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This document summarizes research on creep damage development and life expectancy in 9-12% Cr steels. It finds that creep cavities provide a clear indication of creep damage, though they form less in these steels compared to lower alloy ferritic steels. The number of cavities increases with higher stress multiaxiality and temperature but decreases with higher creep strain. Cavity size also tends to be smaller at lower temperatures. While criteria for damage assessment typically used for other steels may need adjustment, replication techniques can still effectively assess microstructure and cavities for evaluating life expectancy of components made from these high-chromium steels.
This document summarizes research on creep damage development and life expectancy in 9-12% Cr steels. It finds that creep cavities provide a clear indication of creep damage, though they form less in these steels compared to lower alloy ferritic steels. The number of cavities increases with higher stress multiaxiality and temperature but decreases with higher creep strain. Cavity size also tends to be smaller at lower temperatures. While criteria for damage assessment typically used for other steels may need adjustment, replication techniques can still effectively assess microstructure and cavities for evaluating life expectancy of components made from these high-chromium steels.
This document summarizes research on creep damage development and life expectancy in 9-12% Cr steels. It finds that creep cavities provide a clear indication of creep damage, though they form less in these steels compared to lower alloy ferritic steels. The number of cavities increases with higher stress multiaxiality and temperature but decreases with higher creep strain. Cavity size also tends to be smaller at lower temperatures. While criteria for damage assessment typically used for other steels may need adjustment, replication techniques can still effectively assess microstructure and cavities for evaluating life expectancy of components made from these high-chromium steels.
Part Part Creep damage development and evaluation in parent material Creep damage development and evaluation in parent material Karl Maile Karl Maile 2 2 Content Content Introduction Experimental work Creep damage development Metallographic findings Influence of stress state (multiaxiality) Influence of temperature and steel grade Life time assessment Creep damage assessment Summary and conclusion 3 3 Introduction Introduction Aim Enlargment of knowledge basis about the evolution of creep damage in components made of new martensitic steels Prevention of premature failure of component Optimization of inspection intervalls AVIF Projects Damage Evolution I III (2000 2009) Supported by FDBR and VGB MPA Universitt Stuttgart and SPG Dresden 4 4 Experimental Experimental work work Creep tests P91, E911 575, 600C 50000 h Quotient of multiaxiality h= H / V 0.33 (uniaxial) 0.5 (internal pressure, circumf. notch, tension force) Measuring of creep strains Replica Metallographic investigations Optical microscopy, SEM, TEM Numerical simulation strains, stresses Evolution of microstructure (precipitates) 5 5 Creep damage development Creep damage development Creep cavities metallographic appearance Polished by vibration technology etched Labor microsection Replica 6 6 Parameters on formation of creep cavities number, size Multiaxiality of stress state Notch tip Inner surface of hollow cylinder p Creep damage development Creep damage development E911, notched, 600C, 32000 h, integral strain over notch =1,6 % Gradient due to the influence of loading situation/multiaxiality Verification by Computertomography 7 7 Parameters on formation of creep cavities number, size Multiaxiality of stress state Creep damage development Creep damage development smooth cylinder internal pressure Notched cylinder internal pressure/tension Trend to an increase of number of cavities with increasing multiaxiality 0,2 0,4 0,6 0 200 400 600 t/t B >0,9 E911 t/t B <0,75 E911 t/t B >0,9 P91 t/t B <0,75 P91 n u m b e r
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1 / m m 2 Quotient of multiaxiality h 8 8 0,5 1,0 1,5 2,0 0 200 400 600 800 t/t B > 0,9 E911, 600C t/t B < 0,75 E911, 600C t/t B > 0,9 P91, 600C t/t B < 0,75 P91, 575C n u m b e r
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1 / m m 2 creep strain % Creep damage development Creep damage development smooth cylinder internal pressure/tension smooth cylinder internal pressure Trend to a decrease of number of cavities with increasing creep strain Parameters on formation of creep cavities number, size Multiaxiality of stress state 9 9 Creep damage development Creep damage development Larger number of cavities at 575 in comparison to that at 600C Parameters on formation of creep cavities number, size Temperature Specimens with test durations > 10000 h No failure Life time expenditure max. 80% Different melts 0,2 0,4 0,6 0 500 1000 P91 - 575C E911- 575C P91 - 600C E911- 600C n u m b e r
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1 / m m 2 quotient of multiaxiality h 10 10 Life time assessment Life time assessment should be based on findings/data of Replica (optical microscopy) assessment of the microstructure number of cavities (qualitatively, quantitatively) and/or porosity orientation of cavities, microcracks to maximum principal stress Strain measurement evolution of time-dependent local creep strain Extraction replica assessment of precipitations 11 11 0,2 0,4 0,6 0,8 1,0 0 500 1000 1500 2000 P91 E911 n u m b e r
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1 / m m 2 life time expenditure t/t B Analysis: P91, E911 575 C, test duration min 10200 h, max. 23000 h Life time assessment Clear indication of cavities Increase number of cavities Validation by ongoing tests with duration > 30000h 12 12 0,4 0,6 0,8 1,0 0 200 400 1500 2000 E911 P91 n u m b e r
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1 / m m 2 life time expenditure t/t B Analysis: P91, E911 600 C, test duration min 10200 h, max. 48000 h Life time assessment Uncertainty (artefactes) Clear indication of cavities limited number of cavities < 500 notched, lowrupture strain 13 13 Richtreihe zur Bewertung der Gefgeausbildung und schdigung zeitstandbeanspruchter Werkstoffe von Hochdruckrohrleitungen und Kesselbauteilen. VGB-TW 507 2. Ausgabe 2005; VGB PowerTech Service GmbH, Essen Rating class Structural or damage condition Limit criteria 1 Subject to creep loading without creep cavities
2a Individual creep cavities Up to 150 voids per mm 2b Numerous creep cavities, randomly oriented More than 150 voids per mm 3a Numerous creep cavities, specific orientation See remarks 3b Chains of creep cavities; individual grain boundary separations At least 2 successive grain boundaries with at least 3 voids 4 Microcracks More than one grain boundary length 5 Macrocracks
Smaller amount of creep cavities in comparison with low alloy ferritic steels At more than 50 hollow cylinders investigated with test durations up to 50000 h no orientation, no chains of creep cavities (1 exception) were found Microstructure Rating charts for Evaluating the Microstructure and Creep Damage of High-Temperature Steels for High- Pressure piping and Boiler Components VGB TW 507e 2nd edition Damage assessment 14 14 Comparison E911 with 14MoV6-3 14MoV6-3; Replica pipe bend, Rating chart 2b Specimen EH8, E911, 600C, t/t B =0,7 t=37700 h, 268 C/mm 2 14MoV6-3; Replica pipe bend, Rating chart 3b Specimen EH17, E911, 600C, t/t B =0,94 t=24410 h, 140 C/mm 2 Damage assessment 15 15 Comparison E911 with 14MoV6-3 14MoV6-3; Replica pipe bend, Rating chart 4 Specimen EH22, E911, 600C, t/t B = 1 t B =32000 h, 167 C/mm 2 , Available results showdifferent course of creep damage development in E911 in comparison to that for lowalloy ferritic steels reported in TW 507 Damage assessment 16 16 High degree of multiaxiality notched specimen, 48.000 h internal pressure and additional axial tension load, 600 C, steel E911 Shortly bevor rupture: indications of chains of cavities with orientation to max principal stress Comparable with rating chart 3b/4 TW 507 Damage assessment However exceptions have been observed 17 17 Cavity size and porosity specimen Cavity size Min Max m average number of cavities Porosity Temperature C Ex- haustion t/t B (%) Creep strain % Test du- ration h P5 smooth; P91 0,56 3,45 638 1,0094 575 >70 0,45 10196 EH24 notched; E911 0,77 3,29 156 1,0079 600 100 3,9 7250 EH7 smooth, E911 1,09 7,69 278 1,0482 600 90 0,9 38000 Cavities of P91 at 575C seems to be smaller than that observed in E911 specimens at 600C If the damaged area as parameter Porosity is used, it is obvious that specimen P5 shows a lower damage degree although the number of cavities in this specimen is larger in comparison to specimen EH7 The comparison of specimen EH24 with EH7 concludes that cavity growth is influenced by the creep strain Damage assessment 18 18 Summary and conclusions Summary and conclusions The available data with longtermcreep tests under multiaxial load show: Creep cavity formation is a clear indication for creep damage also in 9%Cr-steels Replica technique therefore has to be considered as an essential basis for life time assessment of critical components The number of creep cavities is lower than in low alloy ferritic steels however the influence of temperature and casts has to be analyzed in detail At vast majority of the specimens no orientation of the cavities could be found. Also the formation of chains of cavities were rarely observed even at the end of life time (90%). 19 19 Criteria used for low alloy ferritic steels in the rating charts of VGB TW 507 have to be adjusted to the specific situation with 9%Cr- steels (no reduced creep rupture ductility): Rating class Structural or damage condition Limit criteria (approximately - only for 600 C) 1 Subject to creep loading without creep cavities, Up to 50 cavities per mm 2
2 Individual creep cavities Up to 100 cavities per mm 2
3 Increased number of cavities without orientation More than 100 cavities up to 200 cavities per mm 2
4 numerous number of cavities without orientation More than 200 cavities cavities per mm 2
5 numerous number of cavities without orientation, single chains of cavities, individual grain boundary separations
Rating class for 9-11%Cr steels at 600C: No class 2b und 3b Summary and conclusions Summary and conclusions 20 20 Based on the findings and knowledge from the AVIF-project Damage Evolution the following criteria for life time assessment of components made of 9%Cr-steels could be suggested: Condition: homogenous stress state no fatigue interaction Global total strain 1% Local creep strain 2% Increase of creep velocity of 10% Life time exhaustion on basis of Robinson-Rule of max 60% Summary and conclusions Summary and conclusions 21 21 Attaining these values special examimations have to be taken: Surface replica identification of cavities Extraction replica evaluation of state of precipitation Inelastic stress analysis taking into account the real loading conditions and melt specific material (creep) characteristics Summary and conclusions Summary and conclusions 22 22 Thanks for your attention Diese Arbeit wurde gefrdert von der Stiftung Stahlanwendungsforschung im Stifterverband fr die Deutsche Wissenschaft e.V. unter Nummer A 229 gefrdert, wofr an dieser Stelle gedankt sei. Ferner wird dem VGB fr die finanzielle Untersttzung sowie dem Lenkungskreis unter dem Vorsitz von Herrn Hahn (V&M) fr die fachliche Untersttzung gedankt.