Jonathan Parker

Simulation of Creep Deformation and Rupture of Notched Bar Specimens of Grade 92 Steel

Creep strain equations of Grade 92 steel which is used in boilers and piping systems of ultra-supercritical (USC) thermal power plants were developed based on the results of creep tests on smooth round bar specimens of three kinds of Grade 92 steels. In these equations, primary creep behavior was represented by a power-law and tertiary creep behavior was described by an exponential function. Creep parameters were determined as a function of creep rupture times which were calculated from stress and absolute temperature. Additionally, generalized creep failure criteria considering the multiaxial stress were established on the basis of results of creep tests on circumferentially notched round bar specimens. These creep strain equations and creep failure criteria were incorporated into finite element analysis software. Then, creep failure analyses were carried out and the resulting deformation behavior and rupture times were compared with the experimental results. Creep rupture lives were predicted with a good accuracy, within a factor of two in most cases.Copyright

Optimization of Vickers Hardness Parameters for Micro- And Macro-Indentation of Grade 91 Steel

Hardness is being assessed as a potential life-assessment tool for tracking microstructural degradation and remaining life in creep strength enhanced ferritic (CSEF) steels. Such methodology is already being utilized for the CSEF steel Grade 91, which has been widely implemented in both replacement parts and new construction over the last two decades. Additionally, research into the complex microstructural features in welded joints often utilizes hardness surveys to characterize changes caused by thermal processing. New automated hardness testing equipment now affords the ability to develop statistically relevant datasets for these uses. However, proper application and understanding of the data requires knowledge of limitations and variations with the load and spacing of the hardness indents and the potential role of different material conditions in this complex steel. In this work, we have examined the effect of load in three Grade 91 material conditions, as well as the effect of spacing in as-received material to determine optimum parameters for both macrohardness (i.e., >1 kg) and microhardness mapping (i.e.,

Microstructural Characterization of the Heat-Affected Zones in Grade 92 Steel Welds: Double-Pass and Multipass Welds

The microstructure in the heat-affected zone (HAZ) of multipass welds typical of those used in power plants and made from 9 wt pct chromium martensitic Grade 92 steel is complex. Therefore, there is a need for systematic microstructural investigations to define the different regions of the microstructure across the HAZ of Grade 92 steel welds manufactured using the traditional arc welding processes in order to understand possible failure mechanisms after long-term service. In this study, the microstructure in the HAZ of an as-fabricated two-pass bead-on-plate weld on a parent metal of Grade 92 steel has been systematically investigated and compared to a complex, multipass thick section weldment using an extensive range of electron and ion-microscopy-based techniques. A dilatometer has been used to apply controlled thermal cycles to simulate the microstructures in distinctly different regions in a multipass HAZ using sequential thermal cycles. A wide range of microstructural properties in the simulated materials were characterized and compared with the experimental observations from the weld HAZ. It has been found that the microstructure in the HAZ can be categorized by a combination of sequential thermal cycles experienced by the different zones within the complex weld metal, using the terminology developed for these regions based on a simpler, single-pass bead-on-plate weld, categorized as complete transformation, partial transformation, and overtempered.

Creep ductility considerations for high energy components manufactured from creep strength enhanced steels

Abstract It is well established that the tendency for low ductility ‘creep brittle’ fracture behaviour in tempered martensitic steels is linked to the formation and growth of micro voids or ‘cavities’. Details of the contributions of all factors affecting damage development are still under investigation. However, it is known that for tempered martensitic steels voids often initiate over most of the creep life. Nucleation has been recorded on both prior austenite grain boundaries and at other micro structural features such as lath boundaries. The number of voids formed, and the fracture behaviour observed, depend on the type of creep strength enhanced ferritic (CSEF) steel and specific details of fabrication and heat treatment. In Grade 91 steel, void nucleation is sensitive to metallurgical factors such as composition and steel making practices. Key indicators of susceptibility to creep cavitation also include the levels of trace elements present and the presence of hard non-metallic inclusions. In Grade 92 steel, creep void formation has been linked to boron nitrides and other inclusions. These inclusions are present when there has been insufficient control of composition and heat treatment. Metallurgical factors linked to whether a particle will nucleate a void include the nature of the inclusion/matrix interface, the shape and size and the location of the inclusions within the microstructure. This paper describes the results of critical uniaxial and multiaxial testing for CSEF steels and compares data from nominally the same steels which have different metallurgical susceptibilities to void formation.

Microstructural features, mechanical properties and high temperature failures of ferritic to ferritic dissimilar welds

ABSTRACT Dissimilar metal welds (DMWs) between ferritic steel grades are found extensively in the construction of thermal power plants. The potential combinations and approaches for joining dissimilar ferritic steels are nearly limitless. For DMWs, the difference in alloy composition (specifically chromium and carbide-forming elements) provides the main driving force for carbon diffusion during welding, post-weld heat treatment and long-term service at elevated temperatures. Since the high temperature creep strength of local, carbon-denuded zones can be dramatically reduced from that of the parent or filler material, the service performance of ferritic DMWs can be severely reduced. This article reviews experimental observations on microstructural evolution in dissimilar ferritic welds, activities to describe the observed phenomena by modelling and simulation and discusses the performance of these welds at high temperature. Lastly, a well-engineered approach to the design of ferritic DMWs is discussed in the context of thermal power plants which are subject to damage by creep. Abbreviations: HAZ: heat affected zone; PWHT: post weld heat treatment; GMAW: gas-metal arc welding; SMAW: shielded-metal arc welding; GTAW: gas tungsten arc welding; SAW: submerged arc welding; DMW: ferritic dissimilar metal weld; CGHAZ: coarse-grained heat affected zone; FGHAZ: fine-grained heat affected zone; CDZ: carbon-denuded zone; CEZ: carbon-enriched zone; CSEF: creep strength enhanced ferritic

Non-destructive characterisation of N/Al level in P91 steels using electromagnetic sensors

Abstract P91 steels with different N/Al ratios short term tempered or long term aged at a series of temperatures have been characterised using a multifrequency electromagnetic sensor. It was found that the low frequency inductance value is sensitive to the intralath MX precipitates that determine the mean free path for domain wall motion and hence the initial relative permeability of the steels. The electromagnetic sensor is capable of separating P91 steels with low N/Al ratio in the service entry or early service state. In contrast, the hardness measurements were found to be insensitive to the N/Al ratio for the short term tempered samples.

EPRI Guidelines for Fabrication of Components Manufactured From Grade 91 Steel

Over the last 10 years EPRI has been researching critical information on the factors affecting the performance of creep strength enhanced ferritic steels in general and Grade 91 steel in particular. This work has resulted in a major new report which provides recommended guidelines for fabrication and the associated quality assurance to ensure that component properties meet or exceed the minimum expectations of ASME design approaches. The present paper outlines the recommendations in the report and provides technical background for specific aspects of the guide.Copyright

The creep and fracture behaviour of tempered martensitic steels

Abstract Creep strength enhanced ferritic steels contain 9 to 12% Cr and were developed to exhibit excellent high temperature properties. These should be achieved when the microstructure exhibits a tempered martensitic matrix containing a substructure with a high dislocation density and a uniform dispersion of fine, second phase precipitates. It is interesting to note that when properly processed the typical alloy compositions for these steels provide reasonable strength but can exhibit brittle creep behaviour. The levels of ductility required in engineering applications necessitate proper control of composition (including trace elements), steel making and processing and all heat treatments. The properties needed for modern design methods can only be obtained using validated procedures for both uniaxial and multiaxial testing and documentation to establish the mechanisms controlling deformation and fracture for relevant stress states.

Metallurgical and Stress State Factors Which Affect the Creep and Fracture Behavior of 9% Cr Steels

EPRI-supported research has identified critical material information regarding the factors affecting the performance of creep strength-enhanced ferritic steels, in general, and Grade 91 steel, in particular. EPRI recommendations emphasize that a five-point, integrated strategy should be used for the effective life management of components fabricated from tempered martensitic steels. This integration promotes a balanced use of resources which, when properly focused, reduces uncertainty regarding creep and fracture behavior. Tighter control of processes from steel making, steel processing, and heat treatment ensures that alloys with deficient properties never enter service. One cornerstone of this proactive approach is the definition of ‘Metallurgical Risk’ which links the presence of inclusions and trace elements to the susceptibility for creep damage. The improved confidence in the high temperature performance of CSEF steel components promotes reliability, increases efficiency, and minimizes the risk of component fracture.

Weld repair of Grade 91 piping and components in power generation applications, creep performance of repair welds

Creep strength-enhanced ferritic steels, such as Grade 91, are the preferred material for much of the high-energy boiler tubing and piping components used in modern power generating plants. Weld repair techniques that achieve the necessary performance without the need for high-temperature post weld heat treatment (PWHT) offer particular benefits for Grade 91 steel. These benefits arise since there are many examples of poor heat treatment control which have resulted in component microstructures with below the minimum properties expected by design codes. Furthermore, even a controlled PWHT at temperatures at around 760 °C will further temper the base material. This is significant because excessive base metal tempering is one suggested criterion requiring component replacement. Successful demonstration of controlled welding techniques linked to minimal or no PWHT would alleviate these problems. This article presents results from a major project which is aimed at considering options for designing a ‘well-engineered’ repair. In this project, the creep performance of candidate repair methods was evaluated using large, feature test-type specimens containing the entire weldment including both fusion lines and heat-affected zones. The results show that the cross-weld life in Grade 91 steels does not appear to be a function of whether or not the welding procedures include PWHT. The results offer the potential to qualify ‘cold’ weld repairs in these steels.