Fatigue Life Estimation of Pressurized Pipelines Using XFEM: Elastic vs. Plastic Regimes

This study investigates the fatigue behavior of pressurized pipelines under cyclic internal pressure, focusing on the influence of elastic and elastoplastic material responses on crack propagation. The Extended Finite Element Method (XFEM), implemented in Abaqus 2002, is used to model crack initiation and propagation without remeshing. The analysis first considers elastic behavior to estimate maximum stresses and stress intensity factors (SIFs) at crack tips, and then introduces an elastoplastic model to account for local plastic deformation in regions of high stress concentration, improving fatigue life prediction accuracy. The numerical approach is coupled with the Basquin and Manson–Coffin fatigue models and supported by a test matrix varying internal pressure amplitudes to systematically evaluate parameter interactions. The novelty of this work lies in the systematic study of the interaction between internal pressure, material nonlinearity, plastic zone evolution, crack closure, and fatigue life estimation. Unlike previous studies, the analysis includes detailed comparisons with analytical predictions and validated experimental data from the literature, ensuring the reliability of the model. The results show significant differences between the elastic and elastoplastic regimes: under 12 MPa, the maximum stress reached 352.5 MPa and fatigue life was 1639 cycles, while under 28 MPa, stress increased to 850 MPa and life dropped to a single cycle. These findings highlight the critical role of plastic deformation in fatigue crack growth and demonstrate that neglecting plasticity can greatly overestimate pipeline durability, providing a more realistic assessment of structural integrity in pressurized systems.