Estimating the remanent creep life of power plant components

This paper examines the current status of remanent creep life assessment methods for power plant components. Consideration is given mainly to predictive techniques based on post-service examination and testing with application to low alloy ferritic components in fossil plant. The requirements for producing methodologies, namely the development of mechanistic and parametric models for creep damage and failure, are discussed together with aspects on the measurement of the relevant creep damage feature or property. Techniques considered include physical and mechanical property measurement, metallographic examination, strain measurement, and accelerated creep and rupture testing. Methods based on accelerated testing are discussed in detail; extrapolative techniques and application of the life fraction rule are considered both from an experimental and mechanistic viewpoint. Finally, attention is given to the choice of representative stress to apply to uniaxial data. The influence of material parameters on the representative stress is emphasized and upper and lower bounds appropriate to creep brittle and creep ductile material states are considered.     

Influence of postweld heat treatment on creep properties of 1CrO.5Mo and 2.25Cr1Mo weldments

The creep properties of simulated heat-affected zone, weld metal and cross-weld specimens of tCr0.5Mo and cross-weld specimens of 2.25Cr tMo have been studied with reference to the effect of postweld heat treatment (PWHT). A reduction in the creep rupture strength of up to 20% has been observed after PWHT. Contrary to what has been previously proposed, PWHT was in the present investigation found to have only a marginal influence on the creep ductility. The creep rate can increase by up to a factor of 2-4 after postweld heat treatment, probably because of-carbide coarsening during the heat treatment. Preheating at 200°C did not affect the creep properties of 2.25Cr lMo. Overheating, on the other hand, at 650°C for 1000h reduced the rupture time of tCr0.5Mo by almost an order of magnitude. The tensile strength and yield strength of tCrO.5Mo were significantly reduced after postweld heat treatment. Reductions of up to 100-200MPa were observed both at room temperature and at 550°C in some cases.     

Rationalization of creep rupture data of a cold worked steel

A method of presenting creep rupture data in parametric form is described, and this method is illustrated by application to 347 stainless steel.     

Long-term creep strength predictions from short-term creep test data for high Cr creep-resistant steels and microstructural evolution origin of over-predictions

A new tensile creep model that integrates the tensile strength at creep temperature is investigated for its generic applicability in predicting the long-term creep strengths from short-term creep test data for high Cr creep-resistant steels using creep and tensile strength data measured for a grade of 11Cr steel. The results show that, when the long-term creep strengths are specified by stresses producing the required minimum creep rate, they can be accurately predicted using short-term creep test data. However, when they are specified by stresses giving the required creep rupture time, using only short-term creep test data will lead to over-predictions. The microstructure evolution origin of such over-predictions is traced to the Z-phase precipitation during creep in creep-resistant steels with more than 9 wt.% Cr. The conventional concept on the relationship between creep test stress and creep mechanisms is also re-evaluated in light of the new results.     

Influence of aluminium on creep strength of 9–12% Cr steels

The influence of aluminium on creep strength of 9% Cr steels is predicted by a fundamental model for creep. Through thermodynamic modelling the particle structure is determined for a temperature and composition range. This shows how AlN is formed at the expense of MX carbonitrides of VN character when the aluminium content is increased. The remaining MX particles are of NbC type and have approximately one fifth of the original phase fraction. The evolution in microstructure such as particle coarsening is included in the model as well as the recovery. Rupture time is predicted using a modified Norton equation including back-stresses calculated from microstructure. The predictions show correspondence to some of the creep data for the steel P91 over a temperature and stress range. Furthermore, simulation with high Al content verifies the observed early failure of Al rich components. Overall, the simulations show a decrease in rupture time by a factor 6 due to Al additions of up to 0.2%.     

A micro-continuum model for the creep behavior of complex nanocrystalline materials

A nanocrystalline material which has an average grain size of less than 100 nm is characterized with a significant portion of atoms residing in the grain boundaries or in the grain-boundary affected zone (GBAZ), while nanocrystalline materials with a more complex structure may contain additional strengthening nanoparticles or nano pores. In this article we develop a micro-continuum model to capture the creep response of such a complex nanocrystalline system. We make use of the concept of a three-phase composite with the GBAZ serving as the matrix, and grain interiors and dispresed particles (or voids) as two distinct types of inclusions. Both the grain interior and the GB zone are capable of undergoing the rate-dependent plastic deformation, but the strengthening nanoparticles or pores are taken to deform only elastically. During deformation the porosity will continue to evolve; its evolution is also addressed. In addition, the effect of temperature on the overall creep response is also accounted for. Several important features of creep characteristics in light of grain size, and nanoparticle and nanopore concentrations, are illustrated, and it is also demonstrated that the calculated results are in reasonable agreement with available experimental data.     

Influence of Pd addition on the creep behavior of AZ61 magnesium alloy

The effect of Pd addition (0, 2, and 4 wt%) on the microstructure and creep properties of permanent mold AZ61 (Mg-6Al-1Zn) alloy has been studied. The results indicate that Pd addition introduces a lamella-shaped Al₄Pd phase at the grain boundary, in addition to the Mg₁₇Al₁₂ (β) phase. The addition of Pd also suppresses the precipitation of the Mg₁₇Al₁₂ phase and residual Al at grain boundaries during solidification. These effects lead to an improvement in the creep behavior of AZ61. Moreover, extended steady-state creep and reductions in both the minimum creep rate and total creep strain are also observed in the case of 4 wt% Pd addition.     

High temperature corrosion of alloys containing rare earth or refractory elements: a review of current knowledge and possible future developments

The beneficial effects of minor (≤1%) additions of rare earth/reactive elements on the oxidation of HT alloys have been known for many years. Much interest has recently centred on the influence of certain refractory elements present at levels of several weight percent in a number of such alloys. The reasons why minor additions of these reactive elements, especially the rare earths, have beneficial effects have been the subject of systematic studies over the past 10–15 years. Ideas have been influenced by the understanding of the mechanisms of the development of protective chromia or alumina scales; in particular, the role such additions play in assisting the more rapid nucleation and growth of oxides on HT alloys, reducing the period of transient oxidation and the earlier attainment of steady-state scaling conditions. Much attention has also been paid to the mechanisms whereby such additions appear to promote improved scale adherence.

The various theories of high temperature corrosion of such alloys and supporting experimental evidence are reviewed in this paper. The reported information concerning the beneficial role or otherwise of the refractory metals, particularly with respect to hot corrosion in gas turbines, is appraised. Attention is drawn to the potentially beneficial effects of additions of certain of these Group III-VI elements in the development of novel alloys or coatings to resist corrosion in the complex environments of low oxygen potential, which occur in plants to produce synthetic natural gas from oil or coal. Areas for further research are also identified.     

Elevated temperature mechanical properties and microstructures of high pressure die cast magnesium AZ91 alloy cast with different section thicknesses

This paper investigates the influence of variations in the microstructure of high pressure die cast AZ91 on the elevated temperature mechanical properties of the alloy. Thinner-walled high pressure die castings show an improvement in elevated temperature strength, ductility and creep resistance. Further improvements to the creep resistance were achieved by ageing the alloy prior to creep testing. It appears that an increased proportion of fine grained ‘skin’ region in the thinner castings contributed to the improved properties. Also, it appeared that the presence of supersaturated solute Al in the eutectic α-Mg contributes to the poor creep properties, probably due to the microstructural instability. Final failure is associated with the growth of voids either from porosity in the alloy or nucleated from discontinuous precipitates.     

Viscoplastic behavior of a FeCrAl alloy for high temperature steam electrolysis (HTSE) sealing applications between 700 °C and 900 °C

High temperature steam electrolysis (HTSE) is one of the most promising technologies for the industrial production of hydrogen. However one of the remaining problems lies in sealing at high temperature. The reference solution is based on glass seals which presents several drawbacks. That explains why metallic seals are under development. The expected seal will be submitted to creep under low stresses between 700 °C and 900 °C, possibly involving complex loading and thermal history. The candidate material investigated in this work is a FeCrAl (OC404, Sandvik) supplied as a 0.3 mm thick sheet. The ability of this material to develop a protective layer of alumina was studied first, as well as grain size growth during thermal ageing. Creep and tensile tests were performed between 700 °C and 900 °C to determine its mechanical properties. This database was used to propose and identify an elasto-viscoplastic behavior for the material. Creep was described by the Sellars-Tegart law. This law was then used to simulate and predict creep indentation tests performed in the same range of temperatures.     

Microstructure,tensile properties and creep behavior of Al-12Si-3.5Cu-2Ni-0.8Mg alloy produced by different casting technologies

The relationship between the as-cast microstructure and mechanical properties of the Al-12Si-3.5Cu-2Ni-0.8Mg alloys produced by permanent mold casting (PMC) and high pressure die casting (HPDC) is investigated. The alloys in both PMC and HPDC consist of Al, Si, Al₅Cu₂Mg₈Si₆, Al₃CuNi, and Al₇Cu₄Ni phase. However, the microstructure of the HPDC alloy is significantly refined. Compared to the PMC alloy, the ultimate tensile strength of the HPDC alloy is significantly increased from 244 MPa to 310 MPa, while the elongation shows a reverse trend at room temperature. At low stress and temperature range, slight variations of stress exponent and activation energy indicate that the minimum creep rate is controlled by the grain boundary creep. Then the minimum creep rate is higher for the specimen with the smaller grain size, where grain boundary creep is the dominant creep mechanism. At high stress region, the stress exponent for the PMC alloy and HPDC alloy is 5.18 and 3.07, respectively. The different stress exponents and activation energies measured at high stress and high temperature range indicates that the creep mechanism varies with the casting technologies.     

Laser shock processing of aluminium alloys. Application to high cycle fatigue behaviour

Subjecting target metallic samples to a very short pulse (about 20 ns) of intense (GW cm⁻²) laser light generates, through a surface plasma, a high-pressure stress wave propagating to the first millimetre in depth, which is commonly called laser shock processing (LSP). The purpose of this work was to evaluate the role of this novel process on the cyclic properties of A356, Al12Si and 7075 aluminium alloys. Major contributors to the fatigue performance improvements were investigated in order to determine the optimum shock conditions. These were mainly compressive residual stress (RS) levels for which a large range of incident shock conditions was performed. We showed that stress levels were very sensitive to the laser fluence and the number of local impacts, and experimental RS measurements were found to be in good agreement with analytical modelling results. In comparison, a conventional shot peening (SP) treatment was found to lead to higher surface hardening and RS levels, but with a very detrimental roughening not observed after LSP. High cycle (10⁷) fatigue tests carried out on laser- processed, shot-peened and untreated notched samples illustrated the efficiency of LSP as a new, promising method to improve the fatigue limits σ_D of structures, especially in comparison with enhancements displayed by SP (+22% vs. +10%). According to crack detection electric measurements, fatigue performance improvements with LSP mainly occurred during the crack initiation stage.     

Tensile,creep behavior and microstructure evolution of an as-cast Ni-based K417G polycrystalline superalloy

The Ni-based K417G superalloy is extensively applied as aeroengine components for its low cost and good mid-temperature (600–900 °C) properties. Since used in as-cast state, the comprehensive understanding on its mechanical properties and microstructure evolution is necessary. In the present research, the tensile, creep behavior and microstructure evolution of the as-cast K417G superalloy under different conditions were investigated. The results exhibit that tensile cracks tend to initiate at MC carbide and γ/γ′ eutectic structure and then propagate along grain boundary. As the temperature for tensile tests increases from 21 °C to 700 °C, the yield strength and ultimate tensile strength of K417G superalloy decreases slightly, while the elongation to failure decreases greatly because of the intermediate temperature embrittlement. When the temperature rises to 900 °C, the yield strength and ultimate tensile strength would decrease significantly. The creep deformation mechanism varies under different testing conditions. At 760 °C/645 MPa, the creep cracks initiate at MC carbides and γ/γ′ eutectic structures, and propagate transgranularly. While at 900 °C/315 MPa and 950 °C/235 MPa, the creep cracks initiate at grain boundary and propagate intergranularly. As the creep condition changes from 760 °C/645 MPa to 900 °C/315 MPa and 950 °C/235 MPa, the γ′ phase starts to raft, which reduces the creep deformation resistance and increases the steady-state deformation rate.     

高温正火消除85Cr2Mn2Mo钢组织遗传的研究

在研究８５Ｃｒ２Ｍｎ２Ｍｏ钢的组织遗传的基础上,着重研究了该钢组织遗传的消除,采用高温正火工艺,使８５Ｃｒ２Ｍｎ２Ｍｏ钢经重结晶,奥氏体再结晶有效地细化了奥氏体晶粒,切断了组织遗传,并对８５Ｃｒ２Ｍｎ２Ｍｏ钢的奥氏体再结晶温度做了有益的探析。     

Size effects of γ′ precipitate on the creep properties of directionally solidified nickel-base super-alloys at middle temperature

Nickel-base super-alloys consist of two phases named γ-phase of nickel matrix and γ′-phase of precipitates, which are dispersed uniformly in the matrix. The morphologies and sizes of γ′ precipitates have strong effects on the creep properties of the alloys. At the middle temperature (850 °C), the rafting effect of the precipitate is not obvious, and the size effects of precipitates are dominant. In this paper, a crystal plasticity constitutive model is developed, which considers damage and strain gradient to reflect the size effect of the creep property. This model is implemented into ABAQUS as an interface of user material (UMAT). Two different precipitate sizes are studied using a unit-cell model of alloys with the same volume fraction. By Comparison with the experiment data, the simulation results are reasonable to demonstrate the significant size effect of precipitates on the creep properties of nickel-base super-alloys, which indicates that the creep rates are lower and the rupture lives are longer when the precipitate sizes are smaller with constant fraction.     

Higher-order fractional constitutive equations of viscoelastic materials involving three different parameters and their relaxation and creep functions

Two higher-order fractional viscoelastic material models consisting of the fractional Voigt model (FVM) and the fractional Maxwell model (FMM) are considered. Their higher-order fractional constitutive equations are derived due to the models’ constructions. We call them the higher-order fractional constitutive equations because they contain three different fractional parameters and the maximum order of equations is more than one. The relaxation and creep functions of the higher-order fractional constitutive equations are obtained by Laplace transform method. As particular cases, the analytical solutions of standard (integer-order) quadratic constitutive equations are contained. The generalized Mittag–Leffler function and H-Fox function play an important role in the solutions of the higher-order fractional constitutive equations. Finally, experimental data of human cranial bone are used to fit with the models given by this paper. The fitting plots show that the models given in the paper are efficient in describing the property of viscoelastic materials.     

A review of the high temperature oxidation of iron- manganese- aluminium alloys

Research on the oxidation behaviour of alloys from the Fe-Mn-Al system has been devoted primarily to the austenitic alloys with particular attention being paid to their mechanical properties. Information regarding their oxidation behaviour and scale morpology is sparse. There is very little on the behaviour of the ferritic alloys and these show great promise as heat resisting alloys, particularly with small additions of chromium. The oxidation behaviour of iron, manganese and binary iron-manganese alloys is reviewed in this paper, to clarify the behaviour of the more complex ternary alloys.     

Deformation and life assessment of high temperature materials under creep fatigue loading

The knowledge of mechanical long term behaviour under static and cyclic loading for high temperature components requires methodologies for life assessment in order to employ the full potential of materials. A phenomenological life time prediction concept which was developed for multi‐stage creep fatigue loading demonstrates the applicability of rules for synthesis of stress strain path and relaxation including an internal stress concept, as well as mean stress effects. Further, a creep fatigue interaction concept which was also developed covers a wide range of creep dominant loading as well as fatigue dominant loading. Service‐type experiments conducted at different strain rates and hold times for verification purposes demonstrate the acceptability of life prediction method for variation of conventional 1 %Cr‐steels as well as modern high chromium 9‐10 %Cr‐steels. Generally, the service life of components is influenced by multi‐axial behaviour. Multi‐axial experiments with e.g. notched specimens and with cruciform specimens accompanied by advanced methods for calculation of stress strain path and life time prediction stress conditions are of future interest.