Numerical Simulation of Tee Pipe Failure Under Mixed Mode-I/III Loading

Lu Wang; Yujun Xie; Kaile Wang; Yihan Kang; Bingxue Wang; Yuqing Du

doi:doi:10.11648/j.ajee.20251302.12

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| Peer-Reviewed

Numerical Simulation of Tee Pipe Failure Under Mixed Mode-I/III Loading

Lu Wang

, Yujun Xie^*

, Kaile Wang

, Yihan Kang

, Bingxue Wang

, Yuqing Du

Published in American Journal of Energy Engineering (Volume 13, Issue 2)

Received: 8 May 2025 Accepted: 3 June 2025 Published: 11 June 2025

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Abstract

This study probes the brittle fracture mechanisms of an S32205 duplex stainless steel tee pipe (DN300×10 mm) subjected to mixed-mode I/III loading under internal pressures spanning 10 to 30 MPa, leveraging advanced finite element analysis to address reliability concerns in high-pressure oil and gas transport systems. Drawing on recent fracture mechanics insights, an energy-driven three-dimensional framework was formulated to forecast crack propagation, emphasizing metallurgical flaws such as micro-cracks and σ-phase precipitates across varied pressure conditions. By partitioning the crack tip into discrete zones, the model calculates energy release rates and stress intensity factors (K_I, K_III, K_eff) for crack morphologies, including trifurcation, symmetric branching, and lateral bifurcation. Findings reveal that Mode I stresses maximize at the crack’s deepest point (90°), with K_I and K_eff exhibiting nonlinear escalation as pressure, crack depth-to-length ratio (a/c), and crack half-length (c) increase, portending elevated risks of unstable crack advancement. Mode III stresses, peaking at 60° and 120°, induce localized tearing, with K_III displaying marked sensitivity to pressure fluctuations. Pressure-amplified stress concentrations at the branch neck and main pipe abdomen corroborate chevron fracture patterns observed in duplex stainless steel tests, affirming the model’s fidelity. The results elucidate the synergistic degradation of fracture toughness by micro-cracks, σ-phase, and pressure-induced stresses, precipitating brittle failure. Heat treatment at 1030°C with water quenching to mitigate σ-phase and periodic ultrasonic inspections are advocated to bolster tee pipe durability in rigorous oilfield settings.

Published in	American Journal of Energy Engineering (Volume 13, Issue 2)
DOI	10.11648/j.ajee.20251302.12
Page(s)	54-66
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2025. Published by Science Publishing Group

Keywords

Tee Pipe Failure, Mixed-mode I/III Loading, Brittle Fracture, S32205 Duplex Stainless Steel, Energy-based Model, Stress Intensity Factor

References

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APA Style

Wang, L., Xie, Y., Wang, K., Kang, Y., Wang, B., et al. (2025). Numerical Simulation of Tee Pipe Failure Under Mixed Mode-I/III Loading. American Journal of Energy Engineering, 13(2), 54-66. https://doi.org/10.11648/j.ajee.20251302.12

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ACS Style

Wang, L.; Xie, Y.; Wang, K.; Kang, Y.; Wang, B., et al. Numerical Simulation of Tee Pipe Failure Under Mixed Mode-I/III Loading. Am. J. Energy Eng. 2025, 13(2), 54-66. doi: 10.11648/j.ajee.20251302.12

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AMA Style

Wang L, Xie Y, Wang K, Kang Y, Wang B, et al. Numerical Simulation of Tee Pipe Failure Under Mixed Mode-I/III Loading. Am J Energy Eng. 2025;13(2):54-66. doi: 10.11648/j.ajee.20251302.12

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@article{10.11648/j.ajee.20251302.12,
  author = {Lu Wang and Yujun Xie and Kaile Wang and Yihan Kang and Bingxue Wang and Yuqing Du},
  title = {Numerical Simulation of Tee Pipe Failure Under Mixed Mode-I/III Loading
},
  journal = {American Journal of Energy Engineering},
  volume = {13},
  number = {2},
  pages = {54-66},
  doi = {10.11648/j.ajee.20251302.12},
  url = {https://doi.org/10.11648/j.ajee.20251302.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ajee.20251302.12},
  abstract = {This study probes the brittle fracture mechanisms of an S32205 duplex stainless steel tee pipe (DN300×10 mm) subjected to mixed-mode I/III loading under internal pressures spanning 10 to 30 MPa, leveraging advanced finite element analysis to address reliability concerns in high-pressure oil and gas transport systems. Drawing on recent fracture mechanics insights, an energy-driven three-dimensional framework was formulated to forecast crack propagation, emphasizing metallurgical flaws such as micro-cracks and σ-phase precipitates across varied pressure conditions. By partitioning the crack tip into discrete zones, the model calculates energy release rates and stress intensity factors (KI, KIII, Keff) for crack morphologies, including trifurcation, symmetric branching, and lateral bifurcation. Findings reveal that Mode I stresses maximize at the crack’s deepest point (90°), with KI and Keff exhibiting nonlinear escalation as pressure, crack depth-to-length ratio (a/c), and crack half-length (c) increase, portending elevated risks of unstable crack advancement. Mode III stresses, peaking at 60° and 120°, induce localized tearing, with KIII displaying marked sensitivity to pressure fluctuations. Pressure-amplified stress concentrations at the branch neck and main pipe abdomen corroborate chevron fracture patterns observed in duplex stainless steel tests, affirming the model’s fidelity. The results elucidate the synergistic degradation of fracture toughness by micro-cracks, σ-phase, and pressure-induced stresses, precipitating brittle failure. Heat treatment at 1030°C with water quenching to mitigate σ-phase and periodic ultrasonic inspections are advocated to bolster tee pipe durability in rigorous oilfield settings.
},
 year = {2025}
}

Copy | Download

TY  - JOUR
T1  - Numerical Simulation of Tee Pipe Failure Under Mixed Mode-I/III Loading

AU  - Lu Wang
AU  - Yujun Xie
AU  - Kaile Wang
AU  - Yihan Kang
AU  - Bingxue Wang
AU  - Yuqing Du
Y1  - 2025/06/11
PY  - 2025
N1  - https://doi.org/10.11648/j.ajee.20251302.12
DO  - 10.11648/j.ajee.20251302.12
T2  - American Journal of Energy Engineering
JF  - American Journal of Energy Engineering
JO  - American Journal of Energy Engineering
SP  - 54
EP  - 66
PB  - Science Publishing Group
SN  - 2329-163X
UR  - https://doi.org/10.11648/j.ajee.20251302.12
AB  - This study probes the brittle fracture mechanisms of an S32205 duplex stainless steel tee pipe (DN300×10 mm) subjected to mixed-mode I/III loading under internal pressures spanning 10 to 30 MPa, leveraging advanced finite element analysis to address reliability concerns in high-pressure oil and gas transport systems. Drawing on recent fracture mechanics insights, an energy-driven three-dimensional framework was formulated to forecast crack propagation, emphasizing metallurgical flaws such as micro-cracks and σ-phase precipitates across varied pressure conditions. By partitioning the crack tip into discrete zones, the model calculates energy release rates and stress intensity factors (KI, KIII, Keff) for crack morphologies, including trifurcation, symmetric branching, and lateral bifurcation. Findings reveal that Mode I stresses maximize at the crack’s deepest point (90°), with KI and Keff exhibiting nonlinear escalation as pressure, crack depth-to-length ratio (a/c), and crack half-length (c) increase, portending elevated risks of unstable crack advancement. Mode III stresses, peaking at 60° and 120°, induce localized tearing, with KIII displaying marked sensitivity to pressure fluctuations. Pressure-amplified stress concentrations at the branch neck and main pipe abdomen corroborate chevron fracture patterns observed in duplex stainless steel tests, affirming the model’s fidelity. The results elucidate the synergistic degradation of fracture toughness by micro-cracks, σ-phase, and pressure-induced stresses, precipitating brittle failure. Heat treatment at 1030°C with water quenching to mitigate σ-phase and periodic ultrasonic inspections are advocated to bolster tee pipe durability in rigorous oilfield settings.

VL  - 13
IS  - 2
ER  -

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Author Information

Lu Wang

College of Petroleum Engineering, Liaoning Petrochemical University, Fushun, China; College of Pipeline and Civil Engineering, China University of Petroleum (East China), Qingdao, China

Contact Email

http://orcid.org/0009-0005-8343-852X
Yujun Xie

College of Petroleum Engineering, Liaoning Petrochemical University, Fushun, China

Contact Email

http://orcid.org/0009-0007-1771-7840
Kaile Wang

College of Petroleum Engineering, Liaoning Petrochemical University, Fushun, China

http://orcid.org/0009-0006-4344-5933
Yihan Kang

College of Petroleum Engineering, Liaoning Petrochemical University, Fushun, China

http://orcid.org/0009-0002-7761-8442
Bingxue Wang

College of Petroleum Engineering, Liaoning Petrochemical University, Fushun, China

http://orcid.org/0009-0009-3196-0171
Yuqing Du

College of Petroleum Engineering, Liaoning Petrochemical University, Fushun, China

http://orcid.org/0009-0008-8112-1192

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Plain Text BibTeX RIS

APA Style

Wang, L., Xie, Y., Wang, K., Kang, Y., Wang, B., et al. (2025). Numerical Simulation of Tee Pipe Failure Under Mixed Mode-I/III Loading. American Journal of Energy Engineering, 13(2), 54-66. https://doi.org/10.11648/j.ajee.20251302.12

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ACS Style

Wang, L.; Xie, Y.; Wang, K.; Kang, Y.; Wang, B., et al. Numerical Simulation of Tee Pipe Failure Under Mixed Mode-I/III Loading. Am. J. Energy Eng. 2025, 13(2), 54-66. doi: 10.11648/j.ajee.20251302.12

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AMA Style

Wang L, Xie Y, Wang K, Kang Y, Wang B, et al. Numerical Simulation of Tee Pipe Failure Under Mixed Mode-I/III Loading. Am J Energy Eng. 2025;13(2):54-66. doi: 10.11648/j.ajee.20251302.12

Copy | Download

@article{10.11648/j.ajee.20251302.12,
  author = {Lu Wang and Yujun Xie and Kaile Wang and Yihan Kang and Bingxue Wang and Yuqing Du},
  title = {Numerical Simulation of Tee Pipe Failure Under Mixed Mode-I/III Loading
},
  journal = {American Journal of Energy Engineering},
  volume = {13},
  number = {2},
  pages = {54-66},
  doi = {10.11648/j.ajee.20251302.12},
  url = {https://doi.org/10.11648/j.ajee.20251302.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ajee.20251302.12},
  abstract = {This study probes the brittle fracture mechanisms of an S32205 duplex stainless steel tee pipe (DN300×10 mm) subjected to mixed-mode I/III loading under internal pressures spanning 10 to 30 MPa, leveraging advanced finite element analysis to address reliability concerns in high-pressure oil and gas transport systems. Drawing on recent fracture mechanics insights, an energy-driven three-dimensional framework was formulated to forecast crack propagation, emphasizing metallurgical flaws such as micro-cracks and σ-phase precipitates across varied pressure conditions. By partitioning the crack tip into discrete zones, the model calculates energy release rates and stress intensity factors (KI, KIII, Keff) for crack morphologies, including trifurcation, symmetric branching, and lateral bifurcation. Findings reveal that Mode I stresses maximize at the crack’s deepest point (90°), with KI and Keff exhibiting nonlinear escalation as pressure, crack depth-to-length ratio (a/c), and crack half-length (c) increase, portending elevated risks of unstable crack advancement. Mode III stresses, peaking at 60° and 120°, induce localized tearing, with KIII displaying marked sensitivity to pressure fluctuations. Pressure-amplified stress concentrations at the branch neck and main pipe abdomen corroborate chevron fracture patterns observed in duplex stainless steel tests, affirming the model’s fidelity. The results elucidate the synergistic degradation of fracture toughness by micro-cracks, σ-phase, and pressure-induced stresses, precipitating brittle failure. Heat treatment at 1030°C with water quenching to mitigate σ-phase and periodic ultrasonic inspections are advocated to bolster tee pipe durability in rigorous oilfield settings.
},
 year = {2025}
}

Copy | Download

TY  - JOUR
T1  - Numerical Simulation of Tee Pipe Failure Under Mixed Mode-I/III Loading

AU  - Lu Wang
AU  - Yujun Xie
AU  - Kaile Wang
AU  - Yihan Kang
AU  - Bingxue Wang
AU  - Yuqing Du
Y1  - 2025/06/11
PY  - 2025
N1  - https://doi.org/10.11648/j.ajee.20251302.12
DO  - 10.11648/j.ajee.20251302.12
T2  - American Journal of Energy Engineering
JF  - American Journal of Energy Engineering
JO  - American Journal of Energy Engineering
SP  - 54
EP  - 66
PB  - Science Publishing Group
SN  - 2329-163X
UR  - https://doi.org/10.11648/j.ajee.20251302.12
AB  - This study probes the brittle fracture mechanisms of an S32205 duplex stainless steel tee pipe (DN300×10 mm) subjected to mixed-mode I/III loading under internal pressures spanning 10 to 30 MPa, leveraging advanced finite element analysis to address reliability concerns in high-pressure oil and gas transport systems. Drawing on recent fracture mechanics insights, an energy-driven three-dimensional framework was formulated to forecast crack propagation, emphasizing metallurgical flaws such as micro-cracks and σ-phase precipitates across varied pressure conditions. By partitioning the crack tip into discrete zones, the model calculates energy release rates and stress intensity factors (KI, KIII, Keff) for crack morphologies, including trifurcation, symmetric branching, and lateral bifurcation. Findings reveal that Mode I stresses maximize at the crack’s deepest point (90°), with KI and Keff exhibiting nonlinear escalation as pressure, crack depth-to-length ratio (a/c), and crack half-length (c) increase, portending elevated risks of unstable crack advancement. Mode III stresses, peaking at 60° and 120°, induce localized tearing, with KIII displaying marked sensitivity to pressure fluctuations. Pressure-amplified stress concentrations at the branch neck and main pipe abdomen corroborate chevron fracture patterns observed in duplex stainless steel tests, affirming the model’s fidelity. The results elucidate the synergistic degradation of fracture toughness by micro-cracks, σ-phase, and pressure-induced stresses, precipitating brittle failure. Heat treatment at 1030°C with water quenching to mitigate σ-phase and periodic ultrasonic inspections are advocated to bolster tee pipe durability in rigorous oilfield settings.

VL  - 13
IS  - 2
ER  -

Copy | Download