Influence of initial ovality on creep life of P92 pipe bends subjected to in-plane bending

Initial ovality is an inevitable problem in the process of pipe bends manufacturing which results in the stress redistribution of the pipe bends working at high temperature. In order to study the influence of ovality on creep life of pipe bends, full-size creep experiment of P92 pipe bend subjected to in-plane bending has been conducted. The creep strains and outside diameters of dangerous positions have been measured. The microstructures of three different positions of the pipe bend were compared through SEM and the results showed the number and size of the carbide precipitation were the largest at the flank of the pipe bend, which indicated that the creep damage developed fastest at the flank. The modified Kachanov–Robatnov constitutive equations were used to stimulate the creep of P92 pipe bends with FEA software. The representative stress, damage and multiaxiality distributions of the pipe bends have been discussed. The FEA results were consistent with the experimental results and the influence of initial ovality on creep life of P92 pipe bends were analyzed. The results showed that creep life of pipe bends reduced by the increase of ovality and their relationship coincided with the parabolic law.     

考虑塑性徐变的高混凝土坝实测应变转换应力探讨

将应变计组实测应变转换为应力与混凝土的应力状态有关。针对高混凝土坝应力作用水平较高,当混凝土的应力超过一定的限度,混凝土将进入塑性徐变阶段,如果仍基于弹性徐变体的应力-应变关系进行实测应变的应力转换,获得的应力与实际情况不符。该文假设混凝土在高应力作用下将产生塑性流动,根据P.Perzyna假设计算黏塑性应变率,首先推导了最大拉应力屈服准则和Hsieh-Ting-Chen屈服准则的黏塑性应变率计算公式,接着推导了考虑塑性徐变的实测应变转换应力的计算公式,进而探讨了考虑塑性徐变的高混凝土坝实测应变转换为应力。实例分析表明:由于将实测应变转换为应力采用增量法进行计算,在转换过程中,某阶段的应力失真,必然导致后续转换应力的真实性,而考虑塑性徐变的实测应变转换的应力更符合实际情况。     

Analysis of creep lifetime of a ASME Grade 91 welded pipe

A multi-material local approach to creep damage was applied to a ferritic-martensitic ASME Grade 91 steel welded joint at 625 °C. Focus was made on the detailed analysis of the most sensitive area of the weld i.e. the intercritical heat affected zone. Prediction of creep failure of the weld well agrees with experimental results. The model was then applied to the case of a seam-welded pipe exhibiting a roof defect, creep tested at 580 °C, showing consistent results with a more classical engineering assessment.     

Failures of High-Temperature Critical Components in Combined Cycle Power Plants

This article highlights briefly the reported failure of critical parts and equipment in gas turbine, heat recovery steam generator, and steam turbine, in addition to the requirements of lifetime predictions for the high-temperature components in the combined cycle power plant (CCPP). For assessing fracture strength of flawed structural components in high-temperature environments, the first and foremost thing observed is to ascertain the reason for cracking. Special considerations are to be given in case of stress corrosion cracking, environmentally assisted cracking or bulk creep damage. Sensitivity analysis has to be performed to identify the influencing material properties and crack sizes on the load-bearing capacity of the structural component. An elastic–plastic criterion is examined by considering the fracture data of center crack tension specimens on several materials.     

HIDA activity on P91 steel

The 9%-12% Cr-steels are strategic materials for new power plant and for component substitution for plant life extension. One of these steels, P 91 was included in the project BE-1702 (HIDA) to provide crack initiation and growth data for the improvement and validation of procedures for high-temperature defect assessment. The paper presents an outline of the testing programme and the initial results for P 91. In addition to uniaxial and static/cyclic creep crack growth tests on standard fracture mechanics geometries, feature tests are also included in the experimental programme. These consist of internally pressurised pipe welds, pipe bends and 4-point bend pipes, and C-shaped specimens. The majority of these tests are still ongoing. The static and cyclic loading conditions are being employed to consider the range of creep/fatigue interaction in this alloy. All tests are being conducted at 625°C.     

新型耐火耐候钢材高温力学性能与本构模型研究

采用标准试验方法,对首钢集团生产的楼承板用SQ410FRW耐火耐候钢冷轧钢带进行稳态拉伸试验,以测定其典型高温力学性能指标,包括钢材高温弹性模量、规定塑性延伸强度、抗拉强度、断后伸长率和断面收缩率。通过非线性回归方法得出相应的高温折减系数表达式,包括弹性模量折减系数、规定塑性延伸强度折减系数和抗拉强度折减系数。根据试验应力-应变关系曲线,回归得出基于Ramberg-Osgood模型(R-O模型)的应力-应变本构模型,以用于后续有限元参数化建模过程中对结构构件的温度场分析和顺序热力耦合分析。试验结果表明：绝大多数拉伸试样均在平行段内或标距段内发生断裂,且断后伸长率随温度升高呈现总体增大趋势;高温弹性模量、高温规定塑性延伸强度和抗拉强度在600℃及以下时降低较少,均保持在常温名义值的60%以上,基本满足耐火钢的力学性能指标要求;基于R-O模型的应力-应变本构关系表达式的拟合优度均在90%以上,与试验应力-应变曲线吻合良好,故提出的本构模型可用于相关钢结构或组合结构构件的有限元抗火分析。     

Creep damage quantification of 2.25Cr–1Mo steel using scanning electron microscopy

Abstract

The material 2.25Cr–1Mo alloy steel has been used extensively for high temperature applications in power generation plant for over five decades owing to its long term creep resistance. It has been recognised that the lifetime of a high temperature component containing pre-existing defects is dependent not only upon the material's crack propagation resistance but also upon an incubation period before crack growth during which a damage zone ahead of the defect tip develops. The extent of the damage occurring during this incubation period, before crack propagation, is dependent upon the stress intensity at the defect tip, the ductility of the material, and the microstructure in the damage zone. The present paper details a technique for quantifying the early stages of creep damage using image analysis in the scanning electron microscope, and compares the degree, distribution, and orientation of creep damage occurring in two microstructural variables of 2.25Cr–1Mo alloy steel. The paper describes the procedures necessary for generating consistent and reproducible quantitative analysis results, including specimen preparation, defect detection, and measurement criteria. The image analysis process, its accuracy, and application to the study of creep damage mechanisms occurring ahead of defects are discussed.     

200MW机组高温过热器弯管爆裂原因探讨

对２００ＭＷ机组高温热器弯管爆裂事故作了分析,重点进行了高温过热器管材２Ｃｒ１ＭｏＶ钢的高温短时力学性能试验和高温疲劳性能试验。研究表明,调峰机组高温过热器弯管爆裂的主要原因是长期超温运行及循环蠕变损伤所引起的。     

A meso-scale damage evolution model for cyclic fatigue of viscoplastic materials

This study presents an approach to predict the degree of material degradation and the resulting changes in elastic, plastic and creep constitutive properties of viscoplastic materials, during cyclic loading in micro-scale applications. The objective of the study is to address the initiation and growth of homogeneous meso-scale damage, in the form of distributions of micro-cracks and micro-voids, due to cyclic, plastic (rate-independent inelastic) and creep (rate-dependent inelastic) deformations in viscoplastic materials and to evaluate the resulting changes in the effective meso-scale elastic, plastic and creep constitutive properties. An energy partitioning damage evolution (EPDE) model is proposed to describe the viscoplastic damage evolution. Development of the EPDE model constants is then demonstrated for a Pb-free solder, based on cyclic fatigue test data. Application of the EPDE model is demonstrated for solder joint fatigue during thermal cycling of a ball grid array (BGA) electronic assembly. A 3D viscoplastic finite element analysis is conducted, and damage evolution is modeled using a successive initiation (SI) technique reported earlier by the authors. In this approach, the local (meso-scale) material properties are progressively degraded and highly damaged sections of the macro-scale structure are ultimately eliminated, using the EPDE model. Prediction of damage initiation and propagation is presented both with and without property updating, for comparison purposes. The analysis shows that the EPDE model can realistically capture the softening observed during cyclic loading.     

A mean-field micromechanical formulation of a nonlinear constitutive equation of a two-phase composite

In this paper, a mean-field micromechanical approach has been employed to formulate a nonlinear constitutive equation and yield conditions of a two-phase composite considering plastic and creep deformation of constituent phases. The derived constitutive equation is expressed in a piecewise linear-rate form, so it can be easily combined with common structural analyses such as a finite element analysis as well as lamination theories for typical continuous fiber-reinforced composite structures. The model has taken into account the threshold creep of constituent phases and diffusional mass transfer at the inclusion/matrix interface, which play a significant role in high-temperature deformation of short-fiber-reinforced metal matrix composites. A numerical study on anisotropy in Bauschinger effect and thermal-cycling creep of SiC whisker/Al matrix composites has been made based on the developed model.     

考虑应变梯度及刚度劣化的剪切带局部变形分析

基于梯度塑性理论,研究了应变软化阶段的刚度劣化对剪切带内部的局部应变及相对剪切位移的影响。剪切带被看作一维剪切问题,本构关系为线弹性及线性应变软化。考虑刚度劣化后,剪切带的弹性应变由弹性剪切模量、损伤变量及残余剪切模量确定。剪切带的非局部总应变由双线性的本构关系确定。将非局部总应变减去弹性应变,可得剪切带的非局部塑性应变。剪切带非局部塑性应变与流动应力及损伤变量等参数有关,此关系即为在经典弹塑性理论框架之内的考虑刚度劣化的屈服函数。将二阶应变梯度项引入该函数,可得剪切带内部的局部塑性剪切应变及局部总剪切应变的分布规律。对局部塑性剪切应变积分,得到了局部塑性剪切位移。结果表明:考虑了刚度劣化后,剪切带内部的弹性剪切应变及位移增加,而局部塑性剪切应变及位移降低。若不考虑刚度劣化,理论结果可蜕化为以前的结果。理论结果与岩石局部变形的观测结果在定性是一致的。     

ZrB_2基超高温陶瓷复合材料的高温拉伸损伤行为

开展了SiC(20vol%)-石墨(15vol%)/ZrB2复合材料室温及高温拉伸性能实验,发现高温时复合材料的拉伸强度和弹性模量有所降低,并且具有明显的非线性特征。引入热损伤来表征弹性模量随温度的衰减规律,利用强度统计分析方法确定单向应力状态下材料的机械损伤演化方程,建立了材料在热力耦合条件下的高温拉伸损伤非线性本构模型。分析表明:随着温度的升高,SiC-石墨/ZrB2复合材料的热损伤和机械损伤不断增加,延性增强,且脆性-延性破坏转变温度范围为1 250~1 350℃。     

Feature tests on welded components at higher temperatures—Material performance and residual stress evaluation

A reliable maintenance and service of energy generation plants would be impossible without the professional designing, manufacturing and monitoring of welded joints. The lifetime assessment factors of welded components as implemented in the design codes must be updated accounting for the modern materials and the advanced steam parameters used in the piping construction [Weld Strength for high temperature components design and operation (WELDON). European Project No. GRD2-2000-30363, Gampe U, Seliger P, Creep crack growth testing of P91 and P22 pipe bends. Int J Pressure Vessels Piping 2001;78:859-64, INTEGRITY of repair welds in high temperature plants operating under steady and cyclic loading conditions. European Project No. G5RD-CT-1999-00118].Within the EU 5th Framework RTD project ‘WELDON’ tests at high temperatures are performed on component-like feature test specimens like welded pipes and large tensiles in addition to laboratory specimens to study the geometry and size effects on the damage evaluation methodology. The circumferential welds of the pipes are subjected simultaneously to internal pressure and an axial load. The large tensile specimens manufactured from the welded pipes are subjected to uniaxial loading. These components are made from steel grade P22 and P91 and are equipped with gages for on-line monitoring of temperatures, deformations and strains.Residual stresses are measured on these components in as welded and after post-weld heat treatment (PWHT) conditions and are monitored during creep testing with interruptions and after failure. X-ray and hole drilling techniques are employed in these measurements. These data will be used to validate the FE modelling of residual stresses and damage assessment.The results obtained from long time creep tests, metallographic investigations of damage development in the different zones of the weldment and residual stress measurements are presented in this paper.     

Large strain constitutive modelling and computation for isotropic,creep elastoplastic damage solids

A three-dimensional fully coupled creep elastoplastic damage model at finite strain for isotropic non-linear material is developed. The model is based on the thermodynamics of an irreversible process and the internal state variable theory. A hyperelastic form of stress–strain constitutive relation in conjunction with the multiplicative decomposition of the deformation gradient into elastic and inelastic parts is employed. The pressure-dependent plasticity with strain hardening and the damage model with two damage internal variables are particularly considered. The rounding of stress–strain curves appearing in cycling loading is reproduced by introduction of the creep mechanism into the model. A numerical integration procedure for the coupled constitutive equations with three hierarchical phases is proposed. A consistent tangent matrix with consideration of the fully coupled effects at finite strain is derived. Numerical examples are tested to demonstrate the capability and performance of the present model at large strain.     

Evaluation of creep damage accumulation models: Considerations of stepped testing and highly stressed volume

Many components experience combined temperature and stress loading and are designed to withstand creep. In this study, experimental creep testing was performed under both static and stepped loading conditions with constant temperature for two specimen geometries (tensile and three-point bend). The objective of this study was to evaluate whether existing damage accumulation models accurately predict creep performance when considering step loading and stress gradients. Model predictions, based on static tensile creep data and using a highly stressed volume correction for the three-point bend specimens and the experimental average damage sum, agreed well with experimental data; differences were on average within 38% (static) and 2.2 h (stepped). Comparisons showed more accurate predictions using an exponential Larson–Miller parameter curve and the Pavlou damage accumulation model. Findings of the current study have applicability to component design, where complex geometries often contain stress gradients and it is desirable to predict creep performance from static tensile creep data.     

Viscoplastic response and creep failure time prediction of polymers based on the transient network model

The nonlinear viscoelastic/viscoplastic response of polymeric materials is described by a new model based on previous works in terms of monotonic loading, stress–relaxation, and creep. In the proposed analysis, following a constitutive equation of viscoelasticity, based on the transient network theory, essential modifications are introduced, which account for the nonlinearity and viscoplasticity at small elastic and finite plastic strain regime. In addition, viscoplastic response is successfully analyzed by a proper kinematic formulation, which is combined with a functional form of the rate of plastic deformation. A three-dimensional constitutive equation is then derived for an isotropic incompressible medium. This analysis is capable of capturing the main aspects of inelastic response and the instability stage taking place at the tertiary creep, related to the creep failure. Model simulations described successfully the experimental data of polypropylene, which were performed elsewhere.     

Comparative study on stress–strain hysteresis response of SAC solder joints under thermal cycles

The present study attempts to evaluate the stress-strain hysteresis responses of SAC solder joints in Resistor and FleXBGA144 packages subjected to thermal cyclic loading using several constitutive models. The total deformation of the solder material consists of elastic, rate-independent plastic and rate-dependent creep components. The constitutive models discussed in this study each weighted elastic, plastic and creep deformations differently. At low stresses SAC solder alloys were found to be creep resistant, where at higher stresses, the influence of different microstructures disappears as matrix-creep dominates in this region. Thus, the proper constitutive model requires all the three ingredients of the elastic, the creep, and the time-independent plastic data for different stress levels to effectively predict the hysteresis behavior of the SAC solder alloys. The hysteresis loops predicted by constitutive models were also found in close agreement with the loops generated by FEM for the SAC solder joint subjected to thermal cycling.     

Multiaxial creep–fatigue under anisothermal conditions

Because creep–fatigue is mainly studied in uniaxial tension, it is shown here how to proceed to perform both experiments and calculations under multiaxial loading and when the temperature varies both in time and space. The constitutive equations used are those of elasto‐visco‐plasticity coupled or not, to damage, with isotropic and kinematic hardening. It is shown that the unified damage law first proposed for ductile failure and then for fatigue may also be applied to multiaxial creep–fatigue interactions with a new expression for the damage threshold. The procedure for the identification of material parameters is described in detail. Finally, it is shown that the uncoupled calculation procedure, where damage is calculated as a post‐processing of an elasto‐visco‐plastic computation, gives satisfactory results in comparison to the fully coupled analysis; the latter being more accurate but very expensive in computer time.     

Creep rupture behaviour of circumferentially welded mod. 9Cr–1Mo steel pipe subject to internal pressure and axial load

The multi-axial creep strength of circumferential welds in power piping, including failure mode and failure life against a wide range of stress ratios and stress levels, was newly examined in this paper. The creep rupture behaviour of modified 9Cr–1Mo steel (9Cr–1Mo–VNb steel; ASME P91) pipe with a circumferential weld subject to combined internal pressure and axial load was experimentally investigated at 650 °C. The test results, with several kinds of stress ratios of macroscopic axial and hoop stress can be summarised as follows. Along with the increased stress ratio (axial/hoop), both failure location and failure mode changed from a base metal failure caused by hoop stress to an FGHAZ (fine-grained heat affected zone) failure due to axial stress. The stress ratio where the failure mode changed was ‘0.8’. Strength reduction in FGHAZ failure by axial stress should be considered in the structural design of circumferential welds. A series of FEM creep analysis was carried out to discuss the relation of the failure mode to both the local stress distribution and the damage. The failure mode variation along with the increase in the stress ratio is also discussed based on simplified ductile creep failure analysis.