This research compares creep crack growth behavior of two heats of creep strength enhanced ferritic (CSEF) steel, grade 91. These heats represent extremes of creep damage susceptibility, one heat exhibiting low creep ductility and the other high creep ductility. Creep crack growth tests were performed with compact tension specimens and were monitored with direct current potential drop and optical surface measurements. Load line displacement was measured throughout the duration of the tests. Specimens were sectioned, mounted, and analyzed using optical and scanning electron microscopy to assess the presence of oxidation, micro-cracking, creep damage, and void density. Tests were performed over a range of initial stress intensities on the low ductility material to investigate the impact of creep ductility. Metallurgical evidence and test data for each crack growth test was assessed to evaluate crack growth behavior linked to creep crack growth parameter (C*) and stress/creep damage distribution in the vicinity of the crack.

Simple and effective material examination methods are desired for the diffusion bonding process, so that bonding produced components, such as compact heat exchangers, can be used in nuclear applications. Optical microscopy of diffusion bond process samples is a quick way to examine diffusion bond-line microstructure and to evaluate material quality. The stacked nature of a diffusion bonded-block results in distinct regions of grain growth both at and away from the bond interface. Strong diffusion bond materials exhibit grain growth across the original bond interface plane, weak materials have little-to-no growth across. A series of 316H diffusion bonded specimens of differing quality and strength were examined using optical microscopy. The microstructure both at and away from the bond interface was examined over 15mm long sections of the bond-line. A metric for evaluating bond growth is proposed. This is defined as the Bond Line Growth Threshold (BLGT) and is evaluated as the percentage of the bond line with grains meeting the threshold. Here a fraction of the diffusion bond is considered bonded when its grains exceed a threshold of growth past the bond interface. The BLGT is determined through automated image processing methods.

Super Duplex stainless steels (SDSS) are alloys based on the Fe-Cr-Ni-N system. The chemical composition is tailored to achieve a balanced microstructure of 50% ferrite and 50% austenite. Hyper Duplex Stainless Steels (HDSS) are also duplex materials distinguished by their remarkable yield strength (≥700 MPa) and corrosion resistance (PREN>48). They have been developed as an alternative to the well-established SDSS when superior mechanical and corrosion performance is required. This enhanced performance is attributed to alloying additions, primarily Cr, Mo, and N. In this study, a comparison is conducted between filler metals of SDSS and HDSS for the root welding of SDSS plates. The gas tungsten arc welding (GTAW) process was used to carry out root welding passes and Gas Metal Arc Welding (GMAW) for filling passes on SDSS substrates arranged in a V groove to simulate a repair scenario. The heat input was controlled in both processes, keeping it below 2.0 kJ/mm in the GTAW and 1.2 kJ/mm in the GMAW. GTAW with constant current was used and the parameters achieved producing full penetration welds with SDSS and HDSS. In this case, Nitrogen was used as backing gas to avoid oxidation of the root. Thus, a special GMAW-Pulsed version was applied to achieve good wettability and defect-free joints. ASTM G48 tests were performed to evaluate the corrosion resistance through Critical Pitting Testing (CPT) analysis on the root pass, microstructural analysis via optical microscopy, and impact toughness. Consequently, a comprehensive examination of the welded joints outlines manufacturing conditions, limitations, and the applications of SDSS and HDSS filler metals.

In this paper, the dissimilar metal welds (DMWs) between 617B nickel-based alloy and 10%Cr martensitic heat-resistant steel filled by 617 filler metal was studied, focused on the high temperature creep rupture properties. The high temperature creep rupture properties of welded joints with different welding processes were tested, and the microstructure of welded joints before and after the creep rupture test was observed by OM and SEM. The results showed that, there were three failure modes: base metal failure, type W failure and interface failure, among which interface failure caused the most serious life reduction. The welded joints using ER NiCr-3 filler metal reduced the strain concentration at the interface, so the fracture location shifted from the interface to HAZ of 10%Cr martensitic heat-resistant steel under high temperature and low stress conditions, and creep rupture life was improved. Similarly, weld cap shifted the creep crack propagation path by changing the groove form, so as to altered the stress state of joint and prolong the creep rupture life.

Cast nickel-based superalloys used as structural materials for gas turbine parts need to withstand high temperatures and dynamic mechanical loads. When in contact with ambient air, the formation of protective oxide scales causes a depletion of γ’-precipitates in the surface-near region and leaves a weakened microstructure. This environmentally based degradation of the material might be accelerated under cyclic thermal exposure. In this paper, the cyclic oxidation behavior of two cast nickel-based superalloys and one single crystalline variant are investigated: C1023, CM-247 LC and M-247 SX. Exposure tests were carried out under both isothermal and cyclic conditions in air at 850 °C, 950 °C and 1050 °C for times up to 120 h to investigate the impact of thermal cycling. The differences in oxidation mechanisms are analyzed phenomenologically via light and electron microscopy and brought in correlation with the oxidation kinetics, determined based on net mass change and depletion zone growth. An assessment of the impact of precipitation loss on local mechanical strength is attempted via nano-indentation method. The found relations can be transferred onto an acceleration of crack growth under creep-fatigue and thermo-mechanical fatigue conditions.

CrMoV cast steels are widely utilized for steam turbine and valve casings, and are subjected to operating and loading conditions which can promote damage mechanisms such as thermal fatigue, creep, erosion, etc. These components are subjected to variable, and sometimes severe conditions because of flexible operation. Therefore, there is a growing need for weld repair techniques including those which do not mandate post weld heat treatment (PWHT), e.g. so-called ‘temper bead’ weld repair. In this study, a simulated weld repair was performed using a temper bead technique. The maximum hardness in the heat affected zone (HAZ) CrMoV steel was ≤400HV. The integrity of the repair methodology was investigated using destructive testing, including hardness mapping, Charpy impact tests, tensile tests, low cycle fatigue and cross-weld creep, and the microstructure was assessed using light optical microscopy and scanning electron microscopy (SEM).

Long-term creep tested specimens of the advanced austenitic stainless steel Super 304H were subjected to detailed metallographic analysis with an emphasis on the relationship between creep induced cavities (voids) and microstructural features. The creep specimens were tested between 873 and 973 K (600 and 700°C) at stresses between 110 and 340 MPa, with rupture times up to ~1.8 x 10 8 s (50,000 hours). To characterize damage, the distributions of creep cavities along the length of the gage section were determined and microstructural features associated with the cavities were investigated using optical microscopy and scanning electron microscopy.

Martensitic 9Cr steels have been developed which are strengthened by boron in order to stabilize the microstructure and improve their long-term creep strength. Boron plays a key role in these steels by stabilising the martensitic laths by decreasing the coarsening rate of M 23 C 6 carbides, which act as pinning points in the microstructure. In this work two modified FB2 steel forgings are compared. Both forgings have similar compositions but one underwent an additional remelting process during manufacture. Creep tests showed that this additional processing step resulted in a significant increase in time to failure. In order to investigate the effect of the processing route on microstructural evolution during aging and creep, a range of advanced electron microscopy techniques have been used including ion beam induced secondary electron imaging and High Angle Annular Dark Field (HAADF) imaging in the Scanning Transmission Electron Microscope. These techniques have enabled the particle population characteristics of all the second phase particles (M 23 C 6 , Laves phase, BN and MX) to be quantified for materials from both forging processes. These quantitative data have enabled a better understanding of how the processing route affects the microstructural evolution of FB2 steels.

The United States Department of Energy Office of Fossil Energy and the Ohio Coal Development Office (OCDO) have led a U.S. consortium tasked with development of the materials technology necessary to build an advanced-ultra-Supercritical (A-USC) steam boiler and turbine with steam temperatures up to 760°C (1400°F). Part of this effort has focused on the need for higher temperature capable materials for steam turbine components, specifically cast nickel-base superalloys such as Haynes 282 alloy. As the size of the needed components is much larger than is capable of being produced by vacuum casting methods typically used for these alloys, an alternative casting process has been developed to produce the required component sizes in Haynes 282 alloy. The development effort has progressed from production of sub-scale sand castings to full size sand and centrifugal castings. The aim of this work was to characterize the microstructure and properties of a nickel alloy 282 casting with section size and casting weights consistent with a full sized component. A 2720 kg (6000 lbs.) nickel alloy 282 sand casting was produced and heat treated at MetalTek International. The casting was a half valve body configuration with a gating system simulated and optimized to be consistent with a full sized part. Following casting, heat treatment and NDE inspections, the half valve body was sectioned and tested. Tensile and high temperature creep was performed on material from different casting section thicknesses. Further analysis of the microstructure was carried out using light microscopy (LM), scanning electron microscopy (SEM), and X-ray spectroscopy (EDS). The paper also presents the mechanical properties obtained from the various sections of the large casting.

Sufficient energy availability in combination with lowest environmental pollution is a basic necessity for a high living standard in each country. To guarantee power supply for future generations, improved technologies to achieve higher efficiency combined with reduced environmental impact are needed. This challenge is not only aimed to the power station manufacturers, but also to the producers of special steel forgings, who have to handle with more and more advanced materials and complex processes. Bohler Special Steel is a premium supplier of forged high quality components for the power generation industry. This paper reports about experiences in the fabrication of forged components for steam turbines for ultra-supercritical application - from basic properties up to ultrasonic detectability results. The materials used so far are the highly creep-resistant martensitic 9-10% Cr steel class for operating temperatures up to 625°C developed in the frame of the European Cost research program. Additionally our research activities on the latest generation of high temperature resistant steels for operating temperatures up to 650 degree Celsius – the boron containing 9% Cr martensitic steels (MARBN) - are discussed. In order to improve the creep behavior, MARBN steels with different heat treatments and microstructures were investigated using optical microscopy, SEM and EBSD. Furthermore, short term creep rupture tests at 650 degree Celsius were performed, followed by systematic microstructural investigations. As a result it can be concluded, that advanced microstructures can increase the time to rupture of the selected MARBN steels by more than 10 percent.

The recently developed 12%Cr steel VM12-SHC is characterized by very good creep properties at temperatures up to 620°C. This new material development exhibits an excellent oxidation resistance in steam atmospheres at the typical application temperature but also at temperatures up to 650°C. In comparison to the existing 9% Cr grades T/P91 and T/P92, VM12-SHC steel opens due to its excellent oxidation behavior, new possibilities for its application as a heat exchanger boiler component. It was found that outside its application temperature range VM12-SHC also shows, as all 9-12%Cr steels, the appearance of the so called Z-phase. This effect was investigated to understand its influence on creep properties of this class of ferritic/martensitic steels aiming at controlling the microstructure stabilities for future grade developments. Creep testing has been carried out in the temperature range between 525°C and 700°C. Selected crept specimens have been investigated using light optical microscopy, SEM with EDX and TEM. In this study, the oxidation behavior of a number of typical martensitic 9-12%Cr steels was compared with the newly developed 12% Cr steel VM12-SHC. The compositions and morphologies of oxide scales formed after 5000 h exposure steels in simulated steam environments as function of temperature were characterized by light optical metallography and scanning electron microscopy (SEM) with energy dispersive X-ray analysis (EDX).

25Cr-20Ni-Nb-N (Tp310HCbN) steel is a promising austenitic steel for applications in superheater tubes in coal fired thermal power plants due to the high creep strength and oxidation resistance. In this work, the microstructural evolution of this material during heat treatment and thermal ageing has been investigated. The investigations were carried out by Light Optical Microscopy (LOM), Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM) and Energy Dispersive Spectroscopy (EDS). Besides, equilibrium and Scheil calculations were carried out using the thermodynamic software MatCalc to analyse the stable phases and the solidification process, respectively. Precipitation calculations during solution annealing and subsequent ageing at 650 and 750°C were performed to predict the phase fraction and precipitates radius up to 10.000h ageing time. SEM and TEM investigations of aged specimens revealed the presence of six different precipitates: M 23 C 6 , Cr 2 N, sigma, Z-phase, eta-phase (Cr 3 Ni 2 Si(C,N)) and Nb(C,N). These precipitates were predicted and confirmed by MatCalc simulations. The calculated phase fraction and mean radius show good agreement with experimental data. Finally, simulations of different Cr-, C- and N-content in Tp310HCbN were performed.

Research on low-alloyed, heat-resistant 12Cr2MoWVTiB steel, implemented in China to power plants in 50’s last century, was performed to investigate a possibility of its application for pressure elements of boilers, in particular for membrane walls. The microstructure of the as-received 12Cr2MoWVTiB tube, investigated by light microscopy, scanning- and transmission electron microscopy, consists of ferritic grains with some bainite areas between them as well as primary carbides (MC) and secondary carbides (VC, M 23 C 6 , M 6 C) formed during tempering of the steel. Results of mechanical tests of 12Cr2MoWVTiB welded joints (butt- and fillet welded joints) as well as microstructure analyses of are satisfactory.

Dissimilar metal welds (DMWs) between ferritic and austenitic materials at elevated temperatures have long posed challenges for boiler manufacturers and operators due to their potential for premature failure. As the industry moves towards higher pressures and temperatures to enhance boiler efficiencies, there is a need for superior weld metals and joint designs that optimize the economy of modern boilers and reduce reliance on austenitic materials for steam headers and piping. EPRI has developed a new filler metal, EPRI P87, to enhance the performance of DMWs. Previous work has detailed the development of EPRI P87 for shielded metal arc welding electrodes, gas-tungsten arc welding fine-wire, and its application in an ultra-supercritical steam boiler by B&W. This study examines the weldability of EPRI P87 consumables through various test methods, including Varestraint testing (both trans and spot), long-term creep testing (approximately 10,000-hour running tests), procedure qualification records for tube-to-tube weldments between traditional/advanced austenitic steels and creep-strength enhanced ferritic steels, and elevated temperature tensile testing. Macroscopic examinations from procedure qualification records using light microscopy confirmed the weldability and absence of cracking across all material combinations. The findings demonstrate that EPRI P87 is a weldable alloy with several advantages for DMW applications and highlight that specific weld joint configurations may necessitate the use of high-temperature tensile data for procedure qualifications.

The goal of improving the efficiency of pulverized coal power plants has been pursued for decades. The need for greater efficiency and reduced environmental impact is pushing utilities to ultra supercritical conditions (USC), i.e. steam conditions of 760°C and 35 MPa. The long-term creep strength and environmental resistance requirements imposed by these conditions are clearly beyond the capacity of the currently used ferritic steels and other related alloys. Consequently, new materials based on austenitic stainless steels and nickel-base superalloys are being evaluated as candidate materials for these applications. In the present work, the nickel-base superalloys CCA617, Haynes 230 and Inconel 740, and an austenitic stainless steel Super З04H, were evaluated. The materials were aged for different lengths of time at temperatures relevant to USC applications and the corresponding microstructural changes were characterized by x-ray diffraction, optical, scanning and transmission electron microscopy, with particular attention being given to the structure, morphology and compositions of phases (including γ, γ’, carbides, ordered phases, etc.) and the nature, density and distribution of dislocations and other defects. The results are presented and discussed in light of accompanying changes in microhardness.

This study examines the deformation behavior of P92 steel (ferritic, 9% Cr) at high temperatures (600°C to 900°C) using isothermal hot tensile tests. Particular focus is placed on the stress-strain behavior around its alpha-gamma transition temperature (825°C). Additionally, fire accident simulation heating tests were conducted to assess the integrity of P92 beyond 650°C (relevant for short-term creep) and compare it to stainless steel 1.4404 (potential building material). Finally, microstructural analysis was performed on tested samples, revealing that the martensitic structure with characteristic laths was retained at temperatures up to 750°C.