Study on creep-fatigue damage evaluation for advanced 9%–12% chromium steels under stress controlled cycling

Creep-fatigue interaction is one of the main damage mechanisms in high temperature plants and their components. Assessment of creep-fatigue properties is of practical importance for design and operation of high temperature components. However, the standard evaluation techniques, i.e. time fraction rule and ductility exhaustion one have limitations in accounting for the effects of control mode on the cyclic deformations. It was found that conventional linear cumulative damage rule failed in accurately evaluating the creep-fatigue life under stress controlled condition. The calculated creep damages by time fraction rule were excessively high, which led to overly conservative prediction of failure lives. In the present study, it was suggested that such over estimation of creep damage was mainly caused by anelastic strain upon stress loading. For precise assessment under conditions of stress control, a modified creep damage model accounting for the effect of anelastic creep was proposed. The assessments of creep fatigue data under stress controlled condition were performed with the new approach developed in this paper for a rotor material and a boiler material used in ultra supercritical power plants. It was shown that a more moderate amount of creep damage was obtained by the new model, which gave better predictions of failure life.     

Effects of PWHT on Microstructure and Mechanical Properties of Weld Metals of Ni-Based Superalloy 617 and 263 for Hyper-Supercritical Power Plants

It is well known that solid solution-strengthened alloy 617 and γ' precipitation-strengthened alloy 263 have excellent mechanical properties and corrosion resistance at high temperatures.Hyper-supercritical power plants work at temperatures above 700 ℃,and these superalloys are considered candidate materials for steam turbines components of these power plants.In this study,gas tungsten arc weldability of these superalloys was evaluated,and the effects of postweld heat treatment(PWHT) on the microstructural characteristics and the mechanical properties of their weld metals were investigated.Scanning transmission electron microscopy,energy-dispersive spectroscopy and electron probe microanalysis were utilized for the investigation.The experimental results confirmed that these weld metals had different characteristics in microstructure and mechanical properties.PWHT resulted in the precipitation of intergranular carbides,γ' particles and an increase in tensile strength of these superalloy weld metals.Furthermore,fine γ' particles,which were not detected in the as-welded metal of alloy 263,were precipitated after PWHT and those particles were the reason for the drastic increase in tensile strength.     

Shape Character of Fusion-solidification Zone of EBW Joints for Titanium Alloy

Shape character of fusion-solidification zone of electron beam welding (EBW) joints was studied for TC4 alloy.Four typical shapes of the fusion-solidification zone were gained by appropriate welding processes.The shapes and dimensions of the fusion-solidification zone of TC4 titanium joints were apparently influenced by processing parameters,focusing state and power density distribution.Based on the analyses of processing parameters,focusing state and power density distribution,the integrated parameters of n1 and n2 were put forward,which represented the distribution and intensity of electron beam energy.And a series of the formulations are developed to predict the shape of fusion-solidification zone by the processing parameters.     

Study on shape factor of the fusion-solidification zone of electron beam weld

The concept of shape factors of the fusion-solidification zone is proposed to describe the weld cross section geometry. According to these shape factors, the electron beam weld fusion-solidification zone is divided into four typical shapes and the classification criterion for these typical shapes is suggested. An integrated parameter n, combining the line power density of electron beam and material thermal properties is proposed to describe the relative power input, and another integrated parameter n2 combing the accelerating voltage and focusing current is proposed to reflect the power distribution in the keyhole. A series of new expressions, which can reflect the influence of focusing current, accelerating voltage, beam current, and material thermal properties, are developed to predict the fusion-solidification zone shape based on experimental results nonlinear fitting of n1 and n2.     

PROPERTIES, WELDABILITY AND APPLICATIONS OF ADVANCED WROUGHT SUPERALLOYS FOR GAS TURBINE ENGINES

Alloy selection and alloy design both require consideration of an array of material attributes, including in-service properties, weldability and fabricability. Critical properties of advanced wrought superaUoys for gas turbine applications include high temperature strength, thermal stability, oxidation resistance and fatigue resistance. In this paper, the properties of twelve wrought solid-solution-strengthened and six age-hardenable superalloys are compared. Weldability is an important attribute and can be a major limiting factor in the use of certain alloys. Weldability test methods are discussed and the resistance of alloys to solidification cracking and strain-age cracking is compared. The use of weldability testing in the development of modern wrought superalloys is discussed with several examples cited. Finally, alloy selection for gas turbine components is outlined, taking into account both alloy properties and fabricability.     

Porosity and surface roughness simulation of nickel-aluminum coating in plasma spray forming

As the important evaluation parameters concerning the spray qualities, the porosity and surface roughness of the coatings obtained by thermal spray forming have great influence on their forming accuracy, mechanical properties and service lifetime. But it is difficult to predict or control the two parameters for such a highly nonlinear process. A two-dimensional simulation of coating porosity and surface roughness of nickel-aluminum alloy （Ni-5%Al） in plasma spray forming was presented, which was based on the multi-dimensional statistical behaviors of the droplets as well as the simplification and digitization of the typical splat cross sections. Further analysis involving the influence of the droplet diameters and the scanning velocities of the spray gun on the two parameters was conducted. The simulation and analysis results indicate that the porosity and surface roughness are more influenced by the droplet diameters, but less influenced by the spray gun velocities. The results will provide basis for the prediction or control of coating mechanical properties by depositing parameters.     

Finite element method simulation for tensile process of sintered iron-base material

Different material properties leads to different metal fracture behaviors.Even if the powder material is composed of plastic metal,the fracture still does not show macroscopic plastic deformation characteristics if the material contains a large number of voids.Eight-node isoparametric elastic-plastic finite element method was used to simulate the tensile process of sintered powder material.By setting a number of voids in the analyzed metal cuboid,the initial density was taken into consideration.The material properties of the three-dimensional solid for the tensile simulation were defined with reference to the known pure iron material parameters,The load-displacement curves during elongation were obtained with a universal testing machine,and then the simulated curves were compared with the experimental results.The factors that cause the stress concentration and strength decrease were analyzed according to the simulated equivalent von Mises stress distribution.     

High Current and High Intensity Ion Beam Sources and Their Technological Applications

High-current ion beams have become a powerful tool for improving the surface properties of different materials.The prospects of wide commercial use of such beams for material treatment is not only due to the possibility of improving their properties,but,also for economic expediency.To achieve a high throughput and reduce the cost on ion beam material treatment,ion beams of high average and pulsed power are necessary.This paper gives an overview of work on generation of pulsed and repetitively pulsed beams of accelerated ions with currents ranging from fractions of an ampere to several tens of kA and with pulse duration from several tens of nanoseconds to several hundreds of microseconds.A number of different methods of materials surface properties modification using high power and intense ion beam and plasma are considered.     

Processing and mechanical properties of porous 316L stainless steel for biomedical applications

Highly porous 316L stainless steel parts were produced by using a powder metallurgy process, which includes the selective laser sintering（SLS） and traditional sintering. Porous 316L stainless steel suitable for medical applications was successfully fabricated in the porosity range of 40%-50% （volume fraction） by controlling the SLS parameters and sintering behaviour. The porosity of the sintered compacts was investigated as a function of the SLS parameters and the furnace cycle. Compressive stress and elastic modulus of the 316L stainless steel material were determined. The compressive strength was found to be ranging from 21 to 32 MPa and corresponding elastic modulus ranging from 26 to 43 GPa. The present parts are promising for biomedical applications since the optimal porosity of implant materials for ingrowths of new-bone tissues is in the range of 20%-59% （volume fraction） and mechanical properties are matching with human bone.     

NUMERICAL SIMULATION OF TEMPERATURE FIELD ON FLASH BUTT WELDING FOR HIGH MANGANESE STEELSF

An axial symmetry finite element model coupled with electricity-thermal effect was developed to study the temperature field distribution in process of the flash butt welding （FBW） of frog highmanganese steel. The influence of temperature dependent material properties and the contact resistance were taken into account in FEM ＇simulation. Meanwhile, the lost materials due to .splutter was resolved by using birth and death element. The result of analyzing data shows that the moddel in the FBW flashing is reasonable and feasible, and can exactly simulate the temperature field distribution. The modeling provides reference for analysis of welding technologies on the temperature field of high-manganese steel in FBW.     

LIFE PREDICTION OF HIGH TEMPERATURE STRUCTURALCOMPONENT BY STRAIN RANGE PARTITIONING

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电站烟气脱硫装置的腐蚀机理及其防护选材

介绍了火电行业烟气脱硫装置的腐蚀机理，装置部件的按介质选材，以及使用的防护材料的性能和特点。     

PLC控制下汽车车桥焊接工艺研究

通过对汽车车桥材料的焊接性和焊接结构的分析,研究了PLC控制下的汽车车桥CO_2气体保护焊工艺,并对焊接接头的力学性能和显微组织进行相应地分析,确定了其最佳工艺参数.结果显示,由于PLC技术的引入,焊接接头的性能得到显著改善,完全可以达到相应的标准要求,满足生产需要.     

我国电站用高压锅炉管的现状与国产化

“八五”期间,超高压、亚临界压力的大容量火电机组将更多地投建和运行,发电锅炉容量的增大,运行参数的提高,对电站用钢材特别是受压元件的高压锅炉管在数量、质量和规格上的要求也就更多更高。文章介绍了电站锅炉用管的需求情况、主要性能、用管系列及钢种系列,指出必须尽快改变我国高压锅炉管主要依靠进口的现状以加速高压锅炉管国产化进程,提出了相关的措施和意见。     

NUMERICAL CALCULATION OF TEMPERATURE DISTRIBUTION DURING ELECTRON BEAM TRANSFORMATION HARDENING

本文从理论和实验两方面,对20钢电子束相变硬化处理表面的热传导问题进行了研究.建立了移动半无限大工件、表面受均匀矩形热源加热的稳态、三维热传导模型.用有限差分方法数值求解了工件表面的温度场.由此估算了不同工艺参数处理对的表面最高温度、加热和冷却速度等一些无法实测的数据.基于材料热物性参数为常数的假设,得出了工艺参数与表面熔化温度之间的关系.此关系可作为电子束相变硬化处理时恰当选择工艺参数的依据.在实验方面,通过改变功率、移动速度和束斑尺寸等工艺参数,研究了20钢表面处理层的显微组织、相变区的形状和深度,确定了表面熔化的开始.实验结果与计算值两者符合较好.从而证明此计算模型是有效的.     

T91/P91钢持久性能的统计分析及可靠性预测

利用Z参数方法分析了T91/P91(9Cr--1Mo--V--Nb)钢高温持久性能数据的统计分布规律. 结果表明:形状、热处理工艺等不同的T91/P91钢的高温持久性能数据交替重叠地分布在以应力σ--TTP(时间--温度参数)关系主曲线为中心的数据带中, 而表征T91/P91钢持久性能数据分散性的Z参数服从正态分布. 基于Z参数法对材料高温持久性能的可靠性分析结果, 提出了T91/P91钢的σ--TTP--可靠度R曲线、 σ--断裂时间t_r--R曲线和许用应力[σ]--温度T--R曲线.预测结果与NRIM及ECCC公开的实验数据均符合良好.     

Effect of temperature on fatigue crack growth in P92 steel

Fracture at high temperature has become a critical problem for such high temperature components as those used in power plants or oil refinery plants, because both high operating temperature and pressure are required for better thermal efficiency. Therefore, it is very important to approach such problems from the viewpoint of high temperature material properties. Since fatigue and creep are closely related to such components failures, the fracture behavior in high temperature components must be evaluated through fatigue and creep crack growth tests, and based on these results, better operating conditions can be determined. In this study, recently developed P92 (9Cr-2W) alloy steel, which is a high strength material for high temperature use, is investigated and its fatigue crack growth has been characterized by Paris law. A series of high temperature fatigue tests were carried out at 400, 500, 550, 600, 625, 650, and 700°C to verify the temperature effect. The results indicated that the Paris exponent remained at approximately the same value up to a certain temperature. From 600 to 700°C, creep rupture tests were conducted in order to investigate the creep behavior with temperature. Further analysis has also been carried out to investigate the effect of temperature on fracture mode shift, dimple formation, and its role in crack growth rate and deformability at high temperature.     

陶瓷刀具的断裂韧性及其统计特性分析

实验研究了新型陶瓷刀具材料的断裂韧性及其统计特性。线性回归分析和K—S分布拟合检验的结果表明：该陶瓷刀具材料的断裂韧性很好地服从三参数Weibull分布。并进一步建立了断裂韧性尺寸效应的统计模型。     

Surface analysis of injection molded TV components

Injection molded polymer test specimens produced within the frame of a full factor sampling plan were measured using two different kinds of instrumentations, i.e. a non-contacting Zygo NewView 100 optical interference microscope and a newly developed Rank Taylor Hobson Talyscan probe using a contacting stylus with very low forces. Surface roughness and texture data were subjected to statistical analysis of variance with the purpose of establishing quantitative relationship to processing parameters and to the traditionally used visual judgement of produced components. The paper will present the experimental setup and the major results of the data analysis, i.e., a statistical based selection of amplitude, height distribution, and spatial parameters as well as the relative influence of the mold, the material, and the processing parameters to the surface texture.