod(Tension)of threaded rod(Tension)

K net Y crack

Geometry ParameterGeometry Parameter

Applied StressApplied StressStress Intensity FactorStress Intensity Factor

Y(Y( ) (L) (L PP /I/ ) √( /W)/I/ ) √( /W) KIKI Y( d) (Y( d) (PP /A ) √D/A ) √D

PPthth--EHEEHE of threaded SEN(Bend) α of threaded SEN(Bend) α PPthth--EHEEHE of rod(Tension)of rod(Tension)

Y(Y(SENSEN) x (L x) x (L x PPthth--EHEEHE /I/c) x √(a/W) = /I/c) x √(a/W) = KIKIρρ--sccscc = Y(rod) x (= Y(rod) x (PPthth--EHEH/Area) x √D/Area) x √D


100 x P100 x Pthth--EHEEHE of rod(Tension) / of rod(Tension) / A354BDA354BD Min Min Ultimate Ultimate Tensile = Tensile = %Fu%Futhth--EHEEHE

Validation of Small Threaded Validation of Small Threaded Test SpecimenTest SpecimenTest SpecimenTest Specimen

Compared threaded small specimen fracture results to Compared threaded small specimen fracture results to p pp pTest III full scale rod fracture testTest III full scale rod fracture test

Compare crack initiation threshold load obtained from Compare crack initiation threshold load obtained from small threaded Test V specimens to Test IV rod failuresmall threaded Test V specimens to Test IV rod failure

Compared fractographic features of 2008 threaded Compared fractographic features of 2008 threaded specimen failed in RSL/EHE to fracture surface of 2008 specimen failed in RSL/EHE to fracture surface of 2008 ppfailed shear key rodfailed shear key rod


3"D Rod S13"D Rod S1--G1 v 3"L Threaded G1 v 3"L Threaded SEN(B) Fracture ModeSEN(B) Fracture ModeSEN(B) Fracture Mode SEN(B) Fracture Mode ComparisonComparison

S1S1 G1 SEM F t FG1 SEM F t F 11 VV S2S2 A2A2 A F t FA F t FS1S1--G1 SEM Fracture FaceG1 SEM Fracture Face 11--VV--S2S2--A2A2--A Fracture FaceA Fracture Face

1‐3

4

55


6

Crack Initiation Crack Initiation ——EHEEHEEHE EHE

RODROD Small SpecimenSmall Specimen


Intergranular (IG) Intergranular (IG)

Crack Propagation Crack Propagation ——EHE and FFSEHE and FFSEHE and FFSEHE and FFS



Mixed Mixed —— Cleavage Cleavage and and Dimpled RuptureDimpled Rupture

Brittle Fracture Brittle Fracture ——CleavageCleavageCleavageCleavage



Brittle Fracture Brittle Fracture —— CleavageCleavage

Test Specimens Fracture FaceTest Specimens Fracture Face

Fatigue PreFatigue Pre--Cracked (fpc) SpecimenCracked (fpc) Specimen

Typical Hardness Measurement Indentation

0.160 inch

0.180 inch0.200 inch

0.220 inch

Stop pre-cracking when crack is between 0.180 and 0.200 inch which results in a crack l th th t i i t l 0 210 i h


length that is approximately 0.210 inch

Fractured SurfaceFractured Surface

0.1" EDM slot0.1" EDM slot

fpc zonefpc zone

EHE crackEHE crackEHE crack EHE crack growth regiongrowth region

Fast fractureFast fractureFast fracture Fast fracture impact regionimpact region


*EHE specimen, 3 fpc cycles*EHE specimen, 3 fpc cycles

Effect of Coating on the Effect of Coating on the Threshold for EHEThreshold for EHEThreshold for EHEThreshold for EHE


Test V StatusTest V Status

50% of samples tested50% of samples tested

Data analysis in progressData analysis in progress


Thank YouThank You


test vtest v the “raymond” test - bay bridge info. test v...the first rsl ehe (the first rsl ehe...

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