Estimating structural integrity,using the TPFC approach,of annealed type 304 stainless steel plate and pipes containing surface defects

Test results and an evaluation of the two-parameter fracture criterion (TPFC) are presented. The tests were conducted at room temperature with annealed Type 304 stainless steel flat-plate tensile specimens containing triangular-, ellipsoidal- or rectangular-shaped surface flaws, and pressurised pipe specimens with internal or external triangular-shaped surface defects. Generally accepted analytical techniques are not available for these and other very ductile materials used in many nuclear reactor components and an accurate assessment of the influence of defects on structural component integrity is needed.The TPFC approach was used in conjunction with the initial defect size and the loads required for the initiation of subcritical crack growth, for penetration through the wall thickness and for instability. Generally, the test results obtained from the flat specimens could be used to predict, from a conservative point of view, the behaviour of pipe specimens. Since $\text{K}{}_{\mathrm{<mtext>F</mtext>}}$ is thickness dependent, it is recommended that tests be conducted for the specific thickness of concern using specimens containing surface defects. The TPFC approach can provide an accurate means for predicting structural integrity.     

Influence of machining parameters on surface roughness and susceptibility to hydrogen embrittlement of austenitic stainless steels

In the present work, an investigation on the susceptibility to hydrogen embrittlement of AISI 304 and 310 austenitic stainless steels was performed. The hydrogen embrittlement process leads to degradation of mechanical properties and can be accelerated by the presence of surface defects combined with elevated surface hardness. Tensile test specimens of the selected materials were machined by turning with different cutting parameters in order to create variations in surface finish conditions. The samples thus prepared were submitted to tensile tests before and after hydrogen permeation by cathodic charging. Regarding the AISI 304 steel, it was possible to notice that the presence of strain-induced martensite on the material surface led to severe hydrogen embrittlement. In the case of the AISI 310 steel, due to its higher nickel amount, no martensite formation could be detected, and this steel was found to be less susceptible to embrittlement in the tested conditions.     

Effects of stress concentration on the mechanical properties of X70 in high-pressure hydrogen-containing gas mixtures

This study aims to investigate the mechanical properties of X70 pipeline steel under the synergistic influence of hydrogen and stress concentration. Slow strain rate tensile tests and low-cycle fatigue tests were performed on the specimens with different stress concentration factors (Kt) in 10 MPa nitrogen/hydrogen mixtures. Results show that the degradation degree of the ductility and fatigue life of X70 steel induced by hydrogen increases with the increase of Kt, and as the hydrogen partial pressure in mixtures increases, the influence of Kt on hydrogen-induced degradation increases as well. In addition, finite element analysis was performed via a modified hydrogen diffusion/plasticity coupled model to study the effect of Kt on hydrogen distribution in the specimens, which can influence the mechanical properties of X70. The maximum hydrogen concentration consistently appears at the notch tip of the specimen and increases with the increase of Kt, which is proposed to be one of the reasons for the severe hydrogen embrittlement of the specimens with large Kt. As the axial tensile force on the specimen increases, the maximum hydrogen concentration at the notch tip begins to be dominated by hydrogen in the normal interstitial lattice sites and, subsequently, in the trapping sites.     

Effect of hydrogen on the tensile properties of 42CrMo4 steel quenched and tempered at different temperatures

The influence of hydrogen on the mechanical behaviour of a 42CrMo4 tempered martensitic steel was investigated by means of tensile tests on both smooth and circumferentially-notched round-bar specimens pre-charged with gaseous hydrogen in a pressurized reactor.Hydrogen solubility was seen to decrease with increasing tempering temperature. Moreover, hydrogen embrittlement measured in notched specimens was much greater in the grades with higher hardness, tempered at the lowest temperatures, where a change in the fracture micromechanism from ductile in the absence of hydrogen to intermediate and brittle in the presence of hydrogen was clearly observed. Results were discussed through FEM simulations of local stresses acting on the process zone.     

Fracture toughness and fatigue crack growth properties of the base metal and weld metal of a type 304 stainless steel pipeline for LNG transmission

The fatigue crack growth rate and CTOD tests on type 304 stainless steel and weld metal were studied over the temperature range −162°C to room temperature. The girth weld metal specimens were fabricated using a combination of gas-tungsten-arc-welding and shielded-metal-arc-welding. The seam weld joint was made by submerged arc welding. Fracture toughness was evaluated through CTOD tests with three point bend specimens. The fatigue crack growth rate tests were conducted using compact tension specimens in accordance with ASTM E647. The CTOD values were affected by crack orientation with respect to the rolling direction, but orientation had no influence on the fatigue crack growth rates. The fatigue crack growth rates and the CTOD values decreased with decreasing test temperature.     

Fatigue-crack propagation behaviour of defective weldments

The effect of weld defects on the fatigue-crack growth response of a GTA weld in a nickel-base alloy was studied at room temperature and 538°C (1000°F). The presence of porosity and inclusion defects was found to have little or no effect on the macroscopic crack growth behaviour of this weldment. On the other hand, electron fractographic examination of the defective weld specimens revealed that these defects did influence the microscopic fatigue behaviour in the immediate vicinity of cavities and inclusions.     

Influence of flux cored arc welded cruciform joint dimensions on fatigue life of ASTM 517 `F' grade steels

A mathematical model has been developed to predict the fatigue life of flux-cored arc-welded (FCAW) cruciform joints containing lack of penetration (LOP) defects. High strength, quenched and tempered steel (ASTM 517 `F' grade) has been used as the base material throughout the investigation. The design of experiments (DoE) concept has been used to optimize the required number of experiments. Fatigue experiments have been conducted in a mechanical resonance pulsator, under constant amplitude loading. The model has been developed by use of the Response Surface Method (RSM). Analysis of variance (ANOVA) techniques have been applied to find the significant factors. The adequacy of the developed model has been checked by calculating the correlation coefficient. By using the developed model, the fatigue life of FCAW cruciform joints containing LOP defects can be predicted at a 95% confidence level. The influence of cruciform joint dimensions on fatigue life have been discussed.     

Using an equation based on flow stress to estimate structural integrity of annealed Type 304 stainless steel plate and pipes containing surface defects

An accurate assessment of the influence of defects on structural component integrity is needed. Generally accepted analytical techniques are not available for the very ductile materials used in many nuclear reactor components. This paper presents some results from a test programme to obtain data by which to evaluate proposed models. Plate and pipe specimens containing surface flaws were fabricated from annealed Type 304 stainless steel and tested at room temperature. An evaluation of an empirical equation based on flow stress is presented. In essentially all instances the flow stress is not a constant but varies as a function of the size of the surface flaw.     

Analysis of a carbon composite overwrap pipeline repair system

A relatively new method has been developed to stop external corrosion and structurally reinforce steel pipes by external wrapping of damaged sections using fibre reinforced polymer (FRP) materials. Several different defect geometries representing corrosion patches on steel pipe were characterized using finite-element analysis, by changing the circumferential length of the defect. Pipe vessels containing these defects along with the composite structural repairs were modeled and the results were compared to field tests to determine the effectiveness of the repairs. It was found that the defect width around the circumference had little impact on the ultimate rupture pressure of the repaired vessel, but influenced the stress state in the underlying pipe substrate.     

Influence of irradiation temperature on microstructure of EU batch of ODS Eurofer97 steel irradiated with neutrons

Abstract

A TEM investigation of an EU batch of oxide dispersed strengthened (ODS) Eurofer97 steel specimens, irradiated to 1 and 3 dpa at 300, 450 and 550°C in high flux reactor at Petten, has been performed to understand the influence of irradiation temperature on the characteristics of irradiation defects and, eventually, on the resulting mechanical properties of this material. Specimens irradiated at 300°C revealed the presence of a high density of black dot damage and small self-interstitial atom (SIA) dislocation loops causing substantial hardening and embrittlement. In contrast, negligible black dot damage, low density of large SIA loops and networks of dislocations are observed in specimens irradiated at 450 and 550°C. The lath martensitic structure and ODS particles remain unaffected after irradiation in all specimens. These results are discussed in view of possible activation of defect annihilation mechanisms to explain the observed recovery of mechanical properties at high irradiation temperatures.     

Cr-Mo与Cr-Mo-V钢铸件在精加工后缺陷焊补

论述了汽缸等Ｃｒ－Ｍｏ与Ｃｒ－Ｍｏ－Ｖ钢铸件在精加工及在电厂运行中所产生的裂纹等缺陷修复问题。为避免焊后回火、减少焊后变形,需要采取冷焊技术;而为防止低合金耐热钢的淬硬倾向而产生冷裂纹,采取敷焊层操作技术,同时保证焊补区的综合机械性能,减少合金元素的稀释、碳迁移所采取的奥氏体焊条焊接的冷焊工艺,证明采用合理的冷焊技术并在操作中严格控制是能够满足机组安全运行需要的。     

Hydrogen embrittlement of super duplex stainless steel in acid solution

Super duplex stainless steel (SDSS) is a good choice of material when resistance to harsh environments is needed. Despite the material’s excellent corrosion resistance and high strength, a number of in-service failures have been recorded. The root cause of these failures was environmentally induced cracking initiated at manufacturing and in-service metallurgical defects. In this study the hydrogen embrittlement of pre-strained super duplex stainless steel specimens was investigated after 48 h cathodic charging in 0.1 M H₂SO₄. The metallurgical changes that resulted from four levels of cold work (4, 8, 12, and 16% plastic strain) were considered and their effect on the embrittlement of the SDSS alloy was investigated. After hydrogen charging, the specimens were pulled immediately to failure and the mechanical properties evaluated. The obtaining fracture morphology was investigated using low and high magnification microscopy. Experimental results indicated that charging the super duplex stainless steel alloy with hydrogen caused varying degrees of embrittlement depending on cold work level. Increasing cold work resulted in a reduction of the elongation to failure. Microscopic investigation confirmed the significant effect of cold work on the hydrogen embrittlement susceptibility of the super duplex stainless steel alloy investigated.     

THERMOMECHANICAL BEHAVIOR OF THE SOLIDIFYING SHELL WITHIN CONTINUOUS-CASTING BILLET MOLDS-A NUMERICAL APPROACH

A two-dimensional numerical model is given for the analysis of the coupled thermal and mechanical behavior of the solidifying shell within the mold during continuous casting of steel. The influence of different mold wall profiles on gap formation and heat flow during casting of billets is investigated. The calculated temperatures, stresses, and strains in the shell are used to estimate the risk for formation of longitudinal cracks. The effect of an initiated and growing macroscopic subsurface crack on the shell behavior is studied. The genesis of surface cracks is discussed. The calculated results are shown to be in reasonable agreement with experimental observations reported in the literature.     

纳米级掺合料粗合成纤维湿喷混凝土施工及抗裂性能分析

为考察纳米级掺合料粗合成纤维湿喷混凝土的施工及抗裂性能,开展了凝结时间、回弹率、抗压强度、干缩、平板开裂和温度应力试验,并将其与同配制强度的硅粉钢纤维湿喷混凝土进行比较。结果表明,与硅粉钢纤维湿喷混凝土相比,纳米级掺合料粗合成纤维湿喷混凝土的凝结时间变化不大;回弹率下降了27%;1d抗压强度提高了45%;干缩测值接近,平板总开裂面积降低,温度应力开裂时间延长,开裂敏感性降低。     

纳米级掺合料粗合成纤维湿喷混凝土施工及抗裂性能分析

为考察纳米级掺合料粗合成纤维湿喷混凝土的施工及抗裂性能,开展了凝结时间、回弹率、抗压强度、干缩、平板开裂和温度应力试验,并将其与同配制强度的硅粉钢纤维湿喷混凝土进行比较。结果表明,与硅粉钢纤维湿喷混凝土相比,纳米级掺合料粗合成纤维湿喷混凝土的凝结时间变化不大;回弹率下降了27%;1 d抗压强度提高了45%;干缩测值接近,平板总开裂面积降低,温度应力开裂时间延长,开裂敏感性降低。     

Effects of hydrogen on the fracture toughness of CrMo and CrMoV steels quenched and tempered at different temperatures

Tempering temperatures ranging between 500 and 720 °C were applied in order to analyse the relationship between steel microstructure and the deleterious effect of hydrogen on the fracture toughness of different CrMo and CrMoV steels. The influence of hydrogen on the fracture behaviour of the steel was investigated by means of fracture toughness tests using CT specimens thermally pre-charged with hydrogen gas.First, the specimens were pre-charged with gaseous hydrogen in a pressurized reactor at 19.5 MPa and 450 °C for 21h and elasto-plastic fracture toughness tests were performed under different displacement rates. The amount of hydrogen accumulated in the steel was subsequently determined in order to justify the fracture toughness results obtained with the different steel grades. Finally, scanning electron microscopy was employed to study both the resulting steel microstructures and the fracture micromechanisms that took place during the fracture tests.According to the results, hydrogen solubility was seen to decrease with increasing tempering temperature, due to the fact that hydrogen microstructural trapping is lower in relaxed martensitic microstructures, the strong effect of the presence of vanadium carbides also being noted in this same respect. Hydrogen embrittlement was also found to be much greater in the grades tempered at the lowest temperatures (with higher yield strength). Moreover, a change in the fracture micromechanism, from ductile (microvoid coalescence, MVC), in the absence of hydrogen, to intermediate (plasticity-related hydrogen induced cracking, PRHIC) and brittle (intergranular fracture, IG), was appreciated with the increase in the embrittlement indexes.     

Fatigue life predictions of welded specimens containing lack of penetration defects at ambient and elevated temperatures

Low cycle fatigue tests have been carried out on welded specimens containing buried lack of penetration defects. Tests were performed at ambient and elevated temperatures. Crack propagation data had been obtained previously at ambient and elevated temperatures for parent materials and weld metals. Using the crack propagation data, the defective specimens were analysed by fracture mechanics techniques to obtain fatigue predictions. It was found that, provided defect shape was taken into account, accurate fatigue life predictions could be made.     

ZG12Cr9Mo1Co1NiVNbNB耐热钢材料开发应用研究

随着火电超超临界机组蒸汽参数提高到28 MPa~30 MPa/600℃/620℃,对耐热钢的性能要求进一步提高,在目前耐热钢铸件材料无法满足该参数长期运行的条件下,开发了一种含Co和B的新型耐热钢材料。利用先进的JMatPro计算软件对ZG12Cr9Mo1Co1NiVNbNB进行成分配比和组织及相的模拟,并按计算确定的成分进行试制,通过对进口试块的常规力学性能、高温瞬时拉伸、断裂力学、高温持久-蠕变性能、组织稳定性及相分析和多回火试验后常规力学等使用性能和工艺性能进行了测试、分析,研究表明ZG12Cr9Mo1Co1NiVNbNB材料可适用于620℃等级超超临界机组阀门、汽缸等高温高压部件。     

Formation of white etching cracks at manganese sulfide (MnS) inclusions in bearing steel due to hammering impact loading

Wind turbine gearbox bearings (WTGBs) are failing prematurely, leading to increased operational costs of wind energy. Bearing failure by white structure flaking (WSF) and axial cracking may both be caused by the propagation of white etching cracks (WECs) and have been observed to cause premature failures; however, their damage mechanism is currently not well understood. Crack initiation has been found to occur at subsurface material defects in bearing steel, which may develop into WECs. One hypothesis for WEC formation at these defects, such as non‐metallic inclusions, is that repetitive impact loading of a rolling element on a bearing raceway, due to torque reversals and transient loading during operation, leads to high numbers of stress‐concentrating load cycles at defects that exceed the material yield strength. In this study, a number of tests were carried out using a reciprocating hammer‐type impact rig. Tests were designed to induce subsurface yielding at stress concentrating manganese sulfide (MnS) inclusions. The effects of increasing surface contact stress and number of impact cycles, with and without surface traction, were investigated. Damage adjacent to MnS inclusions, similar to that observed in a failed WTGB raceway, was recreated on bearing steel test specimens. It has been found that increasing the subsurface equivalent stresses and the number of impact cycles both led to increased damage levels. Damage was observed at subsurface equivalent stresses of above 2.48 GPa after at least 50,000 impact cycles. WECs were recreated during tests that applied surface traction for 1,000,000 impacts. Copyright © 2016 John Wiley & Sons, Ltd.     

Effect of hydrogen charging on the mechanical properties of advanced high strength steels

The present work investigates the influence of hydrogen on the mechanical properties of four multiphase high strength steels by means of tensile tests on notched samples. This was done by performing mechanical tests on both hydrogen charged and uncharged specimens at a cross-head displacement speed of 5 mm/min. A considerable hydrogen influence was observed, as the ductility dropped by 8–60%. In order to demonstrate the influence of diffusible hydrogen, some parameters in the experimental set-up were varied. After tensile tests, fractography was performed. It was found that hydrogen charging caused a change from ductile to transgranular cleavage failure near the notch with a transition zone to a fracture surface with ductile features near the centre.