If a subsurface flaw is located near a component surface, the subsurface flaw is transformed to a surface flaw in accordance with a subsurface-to-surface flaw proximity rule. The re-characterization process from subsurface to surface flaw is adopted in all fitness-for-service (FFS) codes in different countries. However, the specific criteria of the recharacterizations are different among the FFS codes. The authors have proposed a new subsurface-to-surface flaw proximity rule based on experimental data and equivalent fatigue crack growth rates. Recently, the authors have highlighted through numerous fatigue crack growth calculations that, on one hand, the proximity rule provided in the current ASME Boiler and Pressure Vessel Code Section Ⅺ (ASME Code Section Ⅺ) can provide non conservative fatigue lives for thin wall components like pipes and, on the other hand, for thick wall components like vessels, the current proximity rule and the proposed one provide relatively similar fatigue lives. It appears therefore that the flaw-to-surface factor should be updated according to the thickness of the component or according to the type of component i.e. pipe or vessel. In this study, fatigue crack growth calculations were carried out on additional flaw configurations in thick wall pipes and thin wall vessels in order define the best limit for the thickness-dependence of the fatigue lives. Finally, a new subsurface to surface proximity rule depending on the thickness of the component is proposed.
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