Fracture toughness of narrow-gap welded joints in the nuclear pressure vessel steel 22 NiMoCr 37

The mechanical testing of narrow-gap welded joints in 100 and 200 mm thick sections of the steel 22 NiMoCr 37 has revealed that the weld metal, and not the heat affected zone (HAZ) or the weld metal-parent metal boundary. is the critical region. This modified gas-shielded welding process operates with a very low heat input of the order of 6.500 J cm⁻¹ pass⁻¹ and the combination of small diameter welding wires and high welding speeds contributes to the excellent joint properties in the as-welded condition.To investigate the effect of preheating and post-welding heat treatment on the mechanical properties of narrow-gap welds, tensile, notch impact, flat bend and fracture toughness test specimens were extracted from joints welded with the following conditions: (1) no preheating: no post-weld heat treatment; (2) no preheating: soaking at 300°C: (3) no preheating: stress-relief heat treatment at 600°C; (4) preheating 200–250°C; no post-weld heat treatment; (5) preheating 200–250°C; soaking at 300°C; (6) preheating 200–250°C; stress relief heat treatment at 600°C. Tensile testing at room temperature and at 250°C of round specimens oriented across the seam revealed the ultimate fracture to be always located in the base material remote from the welded zone. Although pores or slag inclusions had an influence on bend-test results of specimens in the as-welded condition, the results generally show failure free bends to 180°C with no evidence of cracking in the HAZ or at the fusion boundary.Using sharp-notched impact bend specimens with the notch located in the centre of the seam as well as in and across the HAZ, absorbed energy-test temperature curves have been determined for each welding condition. In comparison with the base material impact toughness, the weld exhibits superior toughness in the temperature range − 60 – 0°C, but yielded lower values at room temperature. After stress relieving at 600°C, the impact toughness of the weld reduced significantly, apparently due to precipitations occurring in the weld-metal microstructure. Test results from welded specimens with the no notch in the HAZ show this region to have superior notch impact toughness to the base material.Crack opening displacement (COD) specimens 45 × 90 × 380 mm with the fatigue crack located in the weld metal and in the HAZ were tested at 0 and 20°C using both the recommendation in BS DD 19: 1972 as well as acoustic emission measurements for the determination of COD values. For this method of fracture toughness testing it has been shown that the occurrence of a critical event must be clearly defined as corresponding to stable crack growth or alternatively to unstable crack propagation.     

Fracture mechanics in creep situation interpretation of results on a test specimen

Fracture mechanics in creep situation is a difficult challenge for the 1990s. In France, CEA Saclay has conducted experimental tests on compact tension (CT) specimens at 650°C in order to investigate crack initiation under creep situations. The constitutive material is the 316SPH austenitic stainless steel used for most LMFR structures.Numerical simulations using SYSTUS code and simplified method analysis were performed on one of the tests (CT specimen at 650°C under constant load) to compare some parameters (notch opening, initiation time) with experimental values. The material constitutive law was represented by the complete elasto-viscoplastic CHABOCHE model for computation. Owing to geometrical characteristics such as thickness, the situation of the CT specimen was likely to be intermediate between plane stress and plane strain assumptions. From C^* parameter, incubation time obtained using the R5 rule was conservative in comparison with the test result.The continuum damage model developed at Ecole des Mines de Paris has also been used to assess creep damage in the notch tip area. The crack initiation time has been deduced from critical damage at characteristic distance (X_c = 0.05 mm). Considering critical damage specifically, for a CT specimen (D_c = 0.05), initiation time obtained was higher than the test result.The results of this study will contribute to the development of a methodology for nocivity analysis of cracks in creep situation.     

European experiences of the proposed ASTM test method for crack arrest toughness of ferritic materials

The proposed ASTM test method for measuring the crack arrest toughness of ferritic materials using wedge-loaded, side-grooved, compact specimens was applied to three steels: A514 bridge steel tested at −30°C (CV30–50°C), A588 bridge steel tested at −30°C (CV30–65°C), and A533B pressure vessel steel tested at +10°C (CV30-12°C) and +24°C (CV30+2°C). Five sets of results from different laboratories are discussed here; in four cases FOX DUR 500 electrodes were used for notch preparation, in the remaining case HARDEX-N electrodes were used. In all cases, notches were prepared by spark erosion, although root radii varied from 0.1–1.5 mm. Although fast fractures were successfully initiated, arrest did not occur in a significant number of cases.The results showed no obvious dependence of crack arrest toughness, K_a, (determined by a static analysis) on crack initiation toughness, K₀. It was found that K_a decreases markedly with increasing crack jump distance, Δα/W. A limited amount of further work on smaller specimens of the A533B steel showed that lower K_a values tended to be recorded.It is concluded that a number of points relating to the proposed test method and notch preparation are worthy of further consideration. It is pointed out that the proposed validity criteria may screen out lower bound data. Nevertheless, for present practical purposes, K_a values may be regarded as useful in providing an estimate of arrest toughness — although not necessarily a conservative estimate.     

Moment modified compact tension specimen for measuring crack arrest toughness

Crack arrest toughness in reactor vessel steels in the transition and Charpy upper shelf energy temperature range are of particular interest to the nuclear industry to aid with the analysis of the phenomenon known as pressurized thermal shock (PTS). A test specimen and analysis technique have been developed to measure crack arrest toughness at temperatures from the transition region up to and beyond the Charpy upper shelf energy level. The moment modified compact tension (MMCT) specimen combines a thermal gradient with mechanical loadings to initiate a crack in brittle material below NDT and then have arrest take place in hot, ductile material. A finite element model was used to help design the specimen and fixturing geometry as well as calculate the arrest toughness. Tests have been conducted on ASME SA533 Grade B Class 1 steel plate with a variety of loadings confirming the veracity of the technique and developing valuable data. Crack arrest toughness has been measured from 0°F to 110°F (−18°C to 43°C). This work has been part of a research program performed by C-E, Windsor and funded by the Electric Power Research Institute.     

Integrity assessment of the high temperature engineering test reactor (HTTR) control rod at very high temperatures

The high temperature engineering test reactor (HTTR) is the first high temperature gas-cooled reactor (HTGR) in Japan with a reactor outlet coolant temperature of 950°C at high temperature test operation. The HTTR contains 16 pairs of control rods for which Alloy 800H is chosen of the metallic parts. Because the maximum temperature of the control rods reaches about 900°C at reactor scrams, structural design guideline and design material data on Alloy 800H are needed for the high temperature design. The design guideline for the HTTR control rod is based on ASME Code Case N-47-21. Design material data is also determined and shown in this paper. Under the guideline, temperature and stress analysis was conducted, and it is confirmed that the target life of the control rods of 5 years can be achieved.     

The HTTR reactor pressure vessel and its integrity against a PTS event

Before manufacturing the real steel to be used in the reactor pressure vessel (RPV) of the high temperature engineering test reactor (HTTR) the vessel manufacturer and materials supplier made a sample steel by the same procedure as for the real steel (2.25Cr-1 Mo) and conducted many tests to obtain material strength data for its base and weld metals. The test results showed that the sample steel satisfied the HTTR design requirements. Vessel cooling panels are set on the inner surface of the biological shielding concrete around the RPV, and are circulated with cooling water at 0.5 MPa and 40°C to cool the shielding concrete during normal operation of the reactor. By supposing that the cooling panel breakes and the water discharges to the RPV outer surface heated at 400°C, the stress distribution generated in the vessel wall by a pressurized thermal shock (PTS) event can be calculated using a finite element method code. This paper describes some of the results obtained from the material testing of the sample steel and the estimated result using the scheme developed for a light water reactor pressure vessel, to clarify the integrity of the HTTR-RPV under a PTS event.     

Creep-fatigue crack propagation behavior in a surface cracked plate

A series of experiments were performed in order to clarify the surface crack growth behavior under creep-fatigue condition. Type 304 stainless steel was tested at 550°C and 650°C. Specimens were plates with a surface notch. Loading patterns were axial fatigue, bending fatigue, axial creep-fatigue and bending creep-fatigue. As results were obtained: (1) the beach mark method was available to measure the changes of the crack front shape after the test; (2) the electrical potential method was available to measure the changes of the crack front shape in real time; (3) the crack front shape was affected by the loading mode; and (4) ΔJ and ΔJ_c calculated from the proposed simplified method could characterize the surface crack growth rate.     

Behavior of zirconium fuel cladding under fast pressurization rates

Rapid pressurization test was carried out to evaluate the mechanical behavior of the zirconium cladding under a fast strain rate as well as a biaxial stress state for simulating an out-of-pile reactivity initiated accident (RIA) behavior. Influence of temperature, hydrogen content and alloying elements have been addressed in the conducted mechanical tests. The results showed that pressurization rates of 5.4 GPa/s at room temperature and 3.1 GPa/s at 350 °C were achieved. The corresponding time to failure was similar to expected power transient duration during a RIA. Maximum hoop stress of Zircaloy-4 at room temperature and 350 °C increased, respectively by 24.3 and 16.8% when compared to the conventional burst test results. Failure mode switched from a ductile ballooning to a brittle failure which leads to an axial split of the cladding when the hydrogen was added at a nominal value of 600 ppm. When the test temperature increased, its effect was diminished. Addition of an alloying element influenced the mechanical property differently. Niobium acted beneficially against hydrogen embrittlement in that it increased the ductility of the metal matrix.     

The behaviour of WB 35 piping material under dynamic loading in the high speed tensile test

For the determination of the strength-, deformation- and fracture behaviour of the material 17 MnMoV 6 4 (WB 35) which is used for piping components, tensile tests were carried out at different loading rates (monotonic and impact-type) on smooth and notched pipe strip specimens over a temperature range extending from − 30°C to 250°C.For the conduct of the tests a hydraulic high speed tensile machine having a free motion device was used; the velocity of impact was preset at ca. 7 m/s.With impact-type (dynamically) loaded specimens in general higher strength and deformation values were obtained than with monotonic (statically) loaded ones. In all of the specimens having low deformation values which were investigated microfractographically, ductile portions were found adjacent to the notch on the fracture surface.     

Liquid metal embrittlement of T91 martensitic steel evidenced by small punch test

In this work, the sensitivity of liquid metal embrittlement of the T91 martensitic steel is investigated with the small punch test (SPT). The material was studied in three tempering conditions (as quenched, tempered at 500 and 750 °C), at 300 °C in air and in the liquid lead bismuth eutectic (LBE). The load–displacement curves (four stages, low maximum force and large displacement to fracture) obtained for one test condition of the 750 °C tempered material is in general very different from those of the two other materials. An effect of LBE has been observed for the as quenched and 500 °C tempered steels. For these materials, the curves tend to be linear with a reduced displacement to fracture suggesting a brittle behavior. This ductile to brittle transition induced by liquid metal has been confirmed from the fracture surface analysis where cleavage was observed. In comparison with conventional tensile tests, small punch tests appear to be more sensitive to evidence liquid metal embrittlement.     

III. PWR steam generator response to a scram at 50% load and an open grid transient (bugey-4 nuclear power plant)

Two transients, an open grid and a scram at 50% load, were conducted on unit 4 of the PWR power plant Bugey. The thermal hydraulic response of the steam generator was recorded. For the open grid test, the following observations are noted:No alarming phenomena are observed in the steam generator during the transient. Primary pressure oscillations were very mild, and did not exceed about 4.8 bar/min with a maximum amplitude of ±8 bar. This condition should not result in significant stress levels. Steam generator outer shell metal temperature gradients remained within very acceptable limits; a maximum amplitude of about +13°C and a rate not exceeding 0.8°C/min are obtained. This slow rate is explained by a fall in primary water temperature that allows for a temperature decrease inside the U-tube bundle. Similarly, the temperature rise on the tube sheet does not exceed an amplitude of 20°C with a rate of about 2°C/min. Again these conditions do not lead to any significant thermal shock on the tube sheet. The steam generator feed controls maintain the level within the normal operation range and the small addition of colder feedwater does not lead to great temperature changes because of the large mass of the recirculation water in the steam generator.For the scram at 50% load, the following observations are noted: no severe thermal or pressure transients are observed in this test. Fluid temperature fluctuations occur with rates not exceeding 1°C/s and a maximum amplitude of about 20°C in the downcomer and 10°C on the tube sheet. Steam generator outer shell temperature varies at a rate of about ±0.8°C/min with a maximum amplitude of about 16°C. These thermal transients should lead to thermally induced stresses of acceptable levels.     

Tensile and stress corrosion cracking properties of type 304 stainless steel irradiated to a very high dose

Certain safety-related core internal structural components of light water reactors, usually fabricated from Type 304 or 316 austenitic stainless steels (SSs), accumulate very high levels of irradiation damage (20–100 displacement per atom or dpa) by the end of life. Our databases and mechanistic understanding of the degradation of such highly irradiated components, however, are not well established. A key question is the nature of irradiation-assisted intergranular cracking at very high doses, i.e. is it purely mechanical failure or is it stress-corrosion cracking? In this work, hot-cell tests and microstructural characterization were performed on Type 304 SS from the hexagonal fuel can of the decommissioned EBR-II reactor after irradiation to ≈50 dpa at ≈370 °C. Slow-strain-rate tensile tests were conducted at 289 °C in air and in water at several levels of electrochemical potential (ECP), and microstructural characteristics were analyzed by scanning and transmission electron microscopies. The material deformed significantly by twinning and exhibited surprisingly high ductility in air, but was susceptible to severe intergranular stress corrosion cracking (IGSCC) at high ECP. Low levels of dissolved O and ECP were effective in suppressing the susceptibility of the heavily irradiated material to IGSCC, indicating that the stress corrosion process associated with irradiation-induced grain-boundary Cr depletion, rather than purely mechanical separation of grain boundaries, plays the dominant role. However, although IGSCC was suppressed, the material was susceptible to dislocation channeling at a low ECP, and this susceptibility led to a poor work-hardening capability and low ductility.     

Characterization of heat transfer processes in a melt pool convection and vessel-creep experiment

The results of an integral experiment on melt pool convection and vessel-creep deformation are presented and analyzed. The experiment is performed on a test facility, named Failure Of REactor VEssel Retention (FOREVER). The facility employs a 1/10-scaled 15Mo3-(German)-steel vessel of 400-mm diameter, 15-mm wall thickness and 750-mm height. A high-temperature (1300 °C) oxide melt is prepared in a SiC-crucible placed in a 50 kW induction furnace and is, then, poured into the 1/10th scale vessel. A MoSi₂ 50 kW electric heater is employed in the melt pool to heat and maintain its temperature at 1200 °C. The vessel is pressurized with argon at the desired pressure. In the FOREVER/C1 experiment, the vessel wall, maintained at about 900 °C and pressurized to 26 bars, was subjected to creep deformation in a 24-h non-stop test. The FOREVER/C1 test is the first integral experiment, in which a decay-heated oxidic naturally-convecting melt pool was maintained in long-term contact with the hemispherical lower head of a pressurized, creeping, steel vessel. A sizeable database was obtained on melt pool temperatures, melt pool energy split, heat transfer rates, heat flux distribution on the melt (crust)–vessel contact surface, vessel temperatures and, in particular the vessel wall creep rate as a function of time. The paper provides information on the FOREVER/C1 measured thermal characteristics and analysis of the observed thermal behavior. The coupled nature of thermal and mechanical processes, as well as the effect of other system conditions (such as depressurization) on the melt pool and vessel temperature responses are analyzed.     

The viscoplasticity theory applied to the inelastic analysis at elevated temperatures

Monotonic and cyclic loading tests on strain rate changes are conducted on — 1Mo steel at 600°C. The examination of the tensile stress-strain response suggests that the viscosity function which characterizes the rate-dependency in the viscosity theory used previously at room temperature should not only depend on the overstress but also on the strain. A new extended viscosity control function is introduced to represent such strain dependency.The material constants of this modified viscoplasticity model are determined at temperatures of 25°C to 600°C and the model is applied to deformation tests on — 1Mo steel carried out under time-varying temperature conditions and other conditions.The extended viscoplasticity theory is shown to reproduce such various experimentally observed stress-strain behavior at elevated temperatures.     

Effect of thermal aging on fracture toughness of RPV steel

The effect of thermal aging on mechanical properties and fracture toughness was investigated on pressure vessel steel of light water reactors. Submerged are welded plates of ASME SA508 C1.3 steel were isothermally aged at 350°C, 400°C and 450°C for up to 10,000 hrs. Tensile, Charpy impact and fracture toughness testings were conducted on the base metal and the weld heat affected zone (HAZ) material to evaluate whether thermal aging induced by the plant operation is critical for the integrity of the pressure vessel or not. Tensile properties of the base metal was not changed by thermal aging as far as the thermal aging conditions were concerned. Relatively distinct degradation was observed in fracture toughness J_IC and J-resistance properties of both the base metal and the weld HAZ material, while only slight changes were observed in Charpy impact properties for both of them. However, it was concluded that the effect of thermal aging estimated by 40–80 years of plant operation on fracture toughness of both materials is small.     

Intermediate size pressure vessel programme (ZB 1)

One of the focal points in the discussion about the safety of nuclear power plants is the integrity of the reactor pressure vessel.In order to prove its integrity tests are in progress in an underground test facility of the main power station in Mannheim with an intermediate size vessel from the research programme “Integrity of Components”. Patches of A 533 B and modified A 508 B material were welded into the vessel ZB 1, the test temperatures are approximately 70 and 290°C. The main goal of the tests is to measure the behaviour of artificial and natural flaws during static hydrotests and simulated operational (cyclic) conditions.In the first half of the research programme the objective is to produce a crack growth of some centimetres by cyclic loading between a variable minimum pressure and a maximum pressure of about 24 MPa. The total number of load cycles will be approximately 30 000.In the second half of the tests the vessel will be loaded by a number of pressure cycles which correspond to the loading a reactor pressure vessel experiences during 40 years of operation.During the static and cyclic loading acoustic emission monitoring is being made by German and American laboratories.This paper presents details of the vessel, the test loop, results of the nondestructive examinations conducted to quantify the crack depths and results of the acoustic emission monitoring.     

Creep—fatigue test of a thick-walled vessel under thermal transient loadings

To improve the damage evaluation methods in the design code for Fast Breeder Reactors (FBRs), a series of creep—fatigue tests of structural models under thermal transient loadings are going on at Oarai Engineering Center of the Power Reactor and Nuclear Fuel Development Corporation (PNC). Test models are designed to incorporate representative structures of components and pipings used in FBRs and are subjected to severer cyclic thermal transients than those experienced in FBRs. The test is planned to be continued until failure occurs. This paper describes the creep—fatigue test results and their damage evaluation for the first test model.A 40 mm thick vessel model made of SUS304 austenitic stainless steel was subjected to cyclic thermal transients, in which sodium at 600°C and 250°C flowed repeatedly. The period of each transient was 2 h. Cracks were observed at seven test portions in the model after 1002 cycles of the thermal transients.Elastic and inelastic analyses were performed to evaluate creep—fatigue damage and crack propagation. The safety margins included in the creep—fatigue design methods based on elastic analysis as well as those based on inelastic analysis are discussed. Finally fracture mechanics analyses were performed to explain the observed crack growth.     

Experiments on air ingress during severe accidents in LWRS

Various kinds of experiments on the oxidation of Zircaloy-4 cladding material in different scales and under different conditions at temperatures 800–1300 °C (small scale) and up to 2000 °C (large scale) are presented. The focus of this work was on prototypic mixed air–steam atmospheres and sequential reaction in steam and air, where no data were available before. The separate-effects tests were performed to support the large scale bundle test QUENCH-10 and to deliver first data for model development.     

Simulation tests for temperature mixing in a core bottom model of the HTR-Module

Interatom and Siemens are developing a helium-cooled Modular High Temperature Reactor. Under nominal operating conditions temperature differences of up to 120°C will occur in the 700°C hot helium flow leaving the core. In addition, cold gas leakages into the hot gas header can produce even higher temperature differences in the coolant flow. At the outlet of the reactor only a very low temperature difference of maximum ±15°C is allowed in order to avoid damages at the heat exchanging components due to alternating thermal loads. Since it is not possible to calculate the complex flow behaviour, experimental investigations of the temperature mixing in the core bottom had to be carried out in order to guarantee the necessary reduction of temperature differences in the helium. The presented air simulation tests in a 1:2.9 scaled plexiglass model of the core bottom showed an extremely high mixing rate of the hot gas header and the hot gas duct of the reactor. The temperature mixing of the simulated coolant flow as well as the leakage flows was larger than 95%. Transfered to reactor conditions this means a temperature difference of only ±3°C for the main flow at a quite reasonable pressure drop. For the cold gas leakages temperature differences in the hot gas up to 400°C proved to be permissible. The results of the simulation experiments in the Aerodynamic Test Facility of Interatom permitted to design a shorter bottom reflector of the core.     

Fatigue damage assessment using x-ray diffraction and life prediction methodology

X-ray diffraction line broadening was used to monitor surface damage due to deformation (distortion) that was induced by low cycle fatigue. The integral breadth of selected diffraction peaks was identified as a useful parameter with which to evaluate cumulative fatigue damage. Torsional fatigue tests were conducted on nickel-based Waspaloy material which exhibited planar slip at 1200° F (649°C). X-ray diffraction measurements were taken at 22, 41, 60, and 90% of the life. The data disclosed an increase in breadth with each increment of cycling. The results obtained from line broadening analysis were carefully correlated with observations made on the specimen surface using scanning electron microscopy which showed the progressive distortion occurring in the cycled specimen. The integral breadth, β, was successfully correlated with the applied shear strain to predict the expended fraction of life and hence the remaining cyclic life.