Thermal–mechanical fatigue behaviour of P92 T-piece and Y-piece pipe

This paper presents a study on thermal–mechanical fatigue (TMF) behavior of P92 T-piece and Y-piece pipe at the most critical working fluctuations. Pressure and temperature in isothermal, in-phase (IP) and out-of-phase (OP) loading conditions were taken into account. Cyclic plasticity model considering the effect of temperature was used, in which both kinematic hardening variable and isotropic hardening variable are included. All the parameters used in the simulation were obtained from low cycle fatigue (LCF) tests at different temperatures. These parameters have been validated through the comparison of experimental data with the simulated data. Then, finite-element models (FEM) of P92 T-piece and Y-piece pipe were developed to investigate the location of the most critical region at typical thermal-mechanical loading. Simulated results reveal that the most dangerous position occurs at the region where the inner surface of horizontal pipe and branch pipe crossed for both T-piece and Y-piece pipe which is irrelevant to the types of loading. IP loading is the most serious working condition for both T-piece and Y-piece pipe. Comparing with T-piece pipe, Y-piece pipe at IP loading is the most dangerous condition.     

Low cycle fatigue and creep–fatigue interaction behaviour of 2.25Cr1MoV steel at elevated temperature

This study reports the fatigue behaviour of 2.25Cr1MoV steel under low cycle fatigue (LCF) loading and creep-fatigue interaction (CFI) loading at 355, 455 and 555 °C. Various hold durations up to 600 s were introduced in the CFI tests at the peak/valley strain under strain or stress control. In LCF tests, the steel exhibited remarkable strengthening at 455 °C, which can be ascribed to the effect of dynamic strain aging. In CFI tests, tensile holds were found more damaging than compressive holds but considerably less harmful than the combined tensile-compressive holds. A modified plastic strain energy approach based on the damage mechanisms was proposed to predict fatigue life under LCF and CFI conditions. The predictions obtained compared very favourably with the experimental results.     

Friction and wear behaviour of β-silicon nitride–steel couples under unlubricated conditions

Abstract

The friction and wear behaviour of colloidally processed and pressureless sintered β-silicon nitride (Si₃N₄) ceramics against steel DIN Ck45K under unlubricated condition were investigated using a pin on disk tribometer. β-silicon nitride (Si₃N₄) ceramics consolidated by slip casting from suspensions with different solid loading have been studied, aiming at increasing the use of β-Si₃N₄ as cutting tools in industrial applications. The morphology of the worn surfaces of β-silicon nitride ceramics was analysed by scanning electron microscopy (SEM) and energy dispersion spectroscopy (EDS). Under the conditions used, it was found that β-Si₃N₄ ceramics exhibited a low wear rate (10^?6 mm³ N^?1 m^?1) and the frictional behaviour of β-Si₃N₄ ceramics–steel couples depended on a metallic layer transferred from the steel disk to the β-Si₃N₄ ceramic pin.     

Crack growth behavior of 7075-T6 under biaxial tension–tension fatigue

Crack growth behavior of aluminum alloy 7075-T6 was investigated under in-plane biaxial tension–tension fatigue with stress ratio of 0.5. Two biaxiality ratios, λ (=1 and 1.5) were used. Cruciform specimens with a center hole, having a notch at 45° to the specimen’s arms, were tested in a biaxial fatigue test machine. Crack initiated and propagated coplanar with the notch for λ = 1 in L–T orientation, while it was non-coplanar for λ = 1.5 between L–T and T–L orientations. Uniaxial fatigue crack growth tests in L–T and T–L orientations were also conducted. Crack growth rate in region II was practically the same for biaxial fatigue with λ = 1 in L–T orientation and for the uniaxial fatigue in L–T or T–L orientations, while it was faster for biaxial fatigue with λ = 1.5 at a given crack driving force. However, fatigue damage mechanisms were quite different in each case. In region I, crack driving force at a given crack growth rate was smallest for biaxial fatigue with λ = 1.5 and for uniaxial fatigue in T–L orientation, followed by biaxial fatigue with λ = 1 and uniaxial fatigue in L–T orientation in ascending order at a given crack growth rate.     

Fatigue and creep fatigue crack growth behaviour of alloy 800 at 550°C

Fatigue and creep fatigue crack growth behaviour of alloy 800 at 550°C have been studied to analyse defect assessment in a steam generator. Different grades of alloy 800 have been investigated to reproduce the in service conditions. Fatigue crack growth (FCG) tests were conducted on CT20 and tubular specimens, then on welded tubes. Furthermore the influence of hold times on fatigue crack growth behaviour was studied.

The results obtained on material simulating the weld heat affected zone are in agreement with the tests conducted on welded tubes. Fatigue crack growth characteristics of aged and cold-worked aged material seem to be slightly improved in comparison with base material. Finally a hold time of one minute increases strongly the FCG threshold value determined in pure fatigue but has a negligible influence on crack growth rates.     

Effect of niobium on creep and creep crack growth of cast Ni–Cr austenitic steel

Abstract

An investigation of the effect of Nb on creep properties and creep crack growth rate in a 25Cr–35Ni–0·4C (wt-%) cast steel at 871 and 950°C was carried out. Tensile tests were also carried out at room temperature, 871, and 950°C. The tensile strength and elongation increased with an increase in Nb content at high temperatures. There existed an optimum Nb content for the creep properties and creep crack growth rate. Creep crack growth is controlled by creep deformation.

MST/1222     

Deterministic and probabilistic creep–fatigue–oxidation crack growth modeling

Fatigue, creep, oxidation or their combinations have long been recognized as the principal mechanisms in many high-temperature failures in power plant components, turbine engines, and exhaust systems in vehicles. Depending on the specific materials and loading conditions and temperature, the role of each damage mechanism may change significantly, ranging from independent development to competing and combined creep–fatigue, fatigue–oxidation, and creep–fatigue–oxidation. In this paper a new linear superposition theory is proposed to model the cycle-dependent and time-dependent creep–fatigue–oxidation crack growth phenomena. The model can be reduced to creep–fatigue and fatigue–oxidation crack growth models previously developed by the authors as well as, under some assumptions, the current widely used linear superposition theory. The limits of the current superposition theory and the advantages of the new theory are clearly demonstrated with several worked examples. A general probabilistic analysis procedure is also proposed by introducing the uncertainties of parameters in fatigue, creep, and oxidation crack growth laws with the help of the Monte Carlo simulation.     

Low-cyclic fatigue behaviour of an Al–Cu–Mg–Ag alloy under T6 and T840 conditions

The low-cyclic fatigue (LCF) behaviour of an AA2139 alloy belonging to the Al–Cu–Mg–Ag system was investigated under T6 and T840 conditions. The T840 treatment involves cold rolling with a 40% reduction prior to ageing, and this was effective in increasing the tensile strength of the alloy. Under cyclic loading at total strain amplitudes (ε_ac) of ±0.4 to ±1.0%, the mechanical behaviour is defined as the prevalence of elastic over plastic deformation processes under both the T6/T840 conditions. The initial weak hardening during one to two cycles of loading at ε_ac?>?0.55% and an insignificant softening upon following the cyclic loading to fracture was observed for the T6/T840 conditions. The LCF behaviour of the alloy under the T6/T840 conditions is described by the Basquin–Manson–Coffin relationship.

This paper is part of a Themed Issue on Aluminium-based materials: processing, microstructure, properties, and recycling.     

Effect of cyclic loading on subsequent creep behaviour and its implications in creep–fatigue life assessment

Abstract

Evaluation of creep–fatigue failure is essential in design and fitness evaluation of high-temperature components in power generation plants. Cyclic deformation may alter the creep properties of the material and taking cyclic effects into account may improve the accuracy of creep–fatigue failure life prediction. To evaluate such a possibility, creep tests were conducted on 316FR and modified 9Cr–1Mo steel specimens subjected to prior cyclic loading; their creep deformation and rupture behaviours were compared with those of as-received materials. It was found that creep rupture life and elongation generally decreased following cyclic loading in both materials. In particular, the rupture elongation of 316FR in long-term creep conditions drastically decreases as a result of being cyclically deformed at a large strain range. Use of creep rupture properties after cyclic deformation, instead of those of as-received material, in strain-based and energy-based life estimation approaches brought about a clear improvement of creep–fatigue life prediction.     

Designing P92 grade martensitic steel header pipes against creep–fatigue interaction loading condition: Damage micromechanisms

The boiler tubes and pipes in the present day coal fired power plants are designed against damage arising from the interaction of creep and fatigue. The present investigation reports the microstructural evolution in P92 grade martensitic steel during pure fatigue and hold time fatigue tests conducted at 600 °C. Fatigue life significantly dropped for hold time fatigue tests in comparison with pure fatigue tests. The drop in fatigue life was more for hold time fatigue tests conducted with compressive hold. Grain boundary oxidation and cracking was identified as the major cause for the decrease in fatigue life under compressive hold. Annihilation of dislocations and pinning of dislocations by MX precipitates were observed to be the microstructural changes during cyclic deformation.     

Applicability of improved Dyson–McLean approach to creep deformation behaviour of tempered martensitic P9 steel

Modelling creep deformation of tempered martensitic P9 steel in quenched and tempered, and simulated post weld heat treatment conditions has been performed in the framework of improved Dyson–McLean approach for wide range of stresses at 873 K. In this approach, kinetic creep law coupled with the set of first-order differential equations representing the evolution of microstructural internal-state-variables with strain/time has been employed to describe creep deformation behaviour of tempered martensitic steel. The optimised material constants associated with the model such as dislocation storage parameter (K_d) and rate constants associated with the precipitate coarsening (K_p) and solute depletion (K_s) reflect the influence of two different heat treatments on creep characteristics examined in the present investigation. At all test conditions, good agreement between the predicted and experimental creep strain/strain rate-time data at 873 K has been observed. Further, good correlations have been obtained between the experimental and predicted steady-state creep rates and time to reach the specified strain levels for both the heat treatment conditions.     

Understanding low cycle fatigue and creep–fatigue interaction behavior of 316 L(N) stainless steel weld joint

The aim of this work is to study the time dependent effects on the low cycle fatigue (LCF) behavior of 316 L(N) stainless steel weld joint. Influence of strain rate, temperature, strain range, hold time and hold duration on fatigue life is evaluated. Occurrence of dynamic strain aging, creep damage, overall distribution of damage across the weld joint and the role of microstructure on the failure mode and failure location of the weld joint is discussed as a function of test parameters.     

A cohesive zone model for fatigue and creep–fatigue crack growth in single crystal superalloys

A numerical analysis using cohesive zone model under cyclic loading is proposed to develop a coupled predictive approach of crack growth in single crystal. The process of material damage during fatigue crack growth is described using an irreversible cohesive zone model, which governs the separation of the crack flanks and eventually leads to the formation of free surfaces. The cohesive zone element is modeled to accumulate fatigue damage during loadings and no damage during unloadings. This paper presents the damage model and its application in the study of the crack growth for precracked specimens. The use of cohesive zone approach is validated through a convergence study. Then, a general procedure of parameters calibration is presented in pure fatigue crack growth. In the last section, an extension of the cohesive zone model is presented in the case of creep–fatigue regime at high temperature. The model showed its capability to predict with a good agreement the crack growth in the case of complex loading and complex specimen geometries.     

Cyclic creep behaviour under tension–tension loading cycles with hold time of modified 9Cr–1Mo steel

Abstract

Cyclic creep behaviour of modified 9Cr–1Mo steel was investigated by a series of cyclic creep (CC) tests at 600°C, which were performed under controlled tension–tension loading cycles with the magnitude of stress ranges in a constant stress ratio (R?=?0·1). Hold time was applied for a 10 min hold at the maximum stress (σ_max) and minimum stress (σ_min). The CC properties were compared with the static creep (SC) using Norton’s power law, Larson–Miller plot, and Monkman–Grant relation, and the microstructure was examined. For the test conditions employed in the present investigation, retardation in the CC behaviour in terms of a lower creep rate and longer rupture time compared to those in the SC was obtained. The retardation was ascribed to the effects associated with anelastic recovery during the 10 min hold time at the minimum load of the cyclic loading. The creep rupture ductility decreased with a general decrease in stress, and there was no difference in the creep ductility between the CC and SC. The steel displayed a transgranular fracture characterised by the presence of dimples resulting from micro-void coalescence. Carbide precipitation was more coarsened with increasing in exposure time in the CC tests.     

Zone-wise investigation of creep behaviour 9Cr–1Mo steel weld joints

Distinct regions such as weld metal, heat-affected zone (HAZ) and base metal of P9 steel weld joints fabricated by various welding processes were investigated using impression creep testing. Smaller prior austenitic grain size, lower density of precipitates and dislocations resulted in faster recovery and higher creep rate of HAZ in comparison to the weld and base metal. Compared to base metal, shielded metal arc weld (SMAW) and activated tungsten inert gas (A-TIG) weld of the P9 steel weld joints exhibited better resistance to creep and displayed higher activation energy due to their coarser prior austenite grain size. A-TIG HAZ exhibited superior creep properties compared to the SMAW and TIG HAZ due to the presence of higher number density of precipitates.     

Investigation on influence of dynamic strain ageing on fatigue crack growth behaviour of modified 9Cr–1Mo steel

Fatigue crack growth behaviour of modified 9Cr–1Mo steel is examined in the temperature range 300–823 K. An improvement in fatigue crack growth resistance is observed in the dynamic strain ageing regime. The activation energy for the process leading to this is estimated from the temperature-dependence of crack tip strain rate as 55–80 kJ/mole. This indicates that dynamic strain ageing due to interaction of dislocations with interstitial solute elements is responsible for the improved fatigue resistance in this range.     

Effect of primary α content on creep and creep crack growth behaviour of near α-Ti alloy

Abstract

The effect of primary α content on creep and creep crack growth behaviour of a near α-Ti alloy has been investigated at 600°C. The alloy was heat treated at different temperatures so as to obtain different volume fractions of equiaxed primary α in the range from 5 to 40%. Constant load creep tests were carried out at 600°C in the stress range 250–400 MPa until rupture of the specimens. Creep crack growth tests were carried out at 600°C and at an initial stress intensity level of 25 MPa m^1/2. Creep data reveal that minimum creep rate increases and time to rupture decreases with increase in primary α content indicating that higher primary α leads to creep weakening. On similar lines, maximum creep crack growth resistance is associated with the alloy with lowest primary α content (i.e. 5%). Microstructural and fractographic examination has revealed that creep fracture occurs by nucleation, growth and coalescence of microvoids nucleated at primary α/transformed β (matrix) interfaces. On the other hand, creep crack growth occurs by surface cracks nucleated by fracture of primary α particles as well as by growth and coalescence of microvoids nucleated at primary α/transformed β (matrix) interfaces in the interior of the specimen ahead of the crack tip.     

Influence of case-carburizing and micro-defect on competing failure behaviors of Ni–Cr–W steel under gigacycle fatigue

Axial loading test was performed to investigate the influence of case-carburizing and micro-defect on competing failure behaviors of Ni–Cr–W Steel under gigacycle fatigue. The interior failures induced from inclusion and microstructural inhomogeneity become the predominant failure mode in the life regime beyond 10⁵ cycles. The case-carburizing has no effect on the fatigue strength with interior failure. Compared with the lower limit values of experimental S–N data, the predicted results by using GP distribution is relatively suitable. From the viewpoint of reliability, the modeling method of interior S–N curve with the maximum defect size at a given probability is satisfactory.