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This paper proposes penalty factor equations that take into consideration the weld strength over-match given in the classified form similar to the revised equations presented in the Code Case N-779 via cyclic elastic-plastic finite element analysis. It was found that the Ke analysis data reflecting elastic follow-up can be consolidated by normalizing the primary-plus-secondary stress intensity ranges excluding the nonlinear thermal stress intensity component, Sn to over-match degree of yield strength, MF. For the effect of over-match on Kn × Κν, dispersion of the Kn × Κν analysis data can be sharply reduced by dividing total stress intensity range, excluding local thermal stresses, Sp-lt by MF. Finally, the proposed equations were applied to the weld between the safe end and the piping of a pressurizer surge nozzle in pressurized water reactors in order to calculate a cumulative usage factor. The cumulative usage factor was then compared with those derived by the previous Ke factor equations. The result shows that application of the proposed equations can significantly reduce conservatism of fatigue assessment using the previous Ke factor equations

Proposal of the Penalty Factor Equations Considering Weld Strength Over-Match