Stress Intensity Factor solutions for through-clad and underclad defects in WWER reactor pressure vessel nozzles under pressurised thermal shock

Vitalii AntonchenkoLLC "IPP-Centre", Kyiv 01013, UkraineTernopil Ivan Puluj National Technical University, 56, Ruska Str., Ternopil, 46001, Ukraineantonchenko-vo@ipp-centre.com.ua,https://orcid.org/0000-0003-2210-5308Yaroslav DubykLLC "IPP-Centre", Kyiv 01013, UkraineKarpenko Physico-Mechanical Institute of the NAS of Ukraine, Lviv 79060, Ukrainedubyk-yr@ipp-centre.com.ua, https://orcid.org/0000-0002-4327-412X

Volodymyr IasniiTernopil Ivan Puluj National Technical University, 56, Ruska Str., Ternopil, 46001, Ukrainev_iasnii@tntu.edu.ua, https:// orcid.org/0000-0002-5768-5288

Introduction

Brittle fracture assessment is a central requirement in the safety justification of nuclear first-class equipment, and the reactor pressure vessel (RPV) holds particular importance in this context. The allowable operating time of an RPV is ultimately governed by its resistance to brittle fracture, whose margin degrades with neutron irradiation over the plant lifetime. The overall assessment procedure is separated into two complementary tasks: characterisation of the material fracture toughness and its evolution under ageing, and evaluation of the stress intensity factor (SIF) driving any postulated defect. The present work addresses the second task and, more specifically, the development of analytical or semi-analytical SIF solutions suited for rapid engineering evaluation in WWER-1000 nozzle regions containing austenitic cladding.
Although three-dimensional finite element analysis (FEA) is now standard practice for fracture mechanics calculations in the nuclear industry, there remains a strong practical need for fast, closed-form or tabulated SIF solutions. Such solutions are indispensable in probabilistic fracture mechanics (PFM), where Monte Carlo sampling across large populations of postulated flaws requires enormous numbers of individual SIF evaluations. As noted by the FAVOR code developers and subsequent users [1], the ability to evaluate SIFs through weight-function or influence-coefficient look-up rather than repeated finite element runs is essential for computationally tractable PFM assessments. Fast solutions are equally valuable for online stress monitoring, conservative screening of transient scenarios, and inclusion in national regulatory standards. The structural integrity of RPVs during pressurised thermal shock (PTS) events has been the subject of extensive international research and codification. PTS loading, arising from the injection of cold emergency coolant into a hot and pressurised primary circuit, produces steep thermal gradients that, when combined with repressurisation, can generate large tensile stresses at the inner wall of the vessel. The IAEA has published dedicated guidelines for PTS analysis of WWERtype reactors [2], which prescribe both deterministic and-where uncertainty levels are high-probabilistic approaches to integrity assessment. The IAEA TECDOC- [3] demonstrated that, despite the overall similarity of the PTS problem for PWR and WWER designs, significant differences exist among codes and methodologies, particularly in the treatment of
defect characterisation and SIF computation, underlining the need for reactor-type-specific solutions. For WWER-type plants, the VERLIFE unified procedure [4] provides validated guidelines for resistance against fast fracture, covering both deterministic fracture mechanics and, in its more recent revisions, probabilistic approaches for RPV and primary piping lifetime assessment. A comprehensive framework specifically adapted to WWER conditions has also been reported in the open literature [5].
Nozzle regions are recognised as critical locations for RPV integrity, because the geometric discontinuity at the nozzle-toshell junction produces stress concentrations that can exceed those in the beltline shell even when the neutron fluence is lower. This is reflected in U.S. regulatory requirements that extend pressure-temperature ( P T P T P-T\mathrm{P}-\mathrm{T}PT ) limit calculations beyond the beltline to include nozzle materials [6]. The primary regulatory sources for SIF calculation in nozzle geometries are the API 579-1/ASME FFS-1 standard [7] and ASME Boiler and Pressure Vessel Code, Section XI [8]. These documents provide analytical and semi-empirical solutions for circular or quarter-elliptical corner cracks in nozzle regions and are widely referenced in the literature for P T P T P-T\mathrm{P}-\mathrm{T}PT limit evaluation [ 4 , 6 , 9 ] [ 4 , 6 , 9 ] [4,6,9][4,6,9][4,6,9]. However, a fundamental limitation of the ASME formulations is that they were derived for geometrically uniform, uncladded components and do not account for the bi-material interface between the ferritic base metal and the austenitic cladding layer that is characteristic of actual WWER pressure vessels.
The mechanical response of RPV nozzle corner cracks under combined pressure and thermal loading has been investigated by a number of authors using three-dimensional FEA. Lee and Chou [10] evaluated SIFs for nozzle corner cracks in PWR and BWR geometries under both internal pressure and thermal transients, demonstrating that the ASME circular-crack formula is conservative for that crack shape but can underestimate SIFs for elliptical geometries. Dedicated adjusted magnification factor formulas were proposed to correct for the non-circular case. Chapuliot [11] studied SIF solutions for both sharp and bevelled nozzle corners, providing analytical tools specifically aimed at fatigue crack growth evaluation under cyclic thermal loading. Wang et al. [12] recently extended the influence coefficient method (ICM) to the nozzle corner crack problem, developing SIF solutions valid for arbitrary stress distributions applied to the crack face; their formulation was validated against FEA reference solutions over a range of crack sizes. Lu et al. [13] conducted a comprehensive parametric numerical study of nozzle corner crack SIFs in RPVs, yielding tabulated solutions that facilitate rapid engineering assessment. The engineering critical assessment framework for nozzle corner cracks under PTS transients-including the effect of cladding on crack initiation-was systematically examined by Li et al. [9], who applied a failure assessment diagram approach to evaluate critical crack sizes under multiple transient scenarios.
The ICM-also referred to in the literature as the influence function method-is a well-established superposition framework in which the SIF under an arbitrary stress distribution is expressed as a linear combination of polynomial stress coefficients multiplied by pre-computed shape (influence) coefficients. The mathematical foundation traces to the weight function theory of Buckner and Rice, and practical influence coefficient databases for cylindrical pressure vessel geometries were developed early on by Keeney and Bryson [14] for clad cylinders, providing tabulated coefficients for semi-elliptical innersurface flaws over a range of aspect ratios and cladding thicknesses. The FAVOR code, widely used for PFM assessment of U.S. RPVs, relies on weight-function based SIF evaluation for surface-breaking flaws including cladding effects [1].
A distinctive feature of cladded RPVs is the stress discontinuity that arises at the ferritic base metal-austenitic cladding interface due to the mismatch in thermal expansion coefficient and elastic modulus between the two materials. Under PTS conditions, this mismatch produces a localised stress concentration in the cladding and modifies the stress distribution seen by sub-surface cracks. Early finite element studies noted that the presence of cladding generally reduces the SIF under internal pressure loading by suppressing crack opening at the inner wall, but can increase the SIF under thermal loading by superimposing additional tensile stresses in the base metal [15].
For defects that straddle the cladding-base metal interface-the through-clad and underclad crack configurations addressed in the present study-the most directly relevant prior work is that of Marie and Chapuliot [16]. These authors proposed an improved procedure for calculating SIFs of underclad and through-clad defects in RPV cylindrical shell sections subjected to PTS loading, using a polynomial decomposition of the stress field and pre-computed shape factors to handle the stress discontinuity at the interface. The approach separates the total stress field into a component acting through the full ferritic wall thickness and a supplementary component localised within the cladding, allowing the two contributions to the SIF to be evaluated independently and then combined.
Notwithstanding the body of work summarised above, a gap remains for SIF solutions that simultaneously (i) address the three-dimensional nozzle geometry of WWER-1000 vessels with cladding, (ii) cover both through-clad and underclad defect types, (iii) employ the ICM with an explicit interface stress decomposition, and (iv) provide coefficients in a tabular form suitable for direct inclusion in national standards. Existing solutions are either limited to cylindrical shell sections without the nozzle geometry [14, 16], restricted to uncladded geometries [9-12], or do not provide the decomposed cladding coefficients needed to treat the bi-material interface rigorously. The present paper addresses this gap by developing SIF solutions based on three-dimensional FE J-integral evaluation combined with a least-squares refinement of polynomial
shape coefficients, validated against FE reference solutions for representative PTS loading cases. Our primary goal is to develop a simple, fast tool for SIF assessment of WWER reactor pressure vessels. The ultimate objective is to produce practical tabulated coefficients specific to WWER-1000 nozzle geometry for integration into Ukrainian national standards. This paper uses several methodologies for determining shape coefficients. The first step is the influence coefficient method. The second is the refinement of the coefficients using the least-squares method. Both the first and second methods are based on FE model results obtained with a crack inserted into the mesh. The last idea implemented in the paper is to come up with a simple equation for through-clad and under-clad defects for express SIF evaluation.

The influence coefficient method

FE model and methodology

Fig. 1 shows meshes for a crack with a depth of 10 % 10 % 10%10 \%10% of the total wall thickness of the RPV, with ellipse semi-axis ratios a/c of 0.3 and 0.7 .
In our work, we consider the nozzle part of the reactor vessel with the following parameters: inner radius Ri = 1991 Ri = 1991 Ri=1991\mathrm{Ri}=1991Ri=1991 mm , ferrite part thickness h = 345 mm h = 345 mm h=345mm\mathrm{h}=345 \mathrm{~mm}h=345 mm, and cladding thickness r = 9 mm r = 9 mm r=9mm\mathrm{r}=9 \mathrm{~mm}r=9 mm. The nozzle forging itself has a complex geometry, with shell thickening, and the thickness to be used in analysis is ambiguous. In this case, the value h = 345 mm h = 345 mm h=345mm\mathrm{h}=345 \mathrm{~mm}h=345 mm is the smallest distance from the crack centre to the external surface.
Fig. 1 shows a model with a crack depth of 10 % 10 % 10%10 \%10% of the total thickness of the RPV wall and an ellipse semi-axis ratio a / c = a / c = a//c=\mathrm{a} / \mathrm{c}=a/c= 0.3. Considering the symmetry conditions, a finite element model (FEM) representing half of the crack was created. We used three-dimensional solid elements to build the model. The mesh has 205,148 elements and 216,901 nodes. The average orthogonal quality is 0.8922 . The element size near the crack tip can vary widely, depending on the crack's geometric dimensions. If we use a constant element size around the crack front, the largest crack will have the largest mesh size. In all the considered FE models, the size of the finite element around the crack front is as follows: the radius of the first contour is 0.01 mm , and the radius of the outermost contour is 0.14 mm . The element dimension along the crack front is 2 mm .
Figure 1: Model of reactor vessel nozzle with built-in crack.
The Tab. 1 shows the values of elasticity modules for BM and cladding. The data is taken from VERLIFE [4].
Temperature, C 20100200300350 C 20100200300350 ^(@)C20100200300350{ }^{\circ} \mathrm{C} 20100200300350C20100200300350
Cladding 165 160 153 146 142
Base metal 208 201 193 183 177.5
Cladding 165 160 153 146 142 Base metal 208 201 193 183 177.5| Cladding | 165 | 160 | 153 | 146 | 142 | | :---: | :---: | :---: | :---: | :---: | :---: | | Base metal | 208 | 201 | 193 | 183 | 177.5 |
Table 1: Modulus of elasticity, GPa.
To calculate the SIF, we will use ICM: From the FEM results we obtain the value of the J-integral along the crack tip. We assume that the plane deformation conditions are satisfied along the full crack tip. Therefore, the stress intensity coefficient KI was obtained using the J-integral. The following expression is used to obtain the shape factor for each degree of the polynomial:
(1) i j = E J ( a + r b + r ) j π ( a + r ) (1) i j = E J a + r b + r j π ( a + r ) {:(1)i_(j)=(sqrt(E^(**)J))/(((a+r)/(b+r))^(j)sqrt(pi(a+r))):}\begin{equation*} i_{j}=\frac{\sqrt{E^{*} J}}{\left(\frac{a+r}{b+r}\right)^{j} \sqrt{\pi(a+r)}} \tag{1} \end{equation*}(1)ij=EJ(a+rb+r)jπ(a+r)
where the parameter E E E^(**)E^{*}E :
(2) E = E 1 μ (2) E = E 1 μ {:(2)E^(**)=(E)/(1-mu):}\begin{equation*} E^{*}=\frac{E}{1-\mu} \tag{2} \end{equation*}(2)E=E1μ
When using quadratic elements, the average value of the shape factor for each element should be calculated. For the deepest point of the crack, the three nodes of the element are used: point 1 , point 2 and point 3 as represented in Fig. 2.
Figure 2: Parameters of the considered defect, with point representation.
The average shape functions are obtained from the following relations:
(3) i = 1 6 ( i point 1 + 4 i point 2 + i point 3 ) (3) i = 1 6 i point  1 + 4 i point  2 + i point  3 {:(3)i=(1)/(6)(i_("point "1)+4*i_("point "2)+i_("point "3)):}\begin{equation*} i=\frac{1}{6}\left(i_{\text {point } 1}+4 \cdot i_{\text {point } 2}+i_{\text {point } 3}\right) \tag{3} \end{equation*}(3)i=16(ipoint 1+4ipoint 2+ipoint 3)
The WWER-1000 reactor pressure vessel has anticorrosion cladding, which significantly complicates the accurate determination of stress polynomials. Due to the abrupt change in material properties within the cladding region, substantial errors arise when approximating the stress field.
Fig. 3 presents the distributions of the actual stresses obtained from the finite element analysis as well as their interpolated representations. The analysis of the stress plots clearly demonstrates the pronounced influence of the anticorrosion cladding on the stress distribution. The solid blue line corresponds to the actual stresses, while the red dashed line represents the interpolated function.
During the interpolation process, a significant error is observed near the cladding, due to the inability of a smooth polynomial function to capture the steep stress gradients adequately. This error may lead to either overestimation or underestimation of the stress level near the crack tip, thereby affecting the accuracy of subsequent fracture mechanics parameter calculations.
In Fig. 3, we can see a stress discontinuity in the cladding zone, making accurate polynomial selection impossible with this distortion. Therefore, we applied the stress decomposition method presented in VERLIFE [4]. It consists of separating the stresses in the base metal and the cladding. We obtain two smooth functions. The stress decomposition process is schematically shown in Fig. 4.
Then SIF can be found using equation:
(4) K 1 = ( j = 0 4 σ j i j ( a + r b + r ) j + j = 0 1 σ j r i j r ( a + r b + r ) j ) π ( a + r ) (4) K 1 = j = 0 4 σ j i j a + r b + r j + j = 0 1 σ j r i j r a + r b + r j π ( a + r ) {:(4)K_(1)=(sum_(j=0)^(4)sigma_(j)i_(j)((a+r)/(b+r))^(j)+sum_(j=0)^(1)sigma_(jr)i_(jr)((a+r)/(b+r))^(j))sqrt(pi(a+r)):}\begin{equation*} K_{1}=\left(\sum_{j=0}^{4} \sigma_{j} i_{j}\left(\frac{a+r}{b+r}\right)^{j}+\sum_{j=0}^{1} \sigma_{j r} i_{j r}\left(\frac{a+r}{b+r}\right)^{j}\right) \sqrt{\pi(a+r)} \tag{4} \end{equation*}(4)K1=(j=04σjij(a+rb+r)j+j=01σjrijr(a+rb+r)j)π(a+r)
Stress intensity factor analysis is based on the linear elastic fracture mechanics, thus we decompose the complex stress distribution to compute the SIF separately for each type of polynomial loading. The most convenient way is to apply different polynomial loading on the crack surface.
Figure 3: Options for interpolating operating stresses, left - heat-up, right cool-down.
Figure 4: Separation of stresses.

Boundary conditions

ICM works with the results of the FE model calculation. Therefore, it is necessary to calculate the stress distribution and the SIF (J integral) value. The same model is used to calculate SIF (J integral) and stress distribution, only the boundary conditions in the crack zone change, e.g. crack surface is either loaded, or symmetry condition is applied.
The following boundary conditions were used to calculate the FEM:
  • Symmetry condition. The plane of symmetry passes through the crack edge. For the SIF (J integral) calculation, the crack surface is not included in the boundary condition. For the stress field calculation, the crack surface is included in the boundary condition.
  • Restriction of vertical displacement on the model's bottom part.
  • Frictionless boundary conditions on the other vertical end of the model.
  • Load on the crack surface, in case of SIF (J integral) calculations.
  • "End-cap" axial force for the nozzle.
The load on the crack surface is used to determine the stress polynomials. The load on other surfaces is used to determine the stress distribution and the SIF (J integral). The specified boundary conditions are shown in Fig. 5.
The ICM method applies an external load directly to the crack faces, i.e. to determine the SIF arising from a predefined load, by varying the form and surface of load application, the shape coefficients are determined. Those different forms of loading are used to describe the effect of the applied load in the coefficients of polynomials from zero to fourth order. The shape coefficients are calculated separately for the base metal and the cladding, which reflects the material heterogeneity and differences in mechanical properties of two layers.

Coefficients determined by the ICM

After performing FEM calculations with the applied load at the crack tip, we obtained the J integral value, Jint. Using expression (1), we find the values of the shape coefficients.
Tab. 2 - Tab. 5 show the shape coefficients for surface and subsurface cracks in the RPV nozzle. We considered a wide range of crack sizes from 5 % 5 % 5%5 \%5% to 15 % 15 % 15%15 \%15% and ellipse axis ratios of 0.3 and 0.7 .
Figure 5: Boundary conditions for polynomial calculations of SIF values
Size, % % %\%% i 0 i 0 i_(0)i_{0}i0 i 1 i 1 i_(1)i_{1}i1 i 2 i 2 i_(2)i_{2}i2 i 3 i 3 i_(3)i_{3}i3 i r 0 i r 0 i_(r0)i_{r 0}ir0 i r 1 i r 1 i_(r1)i_{r 1}ir1
5 0.9136 0.5538 0.4067 0.3225 0.2094 0.0414
Size, % i_(0) i_(1) i_(2) i_(3) i_(r0) i_(r1) 5 0.9136 0.5538 0.4067 0.3225 0.2094 0.0414| Size, $\%$ | $i_{0}$ | $i_{1}$ | $i_{2}$ | $i_{3}$ | $i_{r 0}$ | $i_{r 1}$ | | :---: | :---: | :---: | :---: | :---: | :---: | :---: | | 5 | 0.9136 | 0.5538 | 0.4067 | 0.3225 | 0.2094 | 0.0414 |
E 1 E 2 = 1 E 1 E 2 = 1 (E_(1))/(E_(2))=1\frac{E_{1}}{E_{2}}=1E1E2=1 7.5 0.9165 0.5593 0.4108 0.3257 0.1611 0.0283
10 0.9145 0.5686 0.4226 0.3388 0.1283 0.0216
12.5 0.9113 0.5630 0.4146 0.3291 0.1094 0.0179
15 0.9104 0.5658 0.4177 0.3321 0.0950 0.0156
E 1 / E 2 = 0.7 E 1 / E 2 = 0.7 E_(1)//_(E_(2))=0.7E_{1} /_{E_{2}}=0.7E1/E2=0.7 5 0.9445 0.5660 0.4137 0.3276 0.2247 0.0439
7.5 0.9399 0.5676 0.4149 0.3282 0.1706 0.0296
10 0.9328 0.5705 0.4259 0.3407 0.1345 0.0223
12.5 0.9265 0.5684 0.4173 0.3307 0.1139 0.0183
15 0.9235 0.5708 0.4204 0.3338 0.0983 0.0160
(E_(1))/(E_(2))=1 7.5 0.9165 0.5593 0.4108 0.3257 0.1611 0.0283 10 0.9145 0.5686 0.4226 0.3388 0.1283 0.0216 12.5 0.9113 0.5630 0.4146 0.3291 0.1094 0.0179 15 0.9104 0.5658 0.4177 0.3321 0.0950 0.0156 E_(1)//_(E_(2))=0.7 5 0.9445 0.5660 0.4137 0.3276 0.2247 0.0439 7.5 0.9399 0.5676 0.4149 0.3282 0.1706 0.0296 10 0.9328 0.5705 0.4259 0.3407 0.1345 0.0223 12.5 0.9265 0.5684 0.4173 0.3307 0.1139 0.0183 15 0.9235 0.5708 0.4204 0.3338 0.0983 0.0160| $\frac{E_{1}}{E_{2}}=1$ | 7.5 | 0.9165 | 0.5593 | 0.4108 | 0.3257 | 0.1611 | 0.0283 | | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | | | 10 | 0.9145 | 0.5686 | 0.4226 | 0.3388 | 0.1283 | 0.0216 | | | 12.5 | 0.9113 | 0.5630 | 0.4146 | 0.3291 | 0.1094 | 0.0179 | | | 15 | 0.9104 | 0.5658 | 0.4177 | 0.3321 | 0.0950 | 0.0156 | | $E_{1} /_{E_{2}}=0.7$ | 5 | 0.9445 | 0.5660 | 0.4137 | 0.3276 | 0.2247 | 0.0439 | | | 7.5 | 0.9399 | 0.5676 | 0.4149 | 0.3282 | 0.1706 | 0.0296 | | | 10 | 0.9328 | 0.5705 | 0.4259 | 0.3407 | 0.1345 | 0.0223 | | | 12.5 | 0.9265 | 0.5684 | 0.4173 | 0.3307 | 0.1139 | 0.0183 | | | 15 | 0.9235 | 0.5708 | 0.4204 | 0.3338 | 0.0983 | 0.0160 |
Table 2: Shape factors for TCC with axis ratios of 0.3.
Size, % i 0 i 0 i_(0)i_{0}i0 i 1 i 1 i_(1)i_{1}i1 i 2 i 2 i_(2)i_{2}i2 i 3 i 3 i_(3)i_{3}i3 i r 0 i r 0 i_(r0)i_{r 0}ir0 i r 1 i r 1 i_(r1)i_{r 1}ir1
E 1 E 2 = 1 E 1 E 2 = 1 (E_(1))/(E_(2))=1\frac{E_{1}}{E_{2}}=1E1E2=1 5 0.6720 0.4435 0.3419 0.2795 0.1083 0.0189
7.5 0.7028 0.4578 0.3506 0.2857 0.0900 0.0125
10 0.7176 0.4652 0.3552 0.2891 0.0759 0.0092
12.5 0.7264 0.4695 0.3576 0.2907 0.0661 0.0074
15 0.7343 0.4739 0.3604 0.2927 0.0589 0.0064
E 1 / E 2 = 0.7 E 1 / E 2 = 0.7 E_(1)//_(E_(2))=0.7E_{1} /_{E_{2}}=0.7E1/E2=0.7 5 0.6954 0.4515 0.3458 0.2817 0.1204 0.0209
7.5 0.7210 0.4639 0.3535 0.2874 0.0977 0.0136
10 0.7325 0.4702 0.3575 0.2904 0.0813 0.0098
12.5 0.7403 0.4744 0.3600 0.2920 0.0701 0.0078
15 0.7450 0.4776 0.3621 0.2937 0.0618 0.0066
Size, % i_(0) i_(1) i_(2) i_(3) i_(r0) i_(r1) (E_(1))/(E_(2))=1 5 0.6720 0.4435 0.3419 0.2795 0.1083 0.0189 7.5 0.7028 0.4578 0.3506 0.2857 0.0900 0.0125 10 0.7176 0.4652 0.3552 0.2891 0.0759 0.0092 12.5 0.7264 0.4695 0.3576 0.2907 0.0661 0.0074 15 0.7343 0.4739 0.3604 0.2927 0.0589 0.0064 E_(1)//_(E_(2))=0.7 5 0.6954 0.4515 0.3458 0.2817 0.1204 0.0209 7.5 0.7210 0.4639 0.3535 0.2874 0.0977 0.0136 10 0.7325 0.4702 0.3575 0.2904 0.0813 0.0098 12.5 0.7403 0.4744 0.3600 0.2920 0.0701 0.0078 15 0.7450 0.4776 0.3621 0.2937 0.0618 0.0066| | Size, % | $i_{0}$ | $i_{1}$ | $i_{2}$ | $i_{3}$ | $i_{r 0}$ | $i_{r 1}$ | | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | | $\frac{E_{1}}{E_{2}}=1$ | 5 | 0.6720 | 0.4435 | 0.3419 | 0.2795 | 0.1083 | 0.0189 | | | 7.5 | 0.7028 | 0.4578 | 0.3506 | 0.2857 | 0.0900 | 0.0125 | | | 10 | 0.7176 | 0.4652 | 0.3552 | 0.2891 | 0.0759 | 0.0092 | | | 12.5 | 0.7264 | 0.4695 | 0.3576 | 0.2907 | 0.0661 | 0.0074 | | | 15 | 0.7343 | 0.4739 | 0.3604 | 0.2927 | 0.0589 | 0.0064 | | $E_{1} /_{E_{2}}=0.7$ | 5 | 0.6954 | 0.4515 | 0.3458 | 0.2817 | 0.1204 | 0.0209 | | | 7.5 | 0.7210 | 0.4639 | 0.3535 | 0.2874 | 0.0977 | 0.0136 | | | 10 | 0.7325 | 0.4702 | 0.3575 | 0.2904 | 0.0813 | 0.0098 | | | 12.5 | 0.7403 | 0.4744 | 0.3600 | 0.2920 | 0.0701 | 0.0078 | | | 15 | 0.7450 | 0.4776 | 0.3621 | 0.2937 | 0.0618 | 0.0066 |
Table 3: Shape factors for TCC with axis ratios of 0.7
Size, % i 0 i 0 i_(0)i_{0}i0 i 1 i 1 i_(1)i_{1}i1 i 2 i 2 i_(2)i_{2}i2 i 3 i 3 i_(3)i_{3}i3
E 1 E 2 = 1 E 1 E 2 = 1 (E_(1))/(E_(2))=1\frac{E_{1}}{E_{2}}=1E1E2=1 5 0.6823 0.5329 0.4321 0.3600
7.5 0.6903 0.5244 0.4187 0.3456
10 0.6996 0.5238 0.4158 3.3154
12.5 0.7010 0.5180 0.4083 0.3351
15 0.7060 0.5181 0.4076 0.3343
E 1 / E 2 = 0.7 E 1 / E 2 = 0.7 E_(1)//_(E_(2))=0.7E_{1} /_{E_{2}}=0.7E1/E2=0.7 5 0.6987 0.5426 0.4381 0.3640
7.5 0.7066 0.5333 0.4239 0.3490
10 0.7157 0.5322 0.4206 0.3457
12.5 0.7165 0.5257 0.4127 0.3378
15 0.7213 0.5258 0.4121 0.3372
Size, % i_(0) i_(1) i_(2) i_(3) (E_(1))/(E_(2))=1 5 0.6823 0.5329 0.4321 0.3600 7.5 0.6903 0.5244 0.4187 0.3456 10 0.6996 0.5238 0.4158 3.3154 12.5 0.7010 0.5180 0.4083 0.3351 15 0.7060 0.5181 0.4076 0.3343 E_(1)//_(E_(2))=0.7 5 0.6987 0.5426 0.4381 0.3640 7.5 0.7066 0.5333 0.4239 0.3490 10 0.7157 0.5322 0.4206 0.3457 12.5 0.7165 0.5257 0.4127 0.3378 15 0.7213 0.5258 0.4121 0.3372| | Size, % | $i_{0}$ | $i_{1}$ | $i_{2}$ | $i_{3}$ | | :--- | :--- | :--- | :--- | :--- | :--- | | $\frac{E_{1}}{E_{2}}=1$ | 5 | 0.6823 | 0.5329 | 0.4321 | 0.3600 | | | 7.5 | 0.6903 | 0.5244 | 0.4187 | 0.3456 | | | 10 | 0.6996 | 0.5238 | 0.4158 | 3.3154 | | | 12.5 | 0.7010 | 0.5180 | 0.4083 | 0.3351 | | | 15 | 0.7060 | 0.5181 | 0.4076 | 0.3343 | | $E_{1} /_{E_{2}}=0.7$ | 5 | 0.6987 | 0.5426 | 0.4381 | 0.3640 | | | 7.5 | 0.7066 | 0.5333 | 0.4239 | 0.3490 | | | 10 | 0.7157 | 0.5322 | 0.4206 | 0.3457 | | | 12.5 | 0.7165 | 0.5257 | 0.4127 | 0.3378 | | | 15 | 0.7213 | 0.5258 | 0.4121 | 0.3372 |
Table 4: Shape factors for UCC with axis ratios of 0.3.
Size, % i 0 i 0 i_(0)i_{0}i0 i 1 i 1 i_(1)i_{1}i1 i 2 i 2 i_(2)i_{2}i2 i 3 i 3 i_(3)i_{3}i3
E 1 E 2 = 1 E 1 E 2 = 1 (E_(1))/(E_(2))=1\frac{E_{1}}{E_{2}}=1E1E2=1 5 0.6054 0.4779 0.3910 0.3282
7.5 0.6150 0.4731 0.3819 0.3183
10 0.6213 0.4702 0.3767 0.3128
12.5 0.6256 0.4678 0.3728 0.3087
15 0.6301 0.4672 0.3710 0.3068
E 1 / E 2 = 0.7 E 1 / E 2 = 0.7 E_(1)//_(E_(2))=0.7E_{1} /_{E_{2}}=0.7E1/E2=0.7 5 0.6161 0.4839 0.3946 0.3305
7.5 0.6256 0.4786 0.3850 0.3202
10 0.6319 0.4753 0.3795 0.3145
12.5 0.6370 0.4733 0.3757 0.3105
Size, % i_(0) i_(1) i_(2) i_(3) (E_(1))/(E_(2))=1 5 0.6054 0.4779 0.3910 0.3282 7.5 0.6150 0.4731 0.3819 0.3183 10 0.6213 0.4702 0.3767 0.3128 12.5 0.6256 0.4678 0.3728 0.3087 15 0.6301 0.4672 0.3710 0.3068 E_(1)//_(E_(2))=0.7 5 0.6161 0.4839 0.3946 0.3305 7.5 0.6256 0.4786 0.3850 0.3202 10 0.6319 0.4753 0.3795 0.3145 12.5 0.6370 0.4733 0.3757 0.3105| | Size, % | $i_{0}$ | $i_{1}$ | $i_{2}$ | $i_{3}$ | | :--- | :--- | :--- | :--- | :--- | :--- | | $\frac{E_{1}}{E_{2}}=1$ | 5 | 0.6054 | 0.4779 | 0.3910 | 0.3282 | | | 7.5 | 0.6150 | 0.4731 | 0.3819 | 0.3183 | | | 10 | 0.6213 | 0.4702 | 0.3767 | 0.3128 | | | 12.5 | 0.6256 | 0.4678 | 0.3728 | 0.3087 | | | 15 | 0.6301 | 0.4672 | 0.3710 | 0.3068 | | $E_{1} /_{E_{2}}=0.7$ | 5 | 0.6161 | 0.4839 | 0.3946 | 0.3305 | | | 7.5 | 0.6256 | 0.4786 | 0.3850 | 0.3202 | | | 10 | 0.6319 | 0.4753 | 0.3795 | 0.3145 | | | 12.5 | 0.6370 | 0.4733 | 0.3757 | 0.3105 |
15 0.6402 0.4718 0.3734 0.3082
15 0.6402 0.4718 0.3734 0.3082| 15 | 0.6402 | 0.4718 | 0.3734 | 0.3082 | | :--- | :--- | :--- | :--- | :--- |
Table 5: Shape factors for UCC with axis ratios of 0.7

Validation of the obtained coefficients

To validate the obtained coefficients, several practically important cases were studied: internal pressure, temperature gradient, the combined effect of the above factors.
Fig. 6 shows the stress distribution graph for the combined pressure and temperature load case. The left figure shows the stress for the case E clad / E BM = 1 E clad / E BM = 1 E_(clad)//E_(BM)=1\mathrm{E}_{\mathrm{clad}} / \mathrm{E}_{\mathrm{BM}}=1Eclad/EBM=1, and the right figure shows the case E clad / E BM = 0.7 E clad / E BM = 0.7 E_(clad)//E_(BM)=0.7\mathrm{E}_{\mathrm{clad}} / \mathrm{E}_{\mathrm{BM}}=0.7Eclad/EBM=0.7. The right figure shows the stress polynomial function for the base metal, with stresses separated into those in the base metal and those in the cladding.
Figure 6: Stress distribution and polynomial for combined loading: left - E clad / E BM = 1 E clad  / E BM = 1 E_("clad ")//E_(BM)=1\mathrm{E}_{\text {clad }} / \mathrm{E}_{\mathrm{BM}}=1Eclad /EBM=1; right E clad / E BM = 0.7 E clad  / E BM = 0.7 E_("clad ")//E_(BM)=0.7\mathrm{E}_{\text {clad }} / \mathrm{E}_{\mathrm{BM}}=0.7Eclad /EBM=0.7.
Tab. 6 presents the results of verification calculations of test cases and existing formulas for evaluating SIF for a throughclad cracks.
Tab. 7 presents the results of verification calculations of test cases for a underclad cracks. The tables present the results for a defect with a depth of 10 % 10 % 10%10 \%10% and an ellipse axis ratio of 0.3 and 0.7 .
Case FEM, MPa m m sqrtm\sqrt{m}m Current approach, Δ , % Δ , % Delta,%\Delta, \%Δ,% Ref [7] radiusc Δ , % Δ , % Delta,%\Delta, \%Δ,% Ref [8] sharp Δ , % Δ , % Delta,%\Delta, \%Δ,% Ref [11] radius Δ , % Δ , % Delta,%\Delta, \%Δ,% Ref [11] sharp Δ , % Δ , % Delta,%\Delta, \%Δ,%
0.3 0.7 0.3 0.7 0.3 0.7 - 0.3 0.7 - 0.3 0.7 - 0.3 0.7 0.3 0.7 0.3quad0.70.3 \quad 0.70.30.7 - 0.3 0.7
II E 1 / E 2 E 1 / E 2 E_(1)//E_(2)E_{1} / E_{2}E1/E2 Pressure 63.4 49.4 62.3 48.6 -1.73-1.60 56.9 -10.1 15.2 58.3 -8.0 18.0 49.4 -22.0 0.0 42.2 -33.3 -14.5
Quadratic temperature distribution 44.4 34.4 43.6 34.0 -1.62-1.32 39.9 -10.1 15.8 40.8 -8.0 18.6 35.4 -20.2 2.9 26.1 -41.3 -24.3
All the power factors 107.6 83.7 105.8 82.6 -1.64-1.37 96.8 -10.0 15.6 99.1 -7.9 18.4 84.8 -21.2 1.3 68.3 -36.5 -18.4
E 1 / E 2 = E 1 / E 2 = E_(1)//E_(2)=E_{1} / E_{2} =E1/E2=
0.7
E_(1)//E_(2)= 0.7| $E_{1} / E_{2} =$ | | :--- | | 0.7 |
Pressure 62.9 49.7 61.9 48.8 -1.56-1.63 54.4 -13.5 9.5 55.7 -11.4 12.1 46.6 -25.9-6.2 98.1 56.0 97.5
temperature distribution 45.6 35.7 45.0 35.2 -1.22-1.19 39.7 -12.8 11.4 40.7 -10.8 14.0 35.0 -23.1-1.8 51.7 13.4 44.9
All the power factors 108.3 85.2 106.9 84.1 -1.29 -1.30 94.1 -13.1 10.5 96.3 -11.0 13.1 81.6 -24.7-4.2 149.7 38.3 75.8
Case FEM, MPa sqrtm Current approach, Delta,% Ref [7] radiusc Delta,% Ref [8] sharp Delta,% Ref [11] radius Delta,% Ref [11] sharp Delta,% 0.3 0.7 0.3 0.7 0.3 0.7 - 0.3 0.7 - 0.3 0.7 - 0.3quad0.7 - 0.3 0.7 II E_(1)//E_(2) Pressure 63.4 49.4 62.3 48.6 -1.73-1.60 56.9 -10.1 15.2 58.3 -8.0 18.0 49.4 -22.0 0.0 42.2 -33.3 -14.5 Quadratic temperature distribution 44.4 34.4 43.6 34.0 -1.62-1.32 39.9 -10.1 15.8 40.8 -8.0 18.6 35.4 -20.2 2.9 26.1 -41.3 -24.3 All the power factors 107.6 83.7 105.8 82.6 -1.64-1.37 96.8 -10.0 15.6 99.1 -7.9 18.4 84.8 -21.2 1.3 68.3 -36.5 -18.4 "E_(1)//E_(2)= 0.7" Pressure 62.9 49.7 61.9 48.8 -1.56-1.63 54.4 -13.5 9.5 55.7 -11.4 12.1 46.6 -25.9-6.2 98.1 56.0 97.5 temperature distribution 45.6 35.7 45.0 35.2 -1.22-1.19 39.7 -12.8 11.4 40.7 -10.8 14.0 35.0 -23.1-1.8 51.7 13.4 44.9 All the power factors 108.3 85.2 106.9 84.1 -1.29 -1.30 94.1 -13.1 10.5 96.3 -11.0 13.1 81.6 -24.7-4.2 149.7 38.3 75.8| Case | | FEM, MPa $\sqrt{m}$ | | Current | approach, | | $\Delta, \%$ | Ref [7] radiusc | | $\Delta, \%$ | Ref [8] sharp | $\Delta, \%$ | | Ref [11] radius | $\Delta, \%$ | Ref [11] sharp | | $\Delta, \%$ | | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | | | | 0.3 | 0.7 | 0.3 | 0.7 | 0.3 | 0.7 | - | 0.3 | 0.7 | - | 0.3 | 0.7 | - | $0.3 \quad 0.7$ | - | 0.3 | 0.7 | | II $E_{1} / E_{2}$ | Pressure | 63.4 | 49.4 | 62.3 | 48.6 | | -1.73-1.60 | 56.9 | -10.1 | 15.2 | 58.3 | -8.0 | 18.0 | 49.4 | -22.0 0.0 | 42.2 | -33.3 | -14.5 | | | Quadratic temperature distribution | 44.4 | 34.4 | 43.6 | 34.0 | | -1.62-1.32 | 39.9 | -10.1 | 15.8 | 40.8 | -8.0 | 18.6 | 35.4 | -20.2 2.9 | 26.1 | -41.3 | -24.3 | | | All the power factors | 107.6 | 83.7 | 105.8 | 82.6 | | -1.64-1.37 | 96.8 | -10.0 | 15.6 | 99.1 | -7.9 | 18.4 | 84.8 | -21.2 1.3 | 68.3 | -36.5 | -18.4 | | $E_{1} / E_{2} =$ <br> 0.7 | Pressure | 62.9 | 49.7 | 61.9 | 48.8 | | -1.56-1.63 | 54.4 | -13.5 | 9.5 | 55.7 | -11.4 | 12.1 | 46.6 | -25.9-6.2 | 98.1 | 56.0 | 97.5 | | | temperature distribution | 45.6 | 35.7 | 45.0 | 35.2 | | -1.22-1.19 | 39.7 | -12.8 | 11.4 | 40.7 | -10.8 | 14.0 | 35.0 | -23.1-1.8 | 51.7 | 13.4 | 44.9 | | | All the power factors | 108.3 | 85.2 | 106.9 | 84.1 | -1.29 | -1.30 | 94.1 | -13.1 | 10.5 | 96.3 | -11.0 | 13.1 | 81.6 | -24.7-4.2 | 149.7 | 38.3 | 75.8 |
Table 6: Comparison of test cases for a 10% through-clad defect.
Case FEM, MPa m m sqrtm\sqrt{m}m Current approach, MPa m MPa m MPasqrt()m\mathrm{MPa} \sqrt{ } \mathrm{m}MPam Δ , % Δ , % Delta,%\Delta, \%Δ,%
0.3 0.7 0.3 0.7 0.3 0.7
E 1 / E 2 = 1 E 1 / E 2 = 1 E_(1)//_(E_(2))=1E_{1} /_{E_{2}}=1E1/E2=1 Pressure 42.1 37.4 39.9 36.7 -5.26 -1.94
Quadratic temperature distribution 29.0 25.7 27.2 25.3 -6.06 -1.63
Case FEM, MPa sqrtm Current approach, MPasqrt()m Delta,% 0.3 0.7 0.3 0.7 0.3 0.7 E_(1)//_(E_(2))=1 Pressure 42.1 37.4 39.9 36.7 -5.26 -1.94 Quadratic temperature distribution 29.0 25.7 27.2 25.3 -6.06 -1.63| | Case | FEM, MPa $\sqrt{m}$ | | Current approach, $\mathrm{MPa} \sqrt{ } \mathrm{m}$ | | $\Delta, \%$ | | | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | | | | 0.3 | 0.7 | 0.3 | 0.7 | 0.3 | 0.7 | | $E_{1} /_{E_{2}}=1$ | Pressure | 42.1 | 37.4 | 39.9 | 36.7 | -5.26 | -1.94 | | | Quadratic temperature distribution | 29.0 | 25.7 | 27.2 | 25.3 | -6.06 | -1.63 |
E 1 E 2 = 0.7 E 1 E 2 = 0.7 (E_(1))/(E_(2))=0.7\frac{E_{1}}{E_{2}}=0.7E1E2=0.7 All the power factors 71.0 63.0 71.3 62.1 0.50 -1.38
Pressure 44.0 38.9 43.3 38.1 -1.72 -1.92
Quadratic temperature distribution 30.8 27.1 30.3 26.7 -1.55 -1.62
All the power factors 74.8 65.9 73.6 64.8 -1.52 -1.65
(E_(1))/(E_(2))=0.7 All the power factors 71.0 63.0 71.3 62.1 0.50 -1.38 Pressure 44.0 38.9 43.3 38.1 -1.72 -1.92 Quadratic temperature distribution 30.8 27.1 30.3 26.7 -1.55 -1.62 All the power factors 74.8 65.9 73.6 64.8 -1.52 -1.65| $\frac{E_{1}}{E_{2}}=0.7$ | All the power factors | 71.0 | 63.0 | 71.3 | 62.1 | 0.50 | -1.38 | | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | | | Pressure | 44.0 | 38.9 | 43.3 | 38.1 | -1.72 | -1.92 | | | Quadratic temperature distribution | 30.8 | 27.1 | 30.3 | 26.7 | -1.55 | -1.62 | | | All the power factors | 74.8 | 65.9 | 73.6 | 64.8 | -1.52 | -1.65 |
Table 7: Comparison of test cases for a 10 % 10 % 10%10 \%10% underclad defect.
Fig. 7 shows the normalized SIF values for a through-clad defect. The results are presented for a pressure load case.
Figure 7: Normalized SIF values for a through-clad defect, for a pressure load case.
From the results presented in Tab. 6 and Tab. 7, we can see that the SIF values calculated using our coefficients are in good agreement with the FEM results, but have a slight error of 2 % 2 % 2%2 \%2%. Therefore, we tried to improve the accuracy of these coefficients using the least squares method. These coefficients were used as the initial value in the solution.

The Least square approximation

The least squares method (LSM) is a statistical approach used to determine the optimal approximation to the solution of an overdetermined system by minimizing the sum of squared deviations between experimental data and the corresponding theoretical values. In the referenced source [10], a system of equations for determining the stress intensity factor for a surface flaw is presented. Based on expression (5), a system of equations was derived for a nozzle configuration without considering a corrosion-resistant cladding layer.
(5) K 1 = [ A 0 M 0 + A 1 ( 2 a π ) M 1 + A 2 ( a 2 2 ) M 2 + A 3 ( 4 a 3 3 π ) M 3 ] π a (5) K 1 = A 0 M 0 + A 1 2 a π M 1 + A 2 a 2 2 M 2 + A 3 4 a 3 3 π M 3 π a {:(5)K_(1)=[A_(0)M_(0)+A_(1)((2a)/(pi))M_(1)+A_(2)((a^(2))/(2))M_(2)+A_(3)((4a^(3))/(3pi))M_(3)]sqrt(pi a):}\begin{equation*} K_{1}=\left[A_{0} M_{0}+A_{1}\left(\frac{2 a}{\pi}\right) M_{1}+A_{2}\left(\frac{a^{2}}{2}\right) M_{2}+A_{3}\left(\frac{4 a^{3}}{3 \pi}\right) M_{3}\right] \sqrt{\pi a} \tag{5} \end{equation*}(5)K1=[A0M0+A1(2aπ)M1+A2(a22)M2+A3(4a33π)M3]πa
Using expression (5) for through-clad defects results in an error of 15-20% in both the lower and upper directions. This is especially true for small crack sizes. Therefore, we suggest accounting for the stress discontinuity at the cladding-to-base metal interface by writing down system 5 with shape coefficients in the cladding.
(6) π ( a + r ) [ A 10 A 11 ( 2 ( a + r ) π ) A 12 ( ( a + r ) 2 2 ) A 13 ( 4 ( a + r ) 3 3 π ) A 10 r A n 0 A n 1 ( 2 ( a + r ) π ) A n 2 ( ( a + r ) 2 2 ) A n 3 ( 4 ( a + r ) 3 3 π ) A n 0 r ] n × 5 [ M 0 M 1 M 2 M 3 M 0 r ] 5 × 1 = [ K 1 K n ] n × 1 (6) π ( a + r ) A 10 A 11 2 ( a + r ) π A 12 ( a + r ) 2 2 A 13 4 ( a + r ) 3 3 π A 10 r A n 0 A n 1 2 ( a + r ) π A n 2 ( a + r ) 2 2 A n 3 4 ( a + r ) 3 3 π A n 0 r n × 5 M 0 M 1 M 2 M 3 M 0 r 5 × 1 = K 1 K n n × 1 {:(6)sqrt(pi(a+r))*[[A_(10)A_(11)((2(a+r))/(pi))A_(12)(((a+r)^(2))/(2))A_(13)((4(a+r)^(3))/(3pi))A_(10 r)],[vdots],[A_(n0)A_(n1)((2(a+r))/(pi))A_(n2)(((a+r)^(2))/(2))A_(n3)((4(a+r)^(3))/(3pi))A_(n0r)]]_(n xx5)[[M_(0)],[M_(1)],[M_(2)],[M_(3)],[M_(0r)]]_(5xx1)=[[K_(1)],[vdots],[K_(n)]]_(n xx1):}\sqrt{\pi(a+r)} \cdot\left[\begin{array}{c} A_{10} A_{11}\left(\frac{2(a+r)}{\pi}\right) A_{12}\left(\frac{(a+r)^{2}}{2}\right) A_{13}\left(\frac{4(a+r)^{3}}{3 \pi}\right) A_{10 r} \tag{6}\\ \vdots \\ A_{n 0} A_{n 1}\left(\frac{2(a+r)}{\pi}\right) A_{n 2}\left(\frac{(a+r)^{2}}{2}\right) A_{n 3}\left(\frac{4(a+r)^{3}}{3 \pi}\right) A_{n 0 r} \end{array}\right]_{n \times 5}\left[\begin{array}{c} M_{0} \\ M_{1} \\ M_{2} \\ M_{3} \\ M_{0 r} \end{array}\right]_{5 \times 1}=\left[\begin{array}{c} K_{1} \\ \vdots \\ K_{n} \end{array}\right]_{n \times 1}(6)π(a+r)[A10A11(2(a+r)π)A12((a+r)22)A13(4(a+r)33π)A10rAn0An1(2(a+r)π)An2((a+r)22)An3(4(a+r)33π)An0r]n×5[M0M1M2M3M0r]5×1=[K1Kn]n×1
Based on expression (4), we write a system of equations to determine the shape coefficients for the ICM method. In this variant, the least-squares method is used to obtain a more accurate solution based on the shape coefficient values presented in Tab. 2 - Tab. 5.
(7) π ( a + r ) [ σ 10 σ 11 ( a + r b + r ) σ 12 ( a + r b + r ) 2 σ 13 ( a + r b + r ) 3 σ 10 r σ 11 r ( a + r b + r ) σ n 0 σ n 1 ( a + r b + r ) σ n 2 ( a + r b + r ) 2 σ n 3 ( a + r b + r ) 3 σ n 0 r σ n 1 r ( a + r b + r ) ] n × 6 [ i 0 i 1 i 2 i 3 i 0 r i 1 r ] 6 × 1 = [ K 1 K n ] n × 1 (7) π ( a + r ) σ 10 σ 11 a + r b + r σ 12 a + r b + r 2 σ 13 a + r b + r 3 σ 10 r σ 11 r a + r b + r σ n 0 σ n 1 a + r b + r σ n 2 a + r b + r 2 σ n 3 a + r b + r 3 σ n 0 r σ n 1 r a + r b + r n × 6 i 0 i 1 i 2 i 3 i 0 r i 1 r 6 × 1 = K 1 K n n × 1 {:(7)sqrt(pi(a+r))*[[sigma_(10)sigma_(11)((a+r)/(b+r))sigma_(12)((a+r)/(b+r))^(2)sigma_(13)((a+r)/(b+r))^(3)sigma_(10 r)sigma_(11 r)((a+r)/(b+r))],[vdots],[sigma_(n0)sigma_(n1)((a+r)/(b+r))sigma_(n2)((a+r)/(b+r))^(2)sigma_(n3)((a+r)/(b+r))^(3)sigma_(n0r)sigma_(n1r)((a+r)/(b+r))]]_(n xx6)[[i_(0)],[i_(1)],[i_(2)],[i_(3)],[i_(0r)],[i_(1r)]]_(6xx1)=[[K_(1)],[vdots],[K_(n)]]_(n xx1):}\sqrt{\pi(a+r)} \cdot\left[\begin{array}{c} \sigma_{10} \sigma_{11}\left(\frac{a+r}{b+r}\right) \sigma_{12}\left(\frac{a+r}{b+r}\right)^{2} \sigma_{13}\left(\frac{a+r}{b+r}\right)^{3} \sigma_{10 r} \sigma_{11 r}\left(\frac{a+r}{b+r}\right) \tag{7}\\ \vdots \\ \sigma_{n 0} \sigma_{n 1}\left(\frac{a+r}{b+r}\right) \sigma_{n 2}\left(\frac{a+r}{b+r}\right)^{2} \sigma_{n 3}\left(\frac{a+r}{b+r}\right)^{3} \sigma_{n 0 r} \sigma_{n 1 r}\left(\frac{a+r}{b+r}\right) \end{array}\right]_{n \times 6}\left[\begin{array}{l} i_{0} \\ i_{1} \\ i_{2} \\ i_{3} \\ i_{0 r} \\ i_{1 r} \end{array}\right]_{6 \times 1}=\left[\begin{array}{l} K_{1} \\ \vdots \\ K_{n} \end{array}\right]_{n \times 1}(7)π(a+r)[σ10σ11(a+rb+r)σ12(a+rb+r)2σ13(a+rb+r)3σ10rσ11r(a+rb+r)σn0σn1(a+rb+r)σn2(a+rb+r)2σn3(a+rb+r)3σn0rσn1r(a+rb+r)]n×6[i0i1i2i3i0ri1r]6×1=[K1Kn]n×1
Equation systems (6) and (7) are formulated for a through-clad defects. However, by excluding the cladding thickness r and the corresponding coefficients M 0 r , i 0 r , i 1 r M 0 r , i 0 r , i 1 r M_(0r),i_(0r),i_(1r)\mathrm{M}_{0 r}, i_{0 r}, i_{1 r}M0r,i0r,i1r, these equations can be adapted for a subclad defect. Equation systems (6) and (7) differ not only in the coefficients associated with the stress polynomial terms, but also in the form of the polynomials themselves. The polynomial expansion expressions are presented below: Eqn. (8) is used for system (6), whereas Eqn. (9) is applied to system (7).
(8) σ = A 0 + A 1 x + A 2 x 2 + A 3 x 3 (9) σ = σ 0 + σ 1 x b + r + σ 2 ( x b + r ) 2 + σ 3 ( x b + r ) 3 (8) σ = A 0 + A 1 x + A 2 x 2 + A 3 x 3 (9) σ = σ 0 + σ 1 x b + r + σ 2 x b + r 2 + σ 3 x b + r 3 {:[(8)sigma=A_(0)+A_(1)x+A_(2)x^(2)+A_(3)x^(3)],[(9)sigma=sigma_(0)+sigma_(1)(x)/(b+r)+sigma_(2)((x)/(b+r))^(2)+sigma_(3)((x)/(b+r))^(3)]:}\begin{align*} & \sigma=A_{0}+A_{1} x+A_{2} x^{2}+A_{3} x^{3} \tag{8}\\ & \sigma=\sigma_{0}+\sigma_{1} \frac{x}{b+r}+\sigma_{2}\left(\frac{x}{b+r}\right)^{2}+\sigma_{3}\left(\frac{x}{b+r}\right)^{3} \tag{9} \end{align*}(8)σ=A0+A1x+A2x2+A3x3(9)σ=σ0+σ1xb+r+σ2(xb+r)2+σ3(xb+r)3

Coefficients determined by least squares method

The least-squares method requires a large amount of input data to determine the average solution, so the system of Eqns. (7) must be overdetermined. During the first iteration of this method, 10 boundary states representing the theoretical operating conditions of the reactor vessel were specified. However, during simulations of real accident scenarios, the stress intensity factor values calculated using the obtained coefficients showed significant errors, exceeding 10 % 10 % 10%10 \%10% in some cases. This indicates that the specified set of boundary conditions does not fully capture the conditions encountered in real accident scenarios. In this regard, an attempt was made to form a system of Eqns. (7) based on two emergency scenarios, followed by verification of the accuracy of calculations for three other scenarios.
The left side of Fig. 8 presents the stress distributions for two accident scenarios. The LOCA scenario is characterized as a transient process with a large temperature gradient across the reactor vessel wall thickness under low internal pressure. The OTHER scenario is characterized as a transient process with combined loading due to pressure and temperature gradient, or a low temperature gradient and high internal pressure. Also, for the solution, it is necessary to have the SIF value for each type and size of crack. The right side of Fig. 8 shows the SIF value for a through-clad defect with a depth of 10 % 10 % 10%10 \%10% and a half-axis ratio of 0.3 .
Figure 8: Stress at the defect location and SIF for a through-clad defect depth of 10 % 10 % 10%10 \%10%.
To determine the coefficients i 0.3 , 10 , r 1 i 0.3 , 10 , r 1 i_(0.3,10,r1)i_{0.3,10, r 1}i0.3,10,r1, we will write down the system of Eqns. (7) for each type and size of crack. As a first approximation, the results from Tab. 2 2 2-2-2 Tab. 5 were used. In the operating temperature range of the RPV, the ratio of the Young's moduli of the cladding and base metal is almost constant and approximately equal to 0.78 . Therefore, the interpolated values of the shape coefficients were used for the calculation. This system is overdetermined, so the values of i 0 . .3 , r 0 , r 1 i 0 . .3 , r 0 , r 1 i_(0..3,r0,r1)i_{0 . .3, r 0, r 1}i0..3,r0,r1 and must satisfy all values of the system.
Size, % i 0 i 0 i_(0)i_{0}i0 i 1 i 1 i_(1)i_{1}i1 i 2 i 2 i_(2)i_{2}i2 i 3 i 3 i_(3)i_{3}i3 i r 0 i r 0 i_(r0)i_{r 0}ir0 i r 1 i r 1 i_(r1)i_{r 1}ir1
E 1 / E 2 = 1 E 1 / E 2 = 1 E_(1)//E_(2)=1E_{1} / E_{2}=1E1/E2=1 5 0.9512 0.5421 0.3560 0.1964 0.2316 0.0425
7.5 0.9479 0.5485 0.4216 0.6293 0.1789 0.0258
10 0.9412 0.5501 0.4244 0.5182 0.1449 0.0164
12.5 0.9348 0.5568 0.4482 0.5153 0.1194 0.0103
15 0.9118 0.5132 0.3226 0.1222 0.1057 0.0078
E 1 / E 2 = 0.7 E 1 / E 2 = 0.7 E_(1)//E_(2)=0.7E_{1} / E_{2}=0.7E1/E2=0.7 5 0.7045 0.4408 0.2907 0.2014 0.1259 0.0276
7.5 0.7317 0.4649 0.3813 0.6321 0.1042 0.0173
10 0.7440 0.4698 0.3588 0.3803 0.0890 0.0113
12.5 0.7507 0.4775 0.3681 0.3351 0.0769 0.0073
15 0.7559 0.4827 0.3759 0.3249 0.0668 0.0049
Size, % i_(0) i_(1) i_(2) i_(3) i_(r0) i_(r1) E_(1)//E_(2)=1 5 0.9512 0.5421 0.3560 0.1964 0.2316 0.0425 7.5 0.9479 0.5485 0.4216 0.6293 0.1789 0.0258 10 0.9412 0.5501 0.4244 0.5182 0.1449 0.0164 12.5 0.9348 0.5568 0.4482 0.5153 0.1194 0.0103 15 0.9118 0.5132 0.3226 0.1222 0.1057 0.0078 E_(1)//E_(2)=0.7 5 0.7045 0.4408 0.2907 0.2014 0.1259 0.0276 7.5 0.7317 0.4649 0.3813 0.6321 0.1042 0.0173 10 0.7440 0.4698 0.3588 0.3803 0.0890 0.0113 12.5 0.7507 0.4775 0.3681 0.3351 0.0769 0.0073 15 0.7559 0.4827 0.3759 0.3249 0.0668 0.0049| | Size, % | $i_{0}$ | $i_{1}$ | $i_{2}$ | $i_{3}$ | $i_{r 0}$ | $i_{r 1}$ | | :--- | :--- | :--- | :--- | :--- | :--- | :--- | :--- | | $E_{1} / E_{2}=1$ | 5 | 0.9512 | 0.5421 | 0.3560 | 0.1964 | 0.2316 | 0.0425 | | | 7.5 | 0.9479 | 0.5485 | 0.4216 | 0.6293 | 0.1789 | 0.0258 | | | 10 | 0.9412 | 0.5501 | 0.4244 | 0.5182 | 0.1449 | 0.0164 | | | 12.5 | 0.9348 | 0.5568 | 0.4482 | 0.5153 | 0.1194 | 0.0103 | | | 15 | 0.9118 | 0.5132 | 0.3226 | 0.1222 | 0.1057 | 0.0078 | | $E_{1} / E_{2}=0.7$ | 5 | 0.7045 | 0.4408 | 0.2907 | 0.2014 | 0.1259 | 0.0276 | | | 7.5 | 0.7317 | 0.4649 | 0.3813 | 0.6321 | 0.1042 | 0.0173 | | | 10 | 0.7440 | 0.4698 | 0.3588 | 0.3803 | 0.0890 | 0.0113 | | | 12.5 | 0.7507 | 0.4775 | 0.3681 | 0.3351 | 0.0769 | 0.0073 | | | 15 | 0.7559 | 0.4827 | 0.3759 | 0.3249 | 0.0668 | 0.0049 |
Table 8: Refined Chapuliot coefficients TCD.
Size, % i 0 i 0 i_(0)i_{0}i0 i 1 i 1 i_(1)i_{1}i1 i 2 i 2 i_(2)i_{2}i2 i 3 i 3 i_(3)i_{3}i3
E 1 / E 2 = 1 E 1 / E 2 = 1 E_(1)//E_(2)=1E_{1} / E_{2}=1E1/E2=1 5 0.7144 0.5577 0.4730 0.8785
7.5 0.7228 0.5516 0.4932 0.9121
10 0.7280 0.5418 0.4572 0.5983
12.5 0.7299 0.5387 0.4560 0.5134
15 0.7178 0.5005 0.3455 0.1666
E 1 / E 2 = 0.7 E 1 / E 2 = 0.7 E_(1)//E_(2)=0.7E_{1} / E_{2}=0.7E1/E2=0.7 5 0.6331 0.4981 0.3957 0.6587
7.5 0.6414 0.4988 0.4529 0.8715
10 0.6470 0.4873 0.3932 0.4395
12.5 0.6496 0.4831 0.3816 0.3321
15 0.6520 0.4818 0.3836 0.3185
Size, % i_(0) i_(1) i_(2) i_(3) E_(1)//E_(2)=1 5 0.7144 0.5577 0.4730 0.8785 7.5 0.7228 0.5516 0.4932 0.9121 10 0.7280 0.5418 0.4572 0.5983 12.5 0.7299 0.5387 0.4560 0.5134 15 0.7178 0.5005 0.3455 0.1666 E_(1)//E_(2)=0.7 5 0.6331 0.4981 0.3957 0.6587 7.5 0.6414 0.4988 0.4529 0.8715 10 0.6470 0.4873 0.3932 0.4395 12.5 0.6496 0.4831 0.3816 0.3321 15 0.6520 0.4818 0.3836 0.3185| | Size, % | $i_{0}$ | $i_{1}$ | $i_{2}$ | $i_{3}$ | | :--- | :--- | :--- | :--- | :--- | :--- | | $E_{1} / E_{2}=1$ | 5 | 0.7144 | 0.5577 | 0.4730 | 0.8785 | | | 7.5 | 0.7228 | 0.5516 | 0.4932 | 0.9121 | | | 10 | 0.7280 | 0.5418 | 0.4572 | 0.5983 | | | 12.5 | 0.7299 | 0.5387 | 0.4560 | 0.5134 | | | 15 | 0.7178 | 0.5005 | 0.3455 | 0.1666 | | $E_{1} / E_{2}=0.7$ | 5 | 0.6331 | 0.4981 | 0.3957 | 0.6587 | | | 7.5 | 0.6414 | 0.4988 | 0.4529 | 0.8715 | | | 10 | 0.6470 | 0.4873 | 0.3932 | 0.4395 | | | 12.5 | 0.6496 | 0.4831 | 0.3816 | 0.3321 | | | 15 | 0.6520 | 0.4818 | 0.3836 | 0.3185 |
Table 9: Refined Chapuliot coefficients UCC.
Fig. 9 and Fig. 10 show the results for other groups of accident scenarios. The graphs show the results of FEM and those based on the refined coefficients determined by system (7). The results for all types of cracks are similar, so only one scenario for one type of crack is presented. It can be seen that the coefficients obtained by the least-squares method are more accurate than those determined by the direct ICM.
Figure 9: SIF in time for LOCA and MSLB test accident scenarios, a / c = 0.3 a / c = 0.3 a//c=0.3\mathrm{a} / \mathrm{c}=0.3a/c=0.3.
Figure 10: SIF in time for PRISE and OTHER test accident scenarios, a / c = 0.7 a / c = 0.7 a//c=0.7\mathrm{a} / \mathrm{c}=0.7a/c=0.7.

Generalized solution for all crack sizes

Modification of the ellipticity factor

The ellipticity factor Q Q QQQ is used as a convenient unifying parameter to describe the influence of the semi-elliptical crack tip shape on the stress intensity factor. It is included in the geometry (shape) function and accounts for the effect of the ratio of crack depth to its half-length, a / c a / c a//c\mathrm{a} / \mathrm{c}a/c, which determines the curvature of the crack tip. As a result, the complex three-dimensional geometry of a semi-elliptical crack tip can be represented by a single dimensionless parameter, thereby significantly simplifying engineering calculations. The use of this coefficient ensures the standardization of analytical approaches while simplifying the evaluation procedure. This is why the ellipticity coefficient has become widely used in engineering methods for crack analysis and has been incorporated into a number of regulatory documents, including the API 579-1/ASME FFS-1 standards [7] and the ASME Code for Boilers and Pressure Vessels, Section XI [8]. The ellipticity factor can be determined from expression (10).
(10) Q = 1 + 1.464 ( a c ) 1.65 (10) Q = 1 + 1.464 a c 1.65 {:(10)Q=1+1.464((a)/(c))^(1.65):}\begin{equation*} Q=1+1.464\left(\frac{a}{c}\right)^{1.65} \tag{10} \end{equation*}(10)Q=1+1.464(ac)1.65
The ellipticity factor reported in the literature was derived from the complete elliptic integral of the second kind, which effectively corresponds to the dimensionless length of a quarter of the ellipse's arc. This approach is appropriate when the classical semi-elliptical shape approximates the crack tip. However, in the actual nozzle geometry, the crack is located at the radius fillet, and its crack tip does not extend to an angle of π / 2 π / 2 pi//2\pi / 2π/2, leading to a deviation from the classical geometric model. Therefore, in this work, it is proposed to use modified ellipticity factors obtained from numerical calculations using the finite element method.
We determine the ratio SIF 0.3 / SIF 0.7 SIF 0.3 / SIF 0.7 SIF_(0.3)//SIF_(0.7)\mathrm{SIF}_{0.3} / \mathrm{SIF}_{0.7}SIF0.3/SIF0.7 based on the FEM results. Fig. 11 shows the dependence of this ratio on the crack size, with each curve corresponding to a separate time step in the accident scenario.
An analysis of results for a non-stationary thermal process reveals variability in defect behavior. A high stability of the SIF ratio characterizes defects located beneath the austenitic cladding. The cladding acts as a thermal and mechanical barrier, smoothing the thermal gradient and ensuring the constancy of boundary conditions. In this case, the effect of ellipticity remains predictable and is almost independent of the crack size or the stage of thermal shock. For cracks that extend directly to the surface of a fillet, there is significant variability in the values of the ratio SIF 0.3 / SIF 0.7 SIF 0.3 / SIF 0.7 SIF_(0.3)//SIF_(0.7)\mathrm{SIF}_{0.3} / \mathrm{SIF}_{0.7}SIF0.3/SIF0.7, which depends on both the defect size and the calculated step of the accident scenario. This is because, unlike under-cladding defects, where the austenitic cladding mechanically restrains the opening of the crack edges, a surface crack lacks this stabilizing effect. Accordingly, we observe the defect's response to an increase in size, leading to its front covering a larger area of the metal. This means that the defect interacts with a broader range of local boundary conditions, determined by both the fillet curvature and the significant length of the front, through which the surface crack introduces significant irregularities in the temperature field.
Figure 11: The relationship between S I F 0.3 S I F 0.3 SIF_(0.3)S I F_{0.3}SIF0.3 and S I F 0.7 S I F 0.7 SIF_(0.7)S I F_{0.7}SIF0.7 with respect to the relative crack depth.
Let's express the ratio SIF 0.3 / SIF 0.7 SIF 0.3 / SIF 0.7 SIF_(0.3)//SIF_(0.7)\mathrm{SIF}_{0.3} / \mathrm{SIF}_{0.7}SIF0.3/SIF0.7 using the generalized SIF equation with a geometric shape factor for cracks with ellipticity of 0.3 and 0.7 .
(11) K 0 , 3 K 0 , 7 = σ π a Q 0 , 3 σ π a Q 0 , 7 (11) K 0 , 3 K 0 , 7 = σ π a Q 0 , 3 σ π a Q 0 , 7 {:(11)(K_(0,3))/(K_(0,7))=(sigma*sqrt((pi a)/(Q_(0,3))))/(sigma*sqrt((pi a)/(Q_(0,7)))):}\begin{equation*} \frac{K_{0,3}}{K_{0,7}}=\frac{\sigma \cdot \sqrt{\frac{\pi a}{Q_{0,3}}}}{\sigma \cdot \sqrt{\frac{\pi a}{Q_{0,7}}}} \tag{11} \end{equation*}(11)K0,3K0,7=σπaQ0,3σπaQ0,7
After simplifying the expression, we find that the ratio does not depend on the crack depth, but depends solely on the ellipticity factor Q .
(12) Q 0 , 7 Q 0 , 3 = ( K 0 , 3 K 0 , 7 ) 2 = X (12) Q 0 , 7 Q 0 , 3 = K 0 , 3 K 0 , 7 2 = X {:(12)(Q_(0,7))/(Q_(0,3))=((K_(0,3))/(K_(0,7)))^(2)=X:}\begin{equation*} \frac{Q_{0,7}}{Q_{0,3}}=\left(\frac{K_{0,3}}{K_{0,7}}\right)^{2}=X \tag{12} \end{equation*}(12)Q0,7Q0,3=(K0,3K0,7)2=X
Let's write down the expression 10 in terms of the coefficients A and B , and substitute it into Eqn. (12) to get
(13) B = A ( 1 X ) X ( a c 0.3 ) 1.65 ( a c 0.7 ) 1.65 (13) B = A ( 1 X ) X a c 0.3 1.65 a c 0.7 1.65 {:(13)B=(A*(1-X))/(X*((a)/(c_(0.3)))^(1.65)-((a)/(c_(0.7)))^(1.65)):}\begin{equation*} B=\frac{A \cdot(1-X)}{X \cdot\left(\frac{a}{c_{0.3}}\right)^{1.65}-\left(\frac{a}{c_{0.7}}\right)^{1.65}} \tag{13} \end{equation*}(13)B=A(1X)X(ac0.3)1.65(ac0.7)1.65
Using expression 13, we will find the coefficient B for each crack when A = 1 A = 1 A=1\mathrm{A}=1A=1. The surface crack is constructed such that the thickness of the weld deposit increases the depth a but does not increase the major axis c of the ellipse; therefore, this must be taken into account when determining the coefficient B. Based on the calculations, a linear function describing the variation in the coefficient B was derived, generalizing the solution across five crack sizes. The expressions for determining the shape coefficient will take the following form:
(14) Q U C C = 1 + ( 0.384 a t + 0.761 ) ( a / c ) 1.65 (14) Q U C C = 1 + 0.384 a t + 0.761 ( a / c ) 1.65 {:(14)Q_(UCC)=1+(-0.384*(a)/(t)+0.761)*(a//c)^(1.65):}\begin{equation*} Q_{U C C}=1+\left(-0.384 \cdot \frac{a}{t}+0.761\right) \cdot(a / c)^{1.65} \tag{14} \end{equation*}(14)QUCC=1+(0.384at+0.761)(a/c)1.65
(15) Q T C C = 1 + ( 2.85 a t + 1.766 ) ( a / c ) 1.65 (15) Q T C C = 1 + 2.85 a t + 1.766 ( a / c ) 1.65 {:(15)Q_(TCC)=1+(-2.85*(a)/(t)+1.766)*(a//c)^(1.65):}\begin{equation*} Q_{T C C}=1+\left(-2.85 \cdot \frac{a}{t}+1.766\right) \cdot(a / c)^{1.65} \tag{15} \end{equation*}(15)QTCC=1+(2.85at+1.766)(a/c)1.65

Single equation for through-clad and underclad defects

The use of exact solutions is sometimes redundant and only complicates calculations, particularly when determining SIF for intermediate crack sizes. In view of this, a generalized approach was developed based on the system of Eqns. (6), allowing for solutions to be found for defects with depths ranging from 5 % 5 % 5%5 \%5% to 15 % 15 % 15%15 \%15% of the wall thickness and for arbitrary crack ellipticity. To improve the results, a modified elliptical coefficient was applied using expressions (14) and (15) for underclad and surface cracks, respectively. The final mathematical dependencies for calculating the SIF are presented in the form of Eqns. (16) and (17).
The data presented in Fig. 8 was used for the calculation. Tab. 10 ppresents the generalized shape coefficients for throughclad defects and underclad defects.
(16) K 1 = [ A 0 M 0 + A 1 ( 2 a π ) M 1 + A 2 ( a 2 2 ) M 2 + A 3 ( 4 a 3 3 π ) M 3 ] π a Q U C C (17) K 1 = [ A 0 M 0 + A 1 ( 2 a π ) M 1 + A 2 ( a 2 2 ) M 2 + A 3 ( 4 a 3 3 π ) M 3 + A 0 r M 0 r ] π a Q T C C (16) K 1 = A 0 M 0 + A 1 2 a π M 1 + A 2 a 2 2 M 2 + A 3 4 a 3 3 π M 3 π a Q U C C (17) K 1 = A 0 M 0 + A 1 2 a π M 1 + A 2 a 2 2 M 2 + A 3 4 a 3 3 π M 3 + A 0 r M 0 r π a Q T C C {:[(16)K_(1)=[A_(0)M_(0)+A_(1)((2a)/(pi))M_(1)+A_(2)((a^(2))/(2))M_(2)+A_(3)((4a^(3))/(3pi))M_(3)]sqrt((pi a)/(Q_(UCC)))],[(17)K_(1)=[A_(0)M_(0)+A_(1)((2a)/(pi))M_(1)+A_(2)((a^(2))/(2))M_(2)+A_(3)((4a^(3))/(3pi))M_(3)+A_(0r)M_(0r)]sqrt((pi a)/(Q_(TCC)))]:}\begin{align*} & K_{1}=\left[A_{0} M_{0}+A_{1}\left(\frac{2 a}{\pi}\right) M_{1}+A_{2}\left(\frac{a^{2}}{2}\right) M_{2}+A_{3}\left(\frac{4 a^{3}}{3 \pi}\right) M_{3}\right] \sqrt{\frac{\pi a}{Q_{U C C}}} \tag{16}\\ & K_{1}=\left[A_{0} M_{0}+A_{1}\left(\frac{2 a}{\pi}\right) M_{1}+A_{2}\left(\frac{a^{2}}{2}\right) M_{2}+A_{3}\left(\frac{4 a^{3}}{3 \pi}\right) M_{3}+A_{0 r} M_{0 r}\right] \sqrt{\frac{\pi a}{Q_{T C C}}} \tag{17} \end{align*}(16)K1=[A0M0+A1(2aπ)M1+A2(a22)M2+A3(4a33π)M3]πaQUCC(17)K1=[A0M0+A1(2aπ)M1+A2(a22)M2+A3(4a33π)M3+A0rM0r]πaQTCC
M 0 M 0 M_(0)M_{0}M0 M 1 M 1 M_(1)M_{1}M1 M 2 M 2 M_(2)M_{2}M2 M 3 M 3 M_(3)M_{3}M3 M r 0 M r 0 M_(r0)M_{r 0}Mr0
UCC 0.7394 0.9862 0.9616 0.0399 -
TCC 1.0865 1.1753 1.3892 2.1169 0.1042
M_(0) M_(1) M_(2) M_(3) M_(r0) UCC 0.7394 0.9862 0.9616 0.0399 - TCC 1.0865 1.1753 1.3892 2.1169 0.1042| | $M_{0}$ | $M_{1}$ | $M_{2}$ | $M_{3}$ | $M_{r 0}$ | | :---: | :---: | :---: | :---: | :---: | :---: | | UCC | 0.7394 | 0.9862 | 0.9616 | 0.0399 | - | | TCC | 1.0865 | 1.1753 | 1.3892 | 2.1169 | 0.1042 |
Table 10: Generalized coefficients.
Fig. 12 and Fig. 13 present the results of the SIF calculations during the accident scenario. The calculations were performed using the generalized shape factor values given in Tab. 10. The graphs presented show that the results obtained using the generalized solution are in good agreement with those from the FEM. For the largest crack, a slight underestimation of the stress intensity factor values is observed, whereas for smaller cracks the calculated SIF values are conservative. Overall, this indicates acceptable accuracy of the proposed generalized approach for analyzing accident scenarios.
Figure 12: SIF in time for LOCA and PRISE test accident scenarios, UCC.
Figure 13: SIF in time for MSLB and OTHER test accident scenarios, a / c = 0.7 a / c = 0.7 a//c=0.7\mathrm{a} / \mathrm{c}=0.7a/c=0.7.

Conclusions

This study assessed analytical methods for evaluating stress intensity factors in cladded WWER reactor pressurevessel nozzles under pressurized thermal-shock conditions. The following conclusions can be drawn:
  • Accurate representation of the stress discontinuity introduced by corrosion-resistant cladding is essential, particularly for shallow surface and through-clad defects; neglecting this effect can lead to SIF deviations on the order of 20 % 20 % 20%20 \%20% for small cracks.
  • The influence coefficient method delivers accurate SIF estimates but requires high-quality finite element meshes and careful numerical implementation near the crack front.
  • The least-squares refinement improves robustness and accuracy when calibrated using representative transient scenarios and yields coefficients that reproduce finite-element reference SIF values with deviations of approximately 2 % 2 % 2%2 \%2% for the verification cases considered.
    Overall, the proposed coefficients and the generalized solution offer a practical, computationally efficient tool for engineering fracture assessments of cladded WWER nozzle regions.

Nomenclature

R i R i R_(i)\mathrm{R}_{i}Ri inner radius of vessel
r cladding thickness
b b bbb thickness of the ferritic vessel
E , μ E , μ E,muE, \muE,μ Young's modulus, Poisson ratio
σ σ sigma\sigmaσ normal to the crack surface stress
i i iii polynomial coefficients
K I K I K_(I)K_{I}KI stress intensity factor
J J integral (Jint)
c , a c , a c,ac, ac,a crack length, crack depth
Q elliptical coefficient
σ j , A j σ j , A j sigma_(j),A_(j)\sigma_{j}, A_{j}σj,Aj stress polynomial coefficients
i j , M j i j , M j i_(j),M_(j)i_{j}, M_{j}ij,Mj shape factors
RPV Reactor Pressure Vessel
SIF Stress Intensity Factor
FEM Finite Element Method / Finite Element Model
PTS Pressurized thermal shock
ICM Influence coefficient method
LSM Least square method
FEM/FEA Finite element model/analysis
R_(i) inner radius of vessel r cladding thickness b thickness of the ferritic vessel E,mu Young's modulus, Poisson ratio sigma normal to the crack surface stress i polynomial coefficients K_(I) stress intensity factor J J integral (Jint) c,a crack length, crack depth Q elliptical coefficient sigma_(j),A_(j) stress polynomial coefficients i_(j),M_(j) shape factors RPV Reactor Pressure Vessel SIF Stress Intensity Factor FEM Finite Element Method / Finite Element Model PTS Pressurized thermal shock ICM Influence coefficient method LSM Least square method FEM/FEA Finite element model/analysis| $\mathrm{R}_{i}$ | inner radius of vessel | | :--- | :--- | | r | cladding thickness | | $b$ | thickness of the ferritic vessel | | $E, \mu$ | Young's modulus, Poisson ratio | | $\sigma$ | normal to the crack surface stress | | $i$ | polynomial coefficients | | $K_{I}$ | stress intensity factor | | J | J integral (Jint) | | $c, a$ | crack length, crack depth | | Q | elliptical coefficient | | $\sigma_{j}, A_{j}$ | stress polynomial coefficients | | $i_{j}, M_{j}$ | shape factors | | RPV | Reactor Pressure Vessel | | SIF | Stress Intensity Factor | | FEM | Finite Element Method / Finite Element Model | | PTS | Pressurized thermal shock | | ICM | Influence coefficient method | | LSM | Least square method | | FEM/FEA | Finite element model/analysis |

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