Development and industrial applications of X-FEM axisymmetric model for fracture mechanics

► An Extended Finite Element Method (X-FEM) axisymmetric model is developed to compute stress intensity factors for cracked components. ► Stress intensity factors for spot welds and kinked cracks in cup specimens based on the X-FEM model agree with analytical and FEM solutions. ► A approximate analytical method is proposed to calculate the stress intensity factors for spot welds in cup specimens of different thicknesses. ► X-FEM model is used to assess the integrity and durability of a cracked rotor coil retaining ring during the power plant operation. In this paper, an Extended Finite Element Method (X-FEM) axisymmetric model is developed and employed to compute stress intensity factors for cracked industrial specimens and components. The X-FEM model implementation is first validated by the analytical and computational stress intensity factors for penny-shaped and circumferential cracks in cylindrical bars. The validated X-FEM model is then employed to obtain the stress intensity factors for spot welds and associated kinked cracks in circular cup specimens with complex geometries. Finally, the X-FEM model is used to assess the integrity and durability of a cracked rotor coil retaining ring during the power plant operation.