Evaluation of tube to collector connection by hydraulic expansion method in PGV-1000 steam generators

Investigations on steam generators failure due to cracking in collector ligaments at perforated parts determined that connection process of the tubes to collector could be one of the main breakdown causes. The stability and strength of tube to collector joint is dependent to the geometry of tube and collector, the joining process and the operational conditions. In this research hydraulic expansion method has been considered as connection method of tube to collector. The Finite Element Method (FEM) was used to simulate the hydraulic expansion process and determine stress condition of the joints. The contact stresses between the tube and collector interface were modeled using contact elements of ANSYS program. Furthermore, the effect of clearance between tube and collector on the residual stresses around of joints was investigated. Some specimens from collector and tube materials were tested at various temperatures and their results were used at rate-independent multi-linear Mises plasticity model for FE analysis. Required connection strength between tube and collector is estimated based on ASME rules and compared with FE results. The results show that the residual tensile stresses could be greatly increased by decreasing of initial clearance. The highest value of residual stresses was observed around of collector holes nevertheless it was considerably lesser than obtained residual stresses in explosive method. The contact pressure and other parameters were in allowable ranges and the friction stresses were negligible.