Search Results for tensile properties

At present there is no recognized standard test method that can be used for the measurement of the tensile properties of additively manufactured lattice structures. The aim of this work was to develop and validate a methodology that would enable this material property to be measured for these geometrically and microstructurally complex material structures. A novel test piece has been designed and trialed to enable lattice struts and substructures to be manufactured and tested in standard bench top universal testing machines and in small scale in-situ SEM loading jigs (not reported in this paper). In conjunction with the mechanical tests, a finite element (FEA) modelling approach has been used to help cross validate the methodology and results, and to enable larger lattice structures to be modelled with confidence. The specimen design and testing approach developed, is described and the results reviewed for AlSi10Mg.

Metallographic tests, micro-hardness tests, mechanics performance tests and Energy Dispersion Spectrum (EDS) were conducted for a 2.25Cr-1Mo main steam pipe weldment served for more than 32 years. Microstructural evolution of the 2.25Cr-1Mo base metal and weld metal was investigated. Degradation in micro-hardness and tensile properties were also studied. In addition, the tensile properties of subzones in the ex-service weldment were characterized by using miniature specimens. The results show that obvious microstructural changes including carbide coarsening, increasing inter lamella spacing and grain boundary precipitates occurred after long-term service. Degradation in micro-hardness is not obvious. However, the effects of long term service on tensile deformation behavior, ultimate tensile strength and yield stress are remarkable. Based on the yield stress of micro-specimens, the order of different subzones is: WM>HAZ>BM, which is consistent with the order of different subzones based on micro-hardness. However, the ultimate tensile strength and fracture strain of HAZ are lower than BM.

A new nickel-based superalloy, designated as GH750, was developed to meet the requirements of high temperature creep strength and corrosion resistance for superheater/reheater tube application of A-USC power plants at temperatures above 750°C. This paper introduces the design of chemical composition, the process performance of tube fabrication, microstructure and the properties of alloy GH750, including thermodynamic calculation, room temperature and high temperature tensile properties, stress rupture strength and thermal stability. The manufacturing performance of alloy GH750 is excellent and it is easy to forge, hot extrusion and cold rolling. The results of the property evaluation show that alloy GH750 exhibits high tensile strength and tensile ductility at room and high temperatures. The 760°C/100,000h creep rupture strength of this alloy is larger than 100MPa clearly. Microstructure observation indicates that the precipitates of GH750 consist of the precipitation strengthening phase γ’, carbides MC and M 23 C 6 and no harmful and brittle TCP phases were found in the specimens of GH750 after long term exposure at 700~850°C. It can be expected for this new nickel-based superalloy GH750 to be used as the candidate boiler tube materials of A-USC power plants in the future.

A Ni-based superalloy named "TOS1X-2" has been developed as a material for A-USC turbine rotors. TOS1X-2 is based on Inconel Alloy 617 and has a modified chemical composition to achieve the higher strength needed for over 700°C-class A-USCs. Aging heat treatment conditions were determined from the mechanical properties and microstructure. We manufactured an actual-scale rotor model made of TOS1X-2. A 31 ton ingot was manufactured, followed by forging of the model rotor with a diameter of 1100 mm and length of 2400 mm without any defects. Metallurgical and mechanical analyses of the model rotor were carried out. All metallurgical and mechanical features of the TOS1X-2 rotor model satisfied the requirements for not only 700°C-class but also over 700°C-class A-USC turbine rotor.

Ni-38Cr-3.8Al has high hardness and high corrosion resistance with good hot workability, and therefore, it has been applied on various applications. However, in order to expand further application, it is important to understand the high temperature properties. Then, this study focused on the high temperature properties such as thermal phase stability, hardness, tensile property, creep property and hot corrosion resistance. As the result of studies, we found that the thermal phase stability of (γ/α-Cr) lamellar structure and the high temperature properties were strongly influenced by the temperature. Although the high temperature properties, except for creep property, of Ni-38Cr-3.8Al were superior to those of conventional Ni-based superalloys, the properties were dramatically degraded beyond 973 K. This is because the lamellar structure begins to collapse around 973 K due to the thermal stability of the lamellar structure. The hot corrosion resistance of Ni-38Cr-3.8Al was superior to that of conventional Ni-based superalloys, however, the advantage disappeared around 1073 K. These results indicate that Ni-38Cr-3.8Al is capable as a heat resistant material which is required the hot corrosion resistance rather than a heat resistant material with high strength at high temperature.

Haynes 282 alloy is a relatively new Ni-based superalloy that is being considered for advanced ultrasupercritical (A-USC) steam turbine casings for steam temperatures up to 760°C. Weld properties are important for the turbine casing application, so block ingots of Haynes 282 alloy were cast for properties studies. Good, sound welds were produced using Haynes 282 weld-wire and a hot gas-tungsten-arc welding method, and tensile and creep-rupture properties were measured on cross-weld specimens. In the fully heat-treated condition (solution annealed + aged), the tensile properties of the welded specimens compare well with as-cast material. In the fully heat-treated condition the creep-rupture life and ductility at 750°C/250MPa and 800°C/200MPa of the cross-weld specimens are similar to the as-cast base metal, and repeat creep tests show even longer rupture life for the welds. However, without heat-treatment or with only the precipitate age-hardening heat-treatment, the welds have only about half the rupture life and much lower creep ductility than the as-cast base metal. These good properties of weldments are positive results for advancing the use of cast Haynes 282 alloy for the A-USC steam turbine casing application.

Improvement of thermal efficiency of new power plants by increasing temperature and pressure of boilers has led us to the development of high creep strength steels in the last 10 years. HCMA is the new steel with base composition of 1.25Cr-0.4Mo-Nb-V-Nd, which has been developed by examining the effects of alloying elements on microstructures, creep strength, weldability, and ductility. The microstructure of the HCMA is controlled to tempered bainite with low carbon content and the Vickers hardness value in HAZ is less than 350Hv to allow the application without preheating and post weld heat treatment. The HCMA tube materials were prepared in commercial tube mills. It has been demonstrated that the allowable stress of the HCMA steel tube is 1.3 times higher than those of conventional 1%Cr boiler tubing steels in the temperatures range of 430 to 530°C. It is noted that creep ductility has been drastically improved by the suitable amount of Nd (Neodymium)-bearing. The steam oxidation resistance and hot corrosion resistance of the HCMA have been proved to be the same level of the conventional 1%Cr and 2%Cr steels. It is concluded that the HCMA has a practical capability to be used for steam generator tubing from the aspect of good fabricability and very high strength. This paper deals with the concept of material design and results on industrial products.

The effect of grain size after solution treatment on the mechanical properties of FENIX-700, including its cooling rate, was investigated. In addition, the dependance of precipitation observed at grain boundaries on the heat treatment conditions was also discussed on the basis of the results of microstructure observations. It was confirmed that the tensile ductility, the creep rupture ductility, and the absorbed energy decreased as the grain size increased. The creep rupture strength, in contrast, increased remarkably as the grain size increased. The tensile strength increased as the cooling rate increased. Experimental results showed that satisfactory mechanical properties would be obtained for a grain size of ASTM G.S.No. 1.0-3.0.

Based on the research and development of Ni-based alloy of 700°C steam turbine bolts and blades worldwide, the process, microstructure, properties characteristics and strengthening mechanism of typical 700°C steam turbine bolts and blades materials Waspaloy are discussed in this study. The result shows that Waspaloy has higher elevated temperature yield strength, creep rupture strength, anti-stress relaxation property and good microstructure stability. The Waspaloy alloy could meet the design requirements of 700°C steam turbine bolts and blades.

Haynes 282 is a great candidate to meet advanced ultra-super-critical (A-USC) steam conditions in modern coal-fired power plants. The standard 2-step aging treatment has been designed for optimizing microstructure therefore providing excellent mechanical properties. We studied an alternative, more economical, 1-step aging treatment and compared microstructure, tensile properties at 750˚C and deformation behavior. Moreover, three cooling rates from the solution temperature were studied to simulate large-scale components conditions. We found that as much as about 20% of fine spherical intragranular γ' particles were successfully precipitated in all cases. Their average size increased as the cooling rate decreased. All four heat-treated alloys exhibited good mechanical properties at 750˚C with a yield strength well over 620MPa. As expected, the yield strength increased and the ductility decreased as the average γ' size decreased. The alloys exhibited a mixed mode of deformation, though the dominant deformation mechanism depended on the different γ' characteristics. The major operative deformation mechanism could be well predicted by strength increment calculations based on the precipitation strengthening model. Our results suggest that wrought Haynes 282 produced by a more economical 1-step aging treatment may be a reliable candidate for high temperature applications under A-USC conditions.

Carbon Capture and Storage (CCS) has become promising technology to reduce CO 2 emissions. However, as a consequence of CCS installation, the electrical efficiency of coal fired power plant will drop down. This phenomenon requires increase in base efficiency of contemporary power plants. Efficiency of recent generation of power plants is limited mainly by maximum live steam temperature of 620°C. This limitation is driven by maximal allowed working temperatures of modern 9–12% Cr martensitic steels. Live steam temperatures of 750°C are needed to compensate the efficiency loss caused by CCS and achieve a net efficiency of 45%. Increase in the steam temperature up to 750°C requires application of new advanced materials. Precipitation hardened nickel-based superalloys with high creep-rupture strength at elevated temperatures are promising candidates for new generation of steam turbines operating at temperatures up to 750°C. Capability to manufacture full-scale forged rotors and cast turbine casings from nickel-based alloys with sufficient creep-rupture strength at 750°C/105 hours is investigated. Welding of nickel-based alloys in homogeneous or heterogeneous combination with 10% Cr martensitic steel applicable for IP turbine rotors is shown in this paper. Structure and mechanical properties of prepared homogeneous and heterogeneous weld joints are presented.

New Fe-base ferritic alloys based on Fe-30Cr-3Al-Nb-Si (wt.%) were proposed with alloy design concepts and strategies targeted at improved performance of tensile and creep-rupture properties, environmental compatibilities, and weldability, compared to Grade 91/92 type ferritic-martensitic steels. The alloys were designed to incorporate corrosion and oxidation resistance from high Cr and Al additions and precipitate strengthening via second-phase intermetallic precipitates (Fe2Nb Laves phase), with guidance from computational thermodynamics. The effects of alloying additions, such as Nb, Zr, Mo, W, and Ti, on the properties were investigated. The alloys with more than 1 wt.% Nb addition showed improved tensile properties compared to Gr 91/92 steels in a temperature range from 600-800°C, and excellent steam oxidation at 800°C as well. Creep-rupture properties of the 2Nb-containing alloys at 700°C were comparable to Gr 92 steel. The alloy with a combined addition of Al and Nb exhibited improved ash-corrosion resistance at 700°C. Additions of W and Mo were found to refine the Laves phase particles, although they also promoted the coarsening of the particle size during aging. The Ti addition was found to reduce the precipitate denuded zone along the grain boundary and the precipitate coarsening kinetics.

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.

Alloy 718 is one of the most widely used for aircraft engine and gas turbine components requiring oxidation and corrosion resistance as well as strength at elevated temperatures. Alloy 718 has been produced in both wrought and cast forms, but metal injection molding and metal-based additive manufacturing (AM) technologies have the potential to create a three-dimensional component. Their mechanical properties are highly dependent on the types of powder processing, but the relationship between microstructures and properties has not been clarified. In this study, the mechanical properties of Alloy 718 manufactured by AM are compared to cast and wrought properties. The electron beam melting processed specimens with strong anisotropy showed higher yield strength, which can be explained by critical resolved shear stress. In addition, the creep deformation showed a complicated behavior which was different from that of wrought alloy. Such abnormal behavior was characterized by γ-channel dislocation activity.

The microstructures and mechanical properties of T122 steel used for superheater tube of the boiler in a 1000 MW ultra supercritical power plant after service for 83,000h at 590℃ were investigated, and compared with data of that served for 56,000h in previous studies. The results show that compared with T122 tube sample service for 56,000h, the tensile properties at room temperature and the size of precipitated phase exhibit few differences, but the lath martensites features are apparent, and the Brinell hardness value are obviously higher. SEM and TEM experiments show that the substructure is still dominated by lath martensite. A few lath martensites recover, subgrains appear and equiaxe, and the dislocation density in grains is relatively low. A large number of second-phase particles precipitated at boundaries of original austenite grains and lath martensite phases, which are mainly M 23 C 6 and Laves phases.

The harsh operating conditions of Advanced Ultra-Supercritical (A-USC) power plants, i.e., steam operation conditions up to 760°C (1400°F)/35 MPa (5000 psi), require the use of Ni-based alloys with high temperature performance. Currently, the U.S. Department of Energy Fossil Energy program together with Electric Power Research Institute (EPRI) and Energy Industries of Ohio (EIO) is pursuing a Component Test (Comets) project to address material- and manufacturing-related issues for A-USC applications. Oak Ridge National Laboratory (ORNL) is supporting this project in the areas of mechanical and microstructure characterization, weld evaluation, environmental effect studies, etc. In this work, we present results from these activities on two promising Ni-based alloys and their weldments for A-USC applications, i.e., Haynes 282 and Inconel 740H. Detailed results include microhardness, tensile, air and environmental creep, low cycle fatigue, creep-fatigue, environmental high cycle fatigue, and supporting microstructural characterization.

The operating temperature of ultrasupercritical (USC) power plants is increasing, with planned temperatures reaching up to 700°C. Austenitic superalloys are promising alternatives to ferritic heat-resistant steels due to their potential for high strength at temperatures around 650-700°C. While austenitic nickel-base superalloys generally exhibit higher creep rupture strength than ferritic heat-resistant steels, they also have drawbacks, including higher thermal expansion, lower creep rupture ductility, and increased costs. Initially, the researchers focused on developing a molybdenum-containing superalloy to achieve low thermal expansion. They systematically investigated the effects of molybdenum and cobalt content, gamma prime phase amount, and aluminum/titanium ratio on thermal expansion, tensile properties, and creep-rupture properties. These investigations were conducted using the conventional molybdenum-containing Alloy 252 as a reference. The developed superalloy, notably free of cobalt and combined with a modified heat treatment, demonstrated significantly improved creep rupture elongation compared to Alloy 252, while maintaining low thermal expansion and high creep rupture strength similar to the reference alloy. Additionally, the research evaluated creep-rupture properties at 700°C for up to approximately 20,000 hours to assess long-term applications. The study also examined the weldability and mechanical properties of weld joints at 750°C, focusing on potential boiler tube applications.

High gamma prime Ni-based superalloys comprising ≥3.5 % Al are difficult to weld due to high propensity of these materials to weld solidification, heat affected zone liquation, and stress-strain cracking. In this study the root cause analysis of cracking and overview on the developed weldable Ni-based superalloys for repair of turbine engine components manufactured from equiaxed (EA), directionally solidified (DS), and single crystal (SX) materials as well as for 3D AM is provided. It is shown that the problem with the solidification and HAZ liquation cracking of turbine engine components manufactured from EA and DS superalloys was successfully resolved by modification of welding materials with boron and silicon to provide a sufficient amount of eutectic at terminal solidification to promote self-healing of liquation cracks along the weld - base material interface. For crack repair of turbine engine components and 3D AM ductile LW4280, LW7901 and LCT materials were developed. It is shown that LW7901 and LCT welding materials comprising 30 - 32 wt.% Co produced sound welds by GTAW-MA on various SX and DS materials. Welds demonstrated high ductility, desirable combination of strength and oxidation properties for tip repair of turbine blades. Examples of tip repair of turbine blades are provided.

Recently, a γ’ precipitation strengthened Ni-base superalloy, USC141, was developed for 700°C class A-USC boiler tubes as well as turbine blades. In boiler tube application, the creep rupture strength of USC141 was much higher than that of Alloy617, and the 105 hours’ creep rupture strength of USC141 was estimated to be about 180MPa at 700°C. This is because fine γ’ particles precipitate in austenite grains and some kinds of intermetallic compounds and carbides precipitate along austenite grain boundaries during creep tests. Good coal ash corrosion resistance is also required for tubes at around 700°C. It is known that coal ash corrosion resistance depends on the contents of Cr and Mo in Ni-base superalloys. Therefore the effect of Cr and Mo contents in USC141 on coal ash corrosion resistance, tensile properties, and creep rupture strengths were investigated. As a result, the modified USC141 containing not less than 23% Cr and not more than 7% Mo showed better hot corrosion resistance than the original USC141. This modified alloy also showed almost the same mechanical properties as the original one. Furthermore the trial production of the modified USC141 tubes is now in progress.

Large scale components of the conventional 600°C class steam turbine were made of the ferritic steel, but the steam turbine plants with main steam temperatures of 700°C or above (A-USC) using the Ni-base superalloys are now being developed in order to further improve the thermal efficiency. The weight of the turbine rotor for the A-USC exceeds 10ton. A lot of high strength superalloys for aircraft engines or industrial gas turbines have been developed up to now. But it is difficult to manufacture the large-scale parts for the steam turbine plants using these conventional high strength superalloys because of their poor manufacturability. To improve high temperature strength without losing manufacturability of the large scale components for the A-USC steam turbine plants, we developed Ni-base superalloy USC800(Ni-23Co-18Cr-8W-4Al-0.1C [mass %]) which has temperature capability of 800°C with high manufacturability achieved by controlling microstructure stability and segregation property. The 700°C class A-USC materials are the mainstream of current development, and trial production of 10 ton-class forged parts has been reported. However, there have been no reports on the development and trial manufacturing of the A-USC materials with temperature capability of 800°C. In this report, results of trial manufacturing and its microstructure of the developed superalloy which has both temperature capability 800°C and good manufacturability are presented. The trial manufacturing of the large forging, boiler tubes and turbine blades using developed material were successfully achieved. According to short term creep tests of the large forging and the tube approximate 100,000h creep strength of developed material was estimated to be 270MPa at 700 °C and 100MPa at 800°C.