The Advanced Materials and Manufacturing Technologies (AMMT) program is aiming at the accelerated incorporation of new materials and manufacturing technologies into nuclear-related systems. Complex Ni-based components fabricated by laser powder bed fusion (LPBF) could enable operating temperatures at T > 700°C in aggressive environments such as molten salts or liquid metals. However, available mechanical properties data relevant to material qualification remains limited, in particular for Ni-based alloys routinely fabricated by LPBF such as IN718 (Ni- 19Cr-18Fe-5Nb-3Mo) and Haynes 282 (Ni-20Cr-10Co-8.5Mo-2.1Ti-1.5Al). Creep testing was conducted on LPBF 718 at 600°C and 650°C and on LPBF 282 at 750°C. finding that the creep strength of the two alloys was close to that of wrought counterparts. with lower ductility at rupture. Heat treatments were tailored to the LPBF-specific microstructure to achieve grain recrystallization and form strengthening γ' precipitates for LPBF 282 and γ' and γ" precipitates for LPBF 718. In-situ data generated during printing and ex-situ X-ray computed tomography (XCT) scans were used to correlate the creep properties of LPBF 282 to the material flaw distribution. In- situ data revealed that spatter particles are the potential causes for flaws formation in LPBF 282. with significant variation between rods based on their location on the build plate. XCT scans revealed the formation of a larger number of creep flaws after testing in the specimens with a higher initial flaw density. which led to a lower ductility for the specimen.

This study aims to elucidate the chemical compositions and microstructural factors that affect longterm creep rupture strength and creep rupture ductility using multiple heats of Gr.92 steel. Evaluating the reduction behavior in long-term creep rupture strength, we propose a relative creep rupture strength value, which is expressed as the logarithmic ratio of the estimated creep strength for each rupture time exceeding 10,000 hours, with 10,000 hours as the reference. Higher initial hardness correlates with greater pronounced strength reduction in the long-term regime. While smaller prior austenite grain sizes lead to greater reductions in creep rupture strength, this effect diminishes above 30 μm. However, no clear correlation was observed between Cr content and creep strength reduction in this study. Brittle creep ruptures with smooth test specimens were observed just below the extensometer ridge in the parallel section of test specimen, indicating notch weakening. Even in heats with excellent creep ductility, the amount of inclusions tended to be higher than in heats with lower creep ductility. Factors other than inclusions also seem to influence long-term creep ductility.

Grade 91 creep strength-enhanced ferritic steel is a critical material in power generation, widely used for high-temperature, high-pressure tubing and piping applications. Its superior elevated-temperature strength derives from a distinctive microstructure of tempered martensite with uniformly dispersed secondary phases (carbides and carbo-nitrides). This microstructure, crucial for reliable service performance, is achieved through precise control of the manufacturing process, including steelmaking, hot forming, and final heat treatment. This investigation builds upon earlier research into the relationship between manufacturing parameters and short-term creep-rupture properties in T91 tubes, and a recent update that included test results exceeding 30,000 hours. This study presents a comprehensive metallurgical analysis of ruptured test specimens. The investigation focuses on correlating manufacturing parameters with not only creep strength but also material ductility and microstructural evolution during long-term exposure, providing valuable insights into the material’s behavior under extended service conditions.

MarBN steels, originally developed by Professor Fujio Abe at NIMS Japan, have undergone significant advancement in the UK through a series of government-funded collaborative projects (IMPACT, IMPEL, INMAP, IMPULSE, and IMPLANT). These initiatives have achieved several major milestones, including operational power plant trials, full-scale extruded pipe production, matching welding consumable development, and most notably, the creation of IBN-1—a new steel demonstrating 30-45% higher creep strength than Grade 92. However, like other creep strength-enhanced ferritic steels, IBN-1 shows reduced creep ductility under the lower stress conditions typical of operational use. Since adequate creep ductility is essential for component damage tolerance and effective in-service monitoring, this study investigates the effects of an alternative normalizing and tempering heat treatment on cast IBN-1. The research presents creep rupture test results showing improved ductility and analyzes the microstructural mechanisms responsible for this enhancement.

The effect of boron nitrides (BN) and aluminum nitrides (AlN) on long-term creep life and rupture ductility has been investigated for martensitic 9 to 12Cr steels at 550 to 700 °C. The BN particles form in 9 to 12Cr steels during normalizing heat treatment at 1050 to 1150 °C, suggesting no change in the amount of BN particles during creep. On the other hand, the AlN particles gradually form during creep at 550 to 700 °C, decreasing the concentration of nitrogen free from the AlN particles. The degradation in creep life takes place more significantly with test duration in the steels containing high Al but not in those containing the BN particles. The rupture ductility is evaluated by using a semi-logarithmic diagram of the RA and total elongation, showing the necking dominant and void swelling dominant regions. The BN and AlN particles are responsible for the degradation in RA at low stresses and long times by accelerating the formation of creep voids at interfaces between the BN and AlN particles and alloy matrix.

In the present study, the Inconel 617B superalloy welded trial rotor was fabricated by narrow gap tungsten inert gas (NG-TIG) welding and the effects of temperature on fracture toughness of its welded joint were investigated at 650 ℃ and 730 ℃. Fracture toughness (J0.2) of the base metal was much higher than that of the weld metal at the same temperature, which was attributed to its excellent macroscopical plasticity and the interactions of strain localization, misorientation, and coincidence site lattice (CSL) boundaries. For the base metal, the value of J0.2 was higher at 730 ℃ than at 650 ℃, resulting from the appreciable increase in ductility and decrease in strain localization as the temperature increased. For the weld metal, higher temperature (730 ℃) reduced strength but hardly improved plasticity, and the regions of high strain localization uniformly distributed in the weld metal, resulting in completely tearing the whole interface apart and lower fracture toughness of the weld metal.

The relationship between the hot workability and the precipitation morphology of γ′ phase in the Alloy U520 was examined with a focus on the presence of γ′-nodule. To change the morphology of γ’ phase, forged bars of the Alloy U520 were solution treated followed by cooling process with the cooling rates of 5~100 K/h. After the heat treatment, both γ’ phases of intragranular particle and nodule along grain boundaries were observed, and the both sizes increased by slowing down the cooling rate. That is, the area fraction of γ’-nodule increased from about 0.1 % in the sample cooled at 100 K/h to about 70 % at 5 K/h. In Gleeble tension test, the slow-cooled samples basically exhibited higher ductility than water-quenched samples below the γ′-solvus temperature. However, the ductility was maximized in the sample cooled at 20 K/h, and excessive decrease of cooling rate resulted in a drop in ductility. EBSD analysis revealed that dynamic recrystallization (DRX) was often occurred in grain interior but suppressed at γ′-nodule area, indicating that presence of γ′-nodule had a negative influence on hot workability at subsolvus temperature.

The Haynes 282 Ni-based superalloy (57Ni-20Cr-10Co-8.5Mo-2.1Ti-1.5Al) is a very promising candidate for the fabrication by additive manufacturing of gas turbine components of complex geometries. Alloy 282 was fabricated by electron beam melting (EBM) and exposed to two different heat treatments, (a) solution anneal (SA) at 1135°C followed by the standard 2-step aging treatment (2h at 1010°C plus 8h at 788°C) and (b) SA followed by 4h 800°C. Large elongated grains were observed for the as-fabricated and annealed EBM 282 materials, with a γ′ (Ni 3 (Al,Ti)) average size of ~100 nm and 20 nm, respectively. The as-fabricated EBM 282 alloy exhibited good ductility at 20-900°C and tensile strength slightly lower than the tensile strength of wrought 282. Annealing the alloy resulted in a moderate increase of the alloy strength at 800 and 900°C but a decrease of the alloy ductility. The creep lifetime at 800°C, 200MPa of the as-fabricated and annealed EBM 282 specimens machined along the build direction was 2 times and 1.5 times superior to the expected lifetime for wrought 282, respectively. For creep specimens machined perpendicular to the build direction, the lifetimes were ~25% lower compared to the wrought alloy. These creep results are directly related to the strong grain texture of the EBM 282 alloy and the limited impact of the initial γ′ (Ni 3 (Al,Ti)) size on alloy 282 creep properties.

In wrought nickel-base alloys used at elevated temperatures for extended periods of time, it is commonly observed that unwanted phases may nucleate and grow. One such phase is the eta phase, based on Ni 3 Ti, which is a plate-shaped precipitate that nucleates at the grain boundaries and grows at the expense of the strengthening gamma prime phase. In order to study the effects of eta phase on creep performance, Alloy 263 was modified to contain 3 different microstructures: standard (contains gamma prime); aged (contains gamma prime and eta); and modified (contains only eta and no gamma prime). These microstructures were then creep tested in the range of 973-1123 K (700-850°C). An extensive test matrix revealed that the eta-only modified alloy had creep rupture strengths within 10% of the standard alloy even though this alloy had no strengthening gamma prime precipitates. It also exhibited superior creep ductility. A preliminary test matrix on the aged material containing eta and gamma prime prior to the creep tests revealed that the performance of this microstructure was generally between that of the standard alloy (best) and the eta-only alloy (worst). The aged material exhibited far superior creep ductility. These results suggest that the presence of the eta phase may not be deleterious to creep ductility, and in fact, may enhance it.

Electron beam melting (EBM) is one of the candidate manufacturing processes for TiAl alloys which have been considered as next generation high-temperature structural materials. The microstructure and mechanical properties of Ti-48Al-2Cr-2Nb (48-2-2) alloy bars fabricated using EBM were investigated, with a particular focus on the effect of processing parameters such as input energy density and building direction. We observed that the microstructure of the alloy bars fabricated using EBM depends strongly on the processing parameters used during the fabrication process of alloy. In particular, the alloy bars fabricated under appropriate processing parameters have a unique layered microstructure composed of duplex regions and equiaxed γ-grain regions (γ bands). Because of their fine microstructure and deformable soft γ bands, the alloy bars with the unique layered microstructure exhibit higher strength and higher ductility at room temperature (RT) than that of cast alloys. In addition, the alloy bars fabricated at an angle between the building direction and the loading axis of 45° show good fatigue properties at RT even without hot isostatic pressing treatment.

Effects of microstructure constituents of α 2 -Ti 3 Al/γ-TiAl lamellae, β-Ti grains and γ grains, with various volume fractions on room-temperature ductility of γ-TiAl based alloys have been studied. The ductility of the alloys containing β phase of about 20% in volume increases to more than 1% as the volume fraction of γ phase increases to 80%. However, γ single phase alloys show very limited ductility of less than 0.2%. Microstructure analysis have revealed that intragranular fracture along γ/γ grain boundary occurred in γ single phase alloy whereas it does not along β/γ interphase in alloys containing β phase. In addition, local strain accumulations along β/γ interphase have been confirmed. The present results, thus, confirmed the significant contribution of β phase, especially the existence of β/γ interphase to enhancement of the room-temperature ductility in multicomponent TiAl alloys.

Either at higher temperatures or when a certain alloying element content is exceeded, γ-TiAl alloys contain the β phase (bcc) or its ordered derivate β o (B2). The relatively soft β phase can facilitate hot deformation, but β o is detrimental for creep strength and ductility. Thus, knowledge about β o →β phase transformation is desirable. Surprisingly, for the binary Ti-Al system it is under discussion whether the ordered β o phase exists. Also, the effect of alloying elements on the β phase ordering is still unclear. In the present work the ordering of the β phase in binary Ti-(39,42,45)Al and ternary Ti-42Al-2X alloys (X=Fe, Cr, Nb, Ta, Mo) which was experimentally investigated by neutron and high energy X-ray diffraction is compared with the results of first principles calculations using density functional theory. Except for Cr the experimentally determined and the predicted behavior correspond.

There are main drivers for the design and assessment of steam turbine components of today such as demands for improved materials, higher plant cycling operation, and reduced life-cycle costs. New materials have been developed over the last decades resulting in advanced martensitic 9-10CrMoV steels already applied in different types of turbines successfully. Heavy cyclic loading getting more importance than in the past results in utilization of the fatigue capabilities at high and low temperatures which might lead to crack initiation and subsequent crack propagation. Fracture mechanics methods and evaluation concepts have demonstrated their applicability to assess the integrity of components with defects or crack-like outage findings. Based on realistic modelling of the failure mechanism, accurate prediction of crack sizes at failure state can be improved defining the appropriate damage criteria. Ductility is a main aspect for robust design but its value definition can depend on component type, design rules, real loading conditions, service experience, and material characteristics. The question which direct material parameter is able to serve as limit value in design and how it can be determined has to be solved. Examples of advanced analysis methods for creep crack growth and fatigue interaction involving the crack initiation time show that the reserves of new martensitic 9-10Cr steels in high temperature application can be well quantified. The creep rupture elongation A u and the loading conditions in the crack far field are main factors. If the A u value is sufficient high also after long-time service, the material remains robust against cracks. Investigations into the influence of stress gradients on life time under fatigue and creep fatigue conditions show that e.g. for 10CrMoWV rotor steel crack growth involvement offers further reserves. The consideration of constraint effect in fracture mechanics applied to suitable materials allows for further potentials to utilize margin resulting from classical design. The new gained knowledge enables a more precise determination of component life time via an adapted material exploitation and close interaction with advanced design rules.

By utilizing computational thermodynamics in a Design of Experiments approach, it was possible to design and manufacture nickel-base superalloys that are strengthened by the eta phase (Ni3Ti), and that contain no gamma prime (Ni3Al,Ti). The compositions are similar to NIMONIC 263, and should be cost-effective, and have more stable microstructures. By varying the aging temperature, the precipitates took on either cellular or Widmanstätten morphologies. The Widmanstätten-based microstructure is thermally stable at high temperatures, and was found to have superior ductility, so development efforts were focused on that microstructure. High temperature tensile test and creep test results indicated that the performance of the new alloys was competitive with NIMONIC 263. SEM and TEM microscopy were utilized to determine the deformation mechanisms during creep.

The paper deals with microstructural evolution in the AISI 316LN + 0.1 wt.% Nb steel during long-term creep exposure at 600 and 625°C. The following minor phases formed: Z-phase (NbCrN), M 23 C 6 , M6X (Cr3Ni2SiX type), η-Laves (Fe2Mo type) and σ-phase. M6X gradually replaced M 23 C 6 carbides. Primary Z-phase particles were present in the matrix after solution annealing, while secondary Z-phase particles formed during creep. Precipitation of Z-phase was more intensive at 625°C. The dimensional stability of Z-phase particles was excellent and these particles had a positive effect on the minimum creep rate. However, niobium also accelerated the formation and coarsening of σ-phase, η-Laves and M6X. Coarse particles, especially of σ-phase, facilitated the development of creep damage, which resulted in poor long-term creep ductility.

Grade 91 steel has achieved broad acceptance within the modern boiler industry to fabricate a variety of critical pressure components including tubing, piping and headers, particularly in Ultra Super Critical (USC), Advanced Ultra Super Critical (A-USC) and Combined Cycle Power Plants (CCPP). The applications for which this material is used enforce severe requirements on strength, corrosion, creep properties and thermal stability during service. The properties of Creep Strength Enhanced Ferritic steels (CSEF) such as Grade 91 are critically dependent on manufacturing factors like steelmaking, heat treatments and welding: poor control of these parameters can severely compromise material properties. In scientific literature, several studies correlate low creep ductility to high content of trace elements such As, Sn, Sb, Pb, Cu, P and S. Since the current reference Codes, namely ASTM/ASME, don’t require particular restrictions for these elements, Electric Power Research Institute (EPRI) has issued guidelines for grade 91 which enforce a significant reduction of impurities and trace elements. This paper discusses steelmaking operating challenges to produce Grade 91 steel with very low contents of the above mentioned residual elements, starting from the furnaces charges, up to the chemical composition measuring equipment used in the steel shop laboratories.

Grade 91 steel has been widely utilized in power plants over the last 20 years. Its specification worldwide has dramatically increased since the acceptance of Code Case 1943 for this material in 1983. Recent evaluation of a combination of ex-service Grade 91 steel components and virgin material has provided a unique opportunity to independently assess the performance of a combination of base metal and weldments. This approach has been grounded in the fundamental objective of linking metallurgical risk factors in Grade 91 steel to the cross-weld creep performance. Establishing critical risk factors in 9Cr steels is regarded as a key consideration in the integration of a meaningful life management strategy for these complex steels. The potential metallurgical risk factors in Grade 91 steel have been fundamentally divided into factors which affect strength, ductility or both. In this study, two heats of ex-service Grade 91 steel which exhibit dramatic differences in strength and ductility have been evaluated in the ex-service condition and re-heat treated to establish a relevant set of strength:ductility variables. This set of variables includes [strength:ductility]: low:low, medium:low, low:high and medium:high. The influence of these strength:ductility variables were investigated for feature type cross-weld creep tests to better evaluate the influence of the initial base material condition on cross-weld creep performance.

This study is concerned with the creep damage evaluation for the welded joint of modified 9Cr-1Mo steels. A finite element prediction method based on ductility exhaustion approach has been proposed. Degradation of creep ductility under multi-axial stress state has been formulated from the experimental results of notched bar specimens for the base metal and the fine-grained heat affected zone, and has been taken into the damage model. Creep test of welded joint specimen of modified 9Cr-1Mo steel has been conducted to confirm the accuracy of the damage evaluation method. It has been concluded that the predicted trend of creep damage has good agreement with the experimental results, but the predicted rupture time become longer than the experimental results of rupture time.

Remaining-life assessment of high temperature components using the small punch (SP) creep testing technique necessitates the evaluation of SP load (F)/uniaxial stress (σ) conversion factor, F/σ, obtained by comparing the SP and uniaxial creep test results. In the present study, the SP creep tests were carried out at 850°C on various Ni-base alloys having different reduction of area in the range of 0.05-0.67 to investigate the influence of creep ductility on the value of F/σ. The F/σ value was determined for each alloy by correlating SP creep rupture data with corresponding uniaxial creep ones. The experimental results revealed that the F/σ value was not well correlated with Vickers hardness, but it increased almost linearly with increasing reduction of area up to around 0.4. This result indicated that the SP creep rupture data could be converted to the uniaxial data if the creep ductility on a given material was available.

The US Advanced Ultra-Supercritical (A-USC) Consortium conducted an extensive program to evaluate available superalloys for use in rotors for steam turbines operating at a nominal temperature of 760 °C (1400 °F). Alloys such as 282, Waspaloy, 740H, 720Li, and 105 were tested in the form of bar supplied from the alloy producers. Ultimately, alloy 282 was down-selected for the turbine rotor based on its combination of creep strength, phase stability, ductility, and fatigue resistance. The next step in development was to produce a full-size rotor forging for testing. A team was established consisting of GE Power (project management and testing), Wyman-Gordon (forging and testing) and Special Metals (melting and billetizing) to pursue the work. A research license to melt the alloy was obtained from Haynes International. The first step of the development was to devise a triple melt (VIM-ESR-VAR) practice to produce 610 mm (24 inch) diameter ingot. Two ingots were made, the first to define the VAR remelting parameters and the second to make the test ingot utilizing optimum conditions. Careful attention was paid to ingot structure to ensure that no solidification segregation occurred. A unique homogenization practice for the alloy was developed by the US Department of Energy (DOE) and National Energy Technology Laboratory (NETL). Billetization was performed on an open die press with three upset and draw stages. This procedure produced an average grain size of ASTM 3. A closed die forging practice was developed based on compressive flow stress data developed by Wyman Gordon Houston for the consortium project. Multiple 18 kg forgings were produced to define the forging parameters that yielded the desired microstructure. The project culminated with a 2.19 metric ton (4830 lb), 1.22 m (48 inch) diameter crack-free pancake forging produced on Wyman Gordon’s 50,000 ton press in Grafton, MA. The forging process produced a disk with an average grain size of ASTM 8 or finer. Forging cut-up, microstructural characterization, and mechanical property testing was performed by GE Power. Fatigue and fracture toughness values of the disk forging exceeded those previously reported for commercially available rolled bar.