Nobuyoshi Komai

10-Year Experience With T23(2.25Cr-1.6W) and T122(12Cr-0.4Mo-2W) in a Power Boiler

Tungsten strengthened ferritic steels, 2.25Cr-1.6W-V-Nb and 12Cr-0.4Mo-2W-V-Nb-Cu have been developed and approved by the ASME Boiler and Pressure Vessels Code Committee for use in Section I construction, designated as T23 and T122, respectively. A field exposure test installing both steel tubes in service along with comparative materials in the tertiary superheater and secondary reheater of a 156 MW utility power boiler has been conducted since April 1993. The tubes were removed to confirm their material properties and corrosion/steam oxidation behaviors after 1-year, 3-year, 6-year, and 10-year periods of service. The tensile and creep rupture strengths of both steels showed no remarkable change during service. Examination of steam oxidation scale on the inner surface of the tubes indicated that the scale growth rate of T122 was extremely small following 1-year service. The growth rate and morphology of steam oxidation scale is discussed, as compared with conventional materials.

Long-Term Service Experience With Advanced Austenitic Alloys in Eddystone Power Station

A service exposure test of advanced austenitic alloys was performed at Eddystone Power Station Unit 1. The alloys tested were TP347HFG, SUPER304H and HR3C as well as 17-14CuMo as a reference material. They were installed in the final super-heater section in 1991 and were removed in 2004. The service exposure duration is 75,075 h with the steam temperature and pressure estimated 615 °C and 35 MPa, respectively. Post exposure examination has proved no marked hot-corrosion and steam oxidation have occurred for the TP347HFG, SUPER304H and HR3C specimens, while severe hot-corrosion and exfoliation of steam-oxide films was pronounced in 17-14CuMo specimens. It is also found that HR3C exhibits the highest tensile strength with a lowest ductility and TP347HFG does vice versa, while the strength of SUPER304H is equivalent to that of 17-14CuMo with much better ductility. Short-term creep rupture strengths of these alloys have been reduced to some extent after the long-term service exposure and a longer-term creep rupture testing has been in progress. Microstructural evolution of the TP347HFG, SUPER304H and HR3C as well as 17-14CuMo during the long-term service exposure have been analyzed using a detailed TEM examination and the chemical analysis of extraction residue of the exposed specimens.Copyright

Prediction of Type IV creep failure of a seam-welded mod. 9Cr-1Mo elbow based on microscopic damage simulation

Abstract Utilising the random-fracture-resistance model of grain boundaries, micro-macro combined creep damage simulation was applied to the prediction of the distribution of small defects in the FGHAZ (fine-grained heat-affected zone) of longitudinal welds in an actual-size elbow of modified 9Cr-1Mo (9Cr-1MoVNb) steel subject to internal pressure at 923 K. Based on the simulation results, a prediction scheme for the final rupture life of welds was considered using the damage mechanics concept together with effective stress. The applicability of nonlinear fracture mechanics was also discussed, assuming the initial crack length determined from the microscopic simulation results. The results thus obtained are summarized as follows: As the simulation results showed, the peaks of small defect density in the subsurface could be predicted, corresponding well with the observed results. Final failure life prediction based on the damage mechanics concept was found to be applicable, by considering both the final failure surface connecting the weakest grain boundaries and the effective stress against this surface. The fracture mechanics approach was also found applicable when assuming the initial crack length from the high peaks of the simulated small defects in the last stage of creep life.

Experimental observation of creep damage evolution in seam-welded elbows of mod. 9Cr-1Mo steel

Seam-welded elbows and straight pipe of the same size as actual high temperature reheat piping for boiler applications were manufactured, and internal pressure creep testing was conducted. Uniaxial creep testing was also performed in order to compare creep damage behaviours. Comparing the observed creep damage evolution and stress analysis results, a creep damage estimation method was discussed. Creep damage distribution varied depending on ovality in the cross sections of the seam-welded elbows. It is important that FEM models for creep analysis incorporate measurement results for the cross-sectional shape of seam-welded elbows. Using the nominal stress of the specimens and the average creep rupture data from small size uniaxial welded joint tests, a simplified prediction method was discussed, which is applicable to creep rupture time prediction for both large creep specimens and seam-welded elbows.

Field Test Results of Newly Developed Austenitic Steels in the Eddystone Unit No.1 Boiler

Six new grade austenitic stainless steel tubes including SUPER304H® (C.C. 2328), TP347HFG, NF709® , TEMPALOY A-3® , HR3C® (TP310HCbN) and TEMPALOY CR30A® were selected and installed in the superheater of the Eddystone No.1 boiler for the purpose of extending tube service life by reducing fire-side and steam-side corrosion. No significant corrosion was observed on the outer surfaces at 75,075h of exposure. Precipitates due to exposure were identified by TEM-EDS analysis. The thickness of steam oxidation scale was less in high-Cr materials, and high Cr content was thus demonstrated to have effectively improved steam oxidation resistance. HR3C showed comparatively poor impact properties, while the other materials exhibited acceptable impact values of over 30J/cm2 at 20°C. All materials showed reduced creep strength compared with unexposed materials after service exposure under high stress test conditions. However the differences became smaller at lower stresses.Copyright

Creep Deformation Behavior and Microstructural Degradation During Creep of Pre-Strained 25Cr-20Ni-Nb-N Steel

The purpose of this study is to clarify the creep deformation behavior and microstructural degradation during creep of pre-strained 25Cr-20Ni-Nb-N steel (TP310HCbN), which has the highest creep strength among austenite stainless steels used for boiler tubes. The creep rupture strengths of the 20% pre-strained materials tested at 650°C under 210 MPa and 180 MPa were higher than those of solution-treated materials. However, the long time creep rupture strengths of the 20% pre-strained materials tested at 700°C and 750°C were lower than those of solution-treated materials. Thus, the creep strengths of the prestrained materials depend on test temperature and stress. Furthermore, the minimum creep rate of the 20% pre-strained materials and re-solution-treated materials tested at 650°C under 300MPa were 1.2 × 10−9 and 1.6 × 10−8 s−1 , respectively. Thus, the minimum creep rate of the 20% pre-strained materials was lower than for re-solution-treated materials. The creep strengthening mechanism of the pre-strained materials at 650°C was considered to be that high-density dislocations were maintained until the late stage of creep. On the other hand, the creep rupture strengths of the 20% pre-strained materials were lower than those of solution-treated materials tested at over 700°C because of agglomeration and coarsening of precipitates and the recovery of dislocations.Copyright

Effect of Boron Addition on Creep Strength in 9Cr-3W-3Co-V-Nb Steels

Recently, boron is being added to high-strength steels for boilers and turbines in order to raise creep strength. However, there are various points that are not yet fully understood with regard to the creep-strengthening mechanism of boron addition. In order to investigate the influence of boron addition on creep strength, varying the amounts of boron and nitrogen were added in 9Cr-3W-3Co-V-Nb steels tempered two different conditions and investigated. Although creep strengths of all materials converged to become similar in the low-stress region, the materials tempering at 780°C with boron addition which exhibited the lowest strength on the high-stress region is seen to have slightly greater strength on the low-stress region. In analysis of the precipitates and grain boundary of creepruptured material conducted using TEM-EDS and Auger diffraction analysis equipment, the presence of boron could not be detected.Copyright

Creep Failure Behavior of Creep-Strength Enhanced Ferritic Steels

Creep-strength enhanced ferritic steels such as Gr.92, Gr.122, Gr.23 and Gr.91 have recently been introduced for power plant applications, and some of these have experienced creep failure in boiler tubes and thick wall components after several years of operation. In order to use these steels safely in power plants, understanding of creep failure behavior is essential. In this study the creep failure of Gr.91 and Gr.92 boiler tube base metal and Type IV cracking of Gr.92, Gr.122, Gr.23 and Gr.91 welds were reproduced in test piece of actual components size. Creep failure mode was investigated, as was microstructural morphology during creep, particularly in the weldment, with discussion based on evidence of void formation and changes in the physical damage in terms of creep life.Copyright