Christopher J. Hyde

On the interpretation of results from small punch creep tests

The small punch creep testing method is highly complex and involves interactions between a number of non-linear processes. The deformed shapes that are produced from such tests are related to the punch and specimen dimensions and to the elastic, plastic, and creep behaviour of the test material, under contact and large deformation conditions, at elevated temperature. Owing to its complex nature, it is difficult to interpret the small punch test creep data in relation to the corresponding uniaxial creep behaviour of the material. One of the aims of this paper is to identify the important characteristics of the creep deformation resulting from ‘localized’ deformations and from the ‘overall’ deformation of the specimen. Following this, the results of approximate analytical and detailed finite element analyses of small punch tests are investigated. It is shown that the regions of the uniaxial creep test curves dominated by primary, secondary, and tertiary creep are not those that are immediately apparent from the displacement versus time records produced during a small punch test. On the basis of the interpretation of the finite element results presented, a method based on a reference stress approach is proposed for interpreting the results of small punch test experimental data. Future work planned for the interpretation of small punch tests data is briefly addressed.

Determination of material properties in the Chaboche unified viscoplasticity model

An experimental programme of cyclic mechanical testing of a 316 stainless steel, at temperatures up to 600°C, under isothermal conditions, for the identification of material constitutive constants, has been carried out using a thermo-mechanical fatigue (TMF) test machine with induction coil heating. The constitutive model adopted is a modified Chaboche unified viscoplasticity model, which can deal with both cyclic effects, such as combined isotropic and kinematic hardening, and rate-dependent effects, associated with viscoplasticity. The characterization of 316 stainless steel is presented and compared with results from cyclic isothermal tests. A least-squares optimization algorithm has been developed and implemented for determining the material constants in order to further improve the general fit of the model to experimental data, using the initially obtained material constants as the starting point in this optimization process. The model predictions using both the initial and optimized material constants are compared to experimental data.

Thermal-mechanical fatigue simulation of a P91 steel in a temperature range of 400–600°C

Abstract This paper deals with the identification of material constants to simulate the effect of cyclic mechanical loading and temperatures. A Chaboche viscoplasticity model was used in this study to model the thermal-mechanical behaviour of a P91 martensitic steel. A fully-reversed cyclic mechanical testing programme was conducted isothermally between 400 and 600°C with a strain amplitude of 0.5%, to identify the model constants using a thermo-mechanical fatigue (TMF) test machine. Thermo-mechanical tests of P91 steel were conducted for two temperature ranges of 400 – 500°C and 400 – 600°C. From the test results, it can be seen that the P91 steel exhibits cyclic softening throughout the life of the specimens, for both isothermal and thermal-mechanical loading and this effect can be modelled by the set of viscoplasticity constants obtained. Finite element simulations of the test specimens show good comparison to isothermal and TMF experimental data.

A unified viscoplastic model for high temperature low cycle fatigue of service-aged P91 steel

The finite element (FE) implementation of a hyperbolic sine unified cyclic viscoplasticity model is presented. The hyperbolic sine flow rule facilitates the identification of strain-rate independent material parameters for high temperature applications. This is important for the thermo-mechanical fatigue of power plants where a significant stress range is experienced during operational cycles and at stress concentration features, such as welds and branched connections. The material model is successfully applied to the characterisation of the high temperature low cycle fatigue behavior of a service-aged P91 material, including isotropic (cyclic) softening and nonlinear kinematic hardening effects, across a range of temperatures and strain-rates.

A Basis for Selecting the Most Appropriate Small Specimen Creep Test Type

Many components in conventional and nuclear power plant, aero-engines, chemical plant etc., operate at temperatures which are high enough for creep to occur. These include plain pipes, pipe bends, branched pipes etc., the manufacture of such components may also require welds to be inserted in them. In most cases, only nominal operating conditions (i.e., pressure, temperatures, system load, etc.) are known and hence precise life predictions are not possible. Also, the proportion of life consumed will vary from position to position within a component and the plant. Hence, nondestructive techniques are adopted to assist in making decisions on whether to repair, continue operating or scrap certain components. One such approach is to use scoop samples removed from the components to make small creep test specimens, i.e., sub-size uniaxial creep test specimens, impression creep test specimens, small punch creep test specimens, and small ring (circular or elliptical) creep test specimens. Each specimen type has its own unique advantages and disadvantages and it may not be obvious which one is the most appropriate test method to use. This paper gives a brief description of each specimen and associated test type and describes their practical limitations. The suitability of each of the methods for determining “bulk” material properties is described and it is shown that an appropriate test type can be chosen.

Theoretical basis and practical aspects of small specimen creep testing

Interest in and the application of small specimen creep test techniques are increasing. This is because it is only possible to obtain small samples of material in some situations, for example, the scoop samples that are removed from in-service components, the heat-affected zones that are created when welds are used to join components and the desire to produce only small amounts of material in alloy development programmes. It is therefore important to review and compare the theoretical basis and practical aspects of each of the small specimen creep testing methods, in order to clearly understand which of the methods is the best for any specific application. This article provides the theoretical basis for each commonly used test method.

High Temperature, Low Cycle Fatigue Characterization of P91 Weld and Heat Affected Zone Material

The high temperature low cycle fatigue behavior of P91 weld metal (WM) and weld joints (cross-weld) is presented. Strain-controlled tests have been carried out at 400 °C and 500 °C. The cyclic behavior of the weld material (WM) and cross-weld (CW) specimens are compared with previously published base material (BM) tests. The weld material is shown to give a significantly harder and stiffer stress–strain response than both the base material and the cross-weld material. The cross-weld tests exhibited a cyclic stress–strain response, which was similar to that of the base material. All specimen types exhibited cyclic softening but the degree of softening exhibited by the cross-weld specimens was lower than that of the base material and all-weld tests. Finite element models of the base metal, weld metal and cross-weld test specimens are developed and employed for identification of the cyclic viscoplasticity material parameters. Heat affected zone (HAZ) cracking was observed for the cross-weld tests.

Comparison of several optimisation strategies for the determination of material constants in the Chaboche visco-plasticity model

Determining representative material constant sets for models that can accurately predict the complex plasticity and creep behaviour of components undergoing cyclic loading is of great interest to many industries. The Chaboche unified visco-plasticity model is an example of a model that, with the correct modifications, shows much promise for this particular application. Methods to approximate material constant values in the Chaboche model have been well established; however, the need for optimisation of these parameters is vital due to assumptions made in the initial estimation process. Optimisation of a material constant set is conducted by fitting the predicted response to the experimental results of cyclic tests. It is expected that any experimental data set (found using the same values of test parameters such as temperature; the dependency of which is not accounted for in the original Chaboche model) should yield a single set of optimised material parameters for a given material. In practice, this may not be the case. Experimental test programs usually include multiple loading waveforms; therefore, it is often possible to optimise for separate, different sets of material constants for the same material operating under comparable conditions. Several optimisation strategies that utilise multiple sets of experimental data to form the objective functions in optimisation programs have been applied and critiqued. A procedure that evaluates objective functions derived from the multiple experimental data types simultaneously (i.e. in the same optimisation iteration) was found to give the most consistently high-quality fitting. In the present work, this is demonstrated using cyclic experimental data for a P91 steel at 600 °C. Similar strategies may be applied to many constitutive laws that require some form of optimisation to determine material constant values.

Use of small specimen creep data in component life management: a review

Small specimen creep testing techniques are novel mechanical test techniques that have been developed over the past 25 years. They mainly include the sub-size uniaxial test, the small punch creep test, the impression creep test, the small ring creep test and the two-bar creep test. This paper outlines the current methods in practice for data interpretation as well as the state-of-the-art procedures for conducting the tests. Case studies for the use of impression creep testing and material strength ranking of creep resistant steels are reviewed along with the requirement for the standardisation of the impression creep test method. A database of small specimen creep testing is required to prove the validity of the tests.

Cyclic Viscoplasticity Testing and Modeling of a Service-Aged P91 Steel

A service-aged P91 steel was used to perform an experimental program of cyclic mechanical testing in the temperature range of 400 °C–600 °C, under isothermal conditions, using both saw-tooth and dwell (inclusion of a constant strain dwell period at the maximum (tensile) strain within the cycle) waveforms. The results of this testing were used to identify the material constants for a modified Chaboche, unified viscoplasticity model, which can deal with rate-dependant cyclic effects, such as combined isotropic and kinematic hardening, and time-dependent effects, such as creep, associated with viscoplasticity. The model has been modified in order that the two-stage (nonlinear primary and linear secondary) softening which occurs within the cyclic response of the service-aged P91 material is accounted for and accurately predicted. The characterization of the cyclic viscoplasticity behavior of the service-aged P91 material at 500 °C is presented and compared to experimental stress–strain loops, cyclic softening and creep relaxation, obtained from the cyclic isothermal tests.