Search Results for brittle fracture

Theoretical and experimental investigations, including fracture tests, acoustic emission (AE) studies, fractography, micro-sclerometric analyses, and spectral/chemical analyses of specimens, have established the possibility of revealing, recognizing in-service acquired, age-related, and prefabricated flaws based solely on AE data. Results show a linear dependence between AE and mechanical deformation power of steel specimens in original and creep stage 3a-3b conditions, decreasing fracture load and J1c value for aging steel, creep processes at stage 3a-3b having J-integral value below 0.05J1c, possibility of assessing and distinguishing different flaw development stages with ≥87% accuracy, revealing zones of tough and brittle fracture, and recognizing inclusions/pre-fabricated flaws and assessing individual/interacting flaws. Experiments confirmed the absence of the Kaiser effect under repeated loading of flawed specimens and demonstrated using AE for defect revelation. Analysis showed that creep-associated AE is mainly continuous, with repeated loading decreasing burst AE contribution during plastic deformation development.

In this study, creep rupture behaviors and rupture mechanisms of dissimilar welded joint between Inconel 617B and COST E martensitic steel were investigated. Creep tests were conducted at 600 ℃ in the stress range 140-240 MPa. Scanning electron microscopy (SEM) and micro-hardness were used to examine the creep rupture behaviors and microstructure characteristics of the joint. The results indicated that the rupture positions of crept joints shifted as stress changed. At higher stress level, the rupture position was located in the base metal (BM) of COST E martensitic steel with much plastic deformation and necking. At relatively lower stress level, the rupture positions were located in the fine-grained heat affected zone (FGHAZ) of COST E or at the interface between COST E and WM both identified to be brittle fracture. Rupture in the FGHAZ was caused by type Ⅳ crack due to matrix softening and lack of sufficient precipitates pinning at the grain boundaries (GBs). Rupture at the interface was related to oxide notch forming at the interface.

This study investigates the microstructure evolution of Type 316H stainless steel, focusing on the identification of major precipitates using advanced characterization techniques. The precipitation sequence at service temperatures of 650°C is identified as M 23 C 6 , followed by Laves phase, grain boundary (GB) sigma phase, and inter-granular sigma phase. At 750°C, the sequence progresses from M 23 C 6 to Laves phase, GB sigma phase, chi phase, and intra-granular sigma phase, with the chi phase forming intra- and inter-granularly after 5,000 hours of aging. During the formation of the sigma and chi phases, carbides and Laves phases dissolve. A Monte Carlo model has been developed to predict detailed microstructure evolution during long-term aging, calibrated using quantitative precipitate evolution measurements of Type 316H. After validation, the model aligns well with experimental data, offering a method to predict the microstructure of Type 316H and potentially other austenitic stainless steels over the lifespan of power plants.

The use of the bainitic class of creep strength enhanced ferritic steels T/P23 and T24 has increased over the last decade in a wide range of applications including replacement headers, superheater and reheater tubing and in waterwall tubing. Many issues have been reported in one or both of these materials including hydrogen induced cracking, reheat cracking and stress corrosion cracking. To appropriately address these issues, work has been initiated that includes a literature review, development of a database of phase transformation temperatures, investigation of tempering behavior, and an analysis of the effect of phase transformation on residual stresses. Such information will be provided in the context of understanding why these two materials appear highly susceptible to these cracking mechanisms.

Hydrogen as a clean fuel is increasingly being used to propel gas turbines and to power combustion engines. Metallic materials including Ni-based alloys are commonly used in conventional gas turbines and combustion engines. However, hydrogen may cause embrittlement in these materials, depending on their chemical composition. In this work, the hydrogen embrittlement behavior of Ni-based alloys containing up to 50 wt.% Fe has been investigated using slow strain rate tensile testing, under cathodic hydrogen charging at room temperature. It was found that the larger the Ni equivalent concentration in an alloy, the more severe the hydrogen embrittlement. It was also found that solid solution alloys have less severe hydrogen embrittlement than precipitation alloys of the same Ni equivalent concentration. In solid solution alloys, hydrogen embrittlement led to cleavage type fracture, which is in line with literature where hydrogen enhanced planar deformation. In precipitation alloys, hydrogen embrittlement resulted in a typical intergranular fracture mode.

Laves phases are intermetallic phases well known for their excellent strength at high temperatures but also for their pronounced brittleness at low temperatures. Especially in high-alloyed steels, Laves phases were long time regarded as detrimental phases as they were found to embrittle the material. Perusing the more recent literature, it seems the negative opinion about the Laves phases has changed during the last years. It is reported that, if the precipitation morphology is properly controlled, transition metal-based Laves phases can act as effective strengthening phases in heat resistant steels without causing embrittlement. For a targeted materials development, the mechanical properties of pure Laves phases should be known. However, the basic knowledge and understanding of the mechanical behavior of Laves phases is very limited. Here we present an overview of experimental results obtained by micromechanical testing of single-crystalline NbCo 2 Laves phase samples with varying crystal structure, orientation, and composition. For this purpose, diffusion layers with concentration gradients covering the complete homogeneity ranges of the hexagonal C14, cubic C15 and hexagonal C36 NbCo 2 Laves phases were grown by the diffusion couple technique. The hardness and Young's modulus of NbCo 2 were probed by nanoindentation scans along the concentration gradient. Single-phase and single crystalline microcantilevers and micropillars of the NbCo 2 Laves phase with different compositions were cut in the diffusion layers by focused ion beam milling. The fracture toughness and the critical resolved shear stress (CRSS) were measured by in-situ microcantilever bending tests and micropillar compression tests, respectively. The hardness, Young's modulus and CRSS are nearly constant within the extended composition range of the cubic C15 Laves phase, but clearly decrease when the composition approaches the boundaries of the homogeneity range where the C15 structure transforms to the off stoichiometric, hexagonal C36 and C14 structure on the Co-rich and Nb-rich, respectively. In contrast, microcantilever fracture tests do not show this effect but indicate that the fracture toughness is independent of crystal structure and chemical composition of the NbCo 2 Laves phase.

As long term laboratory creep data became available the original estimates of the allowable stresses for creep strength enhanced ferritic steels (CSEF) had to be reduced. Thus, even in properly processed steel, the long term performance and creep rupture strength is below that originally predicted from a simple extrapolation of short term data. One of the microstructural degradation mechanisms responsible for the reduction in strength is the development of creep voids. Nucleation, growth and inter linkage of voids also result in a significant loss of creep ductility. Indeed, elongations to rupture of around 5% in 100,000 hours are now considered normal for long term creep tests on many CSEF steels. This relatively brittle behaviour, and the associated creep void development, promotes burst rather than leak type fracture in components. Moreover, the existence of significant densities of voids further complicates in-service assessment of condition and weld repair of these steels. The present paper examines background on the nucleation and development of creep voids in 9 to 12%Cr martensitic steels and discusses factors affecting brittle behavior.

This study investigates the mechanisms of temper embrittlement in 410 martensitic stainless steel, a material widely used in steam turbine blades due to its excellent corrosion resistance and high strength achieved through quenching and tempering heat treatments. While the material’s hardness and impact toughness strongly depend on tempering temperatures, significant embrittlement occurs around 540°C, manifesting as decreased Charpy impact energy alongside increased strength and hardness. To understand this phenomenon at the nanometer scale, high-resolution transmission electron microscopy (TEM) analysis was performed, focusing on electron diffraction patterns along the <110>α-Fe and <113>α-Fe zone axes. The analysis revealed distinctive double electron diffraction spots at 1/3(211) and 2/3(211) positions, with lattice spacing of approximately 3.5 Å—triple the typical α-bcc lattice spacing (1.17 Å). These regions were identified as metastable “zones” resembling ω-phase structures, potentially responsible for the embrittlement. While this newly identified phase structure may not fully explain the complex mechanisms of temper embrittlement, it provides valuable insights for developing improved alloying and heat treatment methods to mitigate embrittlement in martensitic steels.

In power plants operated at elevated temperatures, the operating life of structural materials increases. Therefore, it is very important to be able to predict creep strength in long term above 100,000 h. Furthermore, it has been reported that in the long term, the actual creep strength is lower than the predicted life. Although this problem has been analysed, the reasons remain unclear. In this study, a fracture energy model is used to evaluate the mechanisms of the creep strength reduction for martensitic steels. In the model, changes in fracture energy with rupture time are expressed by a power law. The energy density rate is calculated using stress, rupture elongation, and rupture time. The model indicates two mechanisms of creep strength reduction. One is the increase in rupture elongation, which leads to reduction in creep strength with ductility; the other is the decrease in reduction of area, which leads to reduction in creep strength with brittleness. Difference between the two mechanisms affects creep-fatigue strength. The study also shows that the equation based on the fracture energy model for creep-fatigue life can be obtained by a parallel translation of that for creep.

Creep brittle behaviour in tempered martensitic, creep strength enhanced ferritic (CSEF) steels is linked to the formation of micro voids. Details of the number of voids formed, and the tendency for reductions in creep strain to fracture are different for the different CSEF steels. However, it appears that the susceptibility for void nucleation is related to the presence of trace elements and hard non-metallic inclusions in the base steel. A key factor in determining whether the inclusions present will nucleate voids is the particle size. Thus, only inclusions of a sufficient size (the critical inclusion size is directly linked to the creep stress) will act directly as nucleation sites. This paper compares results from traditional uniaxial laboratory creep testing with data obtained under multiaxial conditions. The need to understand and quantify how metallurgical and structural factors interact to influence creep damage and cracking is discussed and the significant benefits available through the use of high quality steel making and fabrication procedures are highlighted. Details of component behaviour are considered as part of well-engineered, Damage Tolerant, design methods.

According to ASME Case N-888-3, Similar and Dissimilar Metal Welding Using Ambient Temperature SMAW or Machine GTAW Temper Bead Technique, a 48 hr waiting period before conducting the final nondestructive examination (NDE) is required when ferritic filler weld metal is used. The purpose of the 48 hr hold is to confirm the absence of hydrogen-induced cracking in the temper bead heat-affected zone. In previous research, the effect of post-weld heat treatment (PWHT) and temper bead welding (TBW) on the hydrogen-induced cracking (HIC) susceptibility in the coarse-grained heat-affected zone (CGHAZ) in welds of SA-508, P-No. 3 Group 3, pressure vessel steel was investigated using the Delayed Hydrogen Cracking Test (DHCT). In that previous study, the Gleeble thermomechanical simulator was used to generate six CGHAZ microstructural conditions: as-welded (AW), PWHT, and AW with single a TBW reheat at 675, 700, 725, and 735°C. Hydrogen was introduced to the specimen through cathodic charging under in situ constant tensile stress. The HIC susceptibility for these microstructures was ranked by the DHCT at a diffusible hydrogen level significantly exceeding typical GTAW and SMAW processes. The work described in this paper investigates the susceptibility to HIC of these same CGHAZ microstructures with DHCT at variable current densities, further ranking each condition. Test results were analyzed by fracture surface examination of failed tests, and cross-section microstructural analysis under a scanning electron microscope (SEM). Future steps include evaluating critical hydrogen content levels using gas chromatography for each condition. The results from this study will be used to consider potential elimination of the NDE hold time requirement in Case N-888-3 when ferritic weld metal is used.

This study aims to examine the effects of grain boundary oxidation and creep on crack initiation and fracture behaviors in cold worked surface layer, under static tensile stresses in air. To determine these effects in relation to percent cold work and hardness scale, cold-rolled plates with a reduction ratios between 10% and 50% were prepared. Uniaxial constant load (UCL) tests were conducted at elevated temperature in air using smooth round bar specimen. UCL tests with a load of 0.9σy (926MPa) at 550°C show that rupture time for all cold- rolled materials were shorter than that of as-received material. From cross-sectional observation after UCL testing, surface crack at grain boundary and voids were observed in as-received material, whereas creep cracks were also observed in cold-rolled materials. This implied that crack initiation was assisted by cold working. Comparing test results with a load reduced to 0.8σy (823MPa), difference of rupture time was expected as a factor of 5 for as-received material, and measured as 2-3 for cold-rolled materials. It was suggested that cold worked layer was more sensitive to creep than base metal.

The drive for reduced carbon dioxide emissions and improved efficiency in coal fire power plant has led to much work being carried out around the world with regards to material development to enable 700+°C steam temperature operation. At these elevated temperatures and pressures steels just don’t have enough strength, and typically have a temperature limit of around 620°C (possibly up to 650°C in the near future) in the HP environment. Therefore, material development has focused on nickel alloys. European programs such as AD700, COMTES, European 50+ and more recently, NextGen Power and Macplus, have investigated the use of nickel alloys in the steam turbine. Large castings have an important role within the steam turbine, because valves bodies and turbine casings are nearly always produced from a cast component. The geometry of these components is often complex, and therefore, the advantage of using castings for such items is that near net shapes can be produced with minimal machining. This is important, as nickel alloys are expensive, and machining is difficult, so castings offer an attractive cost benefit. Cast shapes can be more efficiently designed with regards to stress management. For example, contouring of fillet regions can help to reduce stress concentrations leads to reduced plant maintenance and casting complex shapes reduces the number of onsite fabrication welds to inspect during outage regimes.

In response to the need to reduce carbon dioxide gas emissions, Japan has been actively researching 700°C-class thermal power plants with a focus on improving overall plant efficiency. This technological advancement is fundamentally grounded in advanced materials development, encompassing the creation of high-strength alloys, fireside corrosion-resistant materials, and steamside oxidation-resistant alloys. A significant challenge emerged as some of the developed materials fell outside the scope of existing domestic technical standards. Moreover, the potential failure modes for advanced ultra-supercritical (A-USC) components operating at 700°C were anticipated to differ substantially from those observed in traditional ultra-supercritical (USC) components at 600°C. Consequently, researchers systematically examined and analyzed the potential failure modes specific to 700°C A-USC components, using these insights to establish comprehensive performance requirements. The research initiative, which commenced in June 2006, was strategically planned to develop a draft technical interpretation by March 2011. This paper provides a detailed overview of the investigative process, encompassing the comprehensive analysis of failure modes, the derivation of performance requirements, and the progression toward developing a new technical interpretation framework for high-temperature power plant components.

An international initiative is underway to develop the first standardized high-temperature solid particle erosion test method for steam turbine applications, addressing limitations of the current room-temperature ASTM G76 standard. Led by EPRI, this program involves laboratories from seven countries in a “Round Robin” testing program, aiming to establish consistent testing procedures for evaluating erosion resistance of materials used in Ultra Supercritical (USC) and advanced USC turbines. The proposed standard will use Type 410 stainless steel tested at 30 and 90-degree impingement angles with 50-micron alumina particles at 200 m/s, both at room temperature and 600°C, providing more relevant conditions for current and next-generation steam turbine applications.

The broken elbow of the final superheater tube (ASME SA213 TP304H) from a coal-fired power plant was evaluated. The root causes were identified by metallographic observation, sensitization evaluation, hardness measurement, and EBSD analysis. The analysis results reached the following conclusions. (1) The tube bending was not performed in accordance with ASME Code requirements—a solid-solution heat treatment was not performed after cold working. (2) The hardness at the elbow is greater than 260 HV, exceeding the ASME code limit. (3) The sensitization was 19%, showing a performance degradation. (4) There are no obvious corrosion elements in the oxide layers of the cracks. (5) Metallographic microstructure analysis shows that there are many intergranular cracks and carbides such as Cr-rich phase and Fe-Cr are precipitated at the grain boundaries, ultimately resulting in strain-induced precipitation hardening damage.

Starting in 2010 a new generation of coal fired power plants in Europe operating at a steam temperature of up 620°C was commissioned. During that commissioning process many cracks occurred in welds of T24 material which was extensively used as membrane wall material in nearly all of the new boilers. The cracks were caused by stress corrosion cracking (SCC) only occurring in the areas of the wall being in contact to high temperature water during operation. The question which step of the commissioning process really caused the cracking was not answered completely even several years after the damage occurred. To answer this question and to define parameters which will lead to cracking in high temperature water many tests were conducted. Generally it was found that slow tensile tests in controlled environment are well suited to get information about materials SCC sensitivity in the laboratory. In the present paper, first the influence of the cracking of welded T24 material in acidic environment containing well-defined amounts of H2S is investigated to address the question if a chemical cleaning process prior to the testing might lead to hydrogen induced SCC. As a second step, cracking behaviour in high temperature water is being investigated. Here the influence of the temperature, the oxygen concentration of the water, the deformation speed of the sample, the heat treatment and the condition of the material on the SCC is analysed.

Hardfacing alloys are commonly used for wear- and galling-resistant surfaces for mechanical parts under high loads, such as valve seats. Cobalt-based Stellite, as well as, stainless-steel-based Norem02 and Tristelle 5183 alloys show similar microstructural features that correlate with good galling resistance. These microstructures contain hard carbides surrounded by a metastable austenite (fcc) phase that transform displacively to martensite (hcp or bcc or bct) under deformation. As a result, the transformed wear surface forms a hard layer that resists transition to a galling wear mechanism. However, at elevated temperature (350°C), the stainless steel hardfacing alloys do not show acceptable galling behavior, unlike Stellite. This effect is consistent with the loss of fcc to bcc/bct phase transformation and the increase in depth of the heavily deformed surface layer. Retention of high hardness and low depth of plastic strain in the surface tribolayer is critical for retaining galling resistance at high temperature.

9-12%Cr martensitic steels can be applied to the next highest temperature components such as boiler tracts, steam pipelines and turbines of advanced ultra-supercritical power plants with steam temperatures of 650°C. New 10%Cr martensitic steels with high B and low N contents can be a worthy candidate for use in production because it has superior creep resistance. At the same time, resistance to cyclic and dynamic loads is very important. In this work, we studied the low cycle fatigue (LCF) properties at room and elevated (500-650°C) temperatures and Charpy impact toughness at temperatures ranging from -196…100°C of advanced 10% Cr martensitic steel with high B and low N contents. The effect of new alloying scheme and corresponding peculiarities of M 23 C 6 carbides on the low cycle fatigue resistance and impact toughness of the 10%Cr martensitic steel is analyzed. It is revealed that fine and densely distributed carbides has no effect on the fatigue resistance except for the slight improvement of fatigue life at small strain amplitudes and shift the ductile-brittle transition temperature (DBTT) to higher but satisfactory value of +10°C as compared to other high-chromium martensitic steels.

In today’s market place power generation plants throughout the world have been trying to reduce their operating costs by extending the service life of their critical machines such as steam turbines and gas turbines beyond the design life criteria. The key ingredient in plant life extension is remaining life assessment technology. This paper will outline remaining life procedures which will incorporate the defect tolerant design concepts applied to the various damage mechanisms such as creep, fatigue, creep-fatigue and stress corrosion cracking. Also other embrittlement mechanisms will also be discussed and how they will influence the life or operation of the component. Application of weld repairs to critical components such as rotors and steam chest casings will be highlighted and how defect tolerant design concept is applied for the repair procedure and the acceptance standard of the nondestructive testing applied. Also highlighted will be various destructive tests such as stress relaxation tests (SRT) which measures creep strength and constant displacement rate test (CDRT) which evaluates fracture resistance or notch ductility. Also shown will be actual life extension examples applied to steam turbine components and weld repairs. Utilization of computer software to calculate fatigue and creep fatigue crack growth will also be presented