Creep resistance of similar and dissimilar weld joints of P91 steel

Abstract

Two experimental weld joints, a similar weld joint of 9Cr–1Mo steel and a dissimilar weld joint of 9Cr–1Mo and 2.25Cr–1Mo steels, were fabricated by the TIG+E method and post-weld heating was applied. Creep testing was carried out at temperatures ranging from 525 to 625°C in the stress range 40–240 MPa. Creep rupture strength was evaluated using the Larson–Miller parameter. Extended metallography including transmission electron microscopy was performed and critical zones were indicated where fractures were concentrated during the creep exposure. At high temperatures rupture of the dissimilar weldment occurred in the heat affected zone (HAZ) of the weld metal while rupture of the similar weldment was located in the HAZ of the parent material. The processes of recovery seem to be the main causes of decrease in creep rupture strength of both weld joints in comparison to the parent materials.     

Effect of temperature on the fracture behaviour of heat‐treated Al–Cu–Li alloy laser welds under low‐cycle fatigue loading

The paper presents the results of the studies of the effect of temperature on the fracture behaviour of Al–Cu–Li alloy laser welds under low‐cycle fatigue loading. The mechanical properties and the microstructure of the welded joints without and after postweld heat treatment (PWHT) were investigated. The tensile strength and the low‐cycle fatigue resistance of the welded joints were studied at various test temperatures (20°C, 85°C and ? 60°C). It was been found that heating up to 85°C and cooling down to ?60°C reduced the maximum number of loading cycles of the welded joints after PWHT by 1.5–2.0 times compared with that at a test temperature of 20°C.     

Influence of post-weld heat treatment on tensile properties of modified 9Cr–1Mo ferritic steel base metal

Abstract

The paper presents the influence of post-weld heat treatment (PWHT) on tensile properties of modified 9Cr–1Mo ferritic steel base metal. Tensile tests at room and elevated temperatures (300–873 K) were performed on specimens in normalised and tempered condition as well as with additional PWHT (993 K for 1 h; 1013 K for 1 h and 1033 K for 1 h). The yield and ultimate tensile strengths decrease gradually up to intermediate temperatures followed by a rapid fall at high temperatures in all heat treatment conditions. At intermediate temperatures, the steel exhibited ductility minima, serrated flow, negative strain rate sensitivity on flow stress and peak in the average work hardening rate. The influence of additional PWHT is reflected in a systematic and gradual decrease in both the yield and tensile strength values with increasing PWHT temperature from 993 to 1033 K for 1 h. However, there has been no appreciable change in ductility values as well as the fracture mode in PWHT conditions compared with those observed in normalised and tempered condition. Comparison of strength values in PWHT conditions suggested that the strength values remained higher than the average values specified in the French Nuclear Design Code, RCC-MR.     

Effect of heat treatment on creep and fracture behaviour of 1·25Cr–O·5Mo steel

Abstract

The effect of tempering treatments on the microstructure and creep behaviour of multipass 1·25Cr–0·5Mo steel weldments has been evaluated. While tempering invariably reduced the hardness, significant changes in microstructure were only found after heat treatment at 750°C. In this case ferrite bands developed adjacent to the fusion boundary. Tempering increased creep deformation and reduced failure lifetime for base metal specimens. For crossweld testpieces, the susceptibility to low ductility failures in the heat affected zone was found to be linked to the development of creep cavities and cracks. Thus, brittle failure modes were a function of stress, temperature, microstructure, post weld heat treatment, and to a lesser extent, specimen geometry.

MST/3069     

Effect of postweld heat treatment on development of interfacial structures in nickel-based transition joints

Abstract

The interfacial structures between 2·25Cr–1Mo steel and Inconel 182 weld metal have been studied after post-weld heat treatments (PWHTs) at 700°C and subsequent aging at 630°C. This aging temperature accelerates the changes in interfacial structure that occur during power-station operation, and thus provides a method of studying the effects of the initial PWHT. The paper shows that during PWHT for ≤8 h at 700°C, arrays of carbide particles develop in the ferritic steel, parallel and very close to the weld metal interface, and that these arrays continue to grow during aging at 630°C for 6000 h. However, the precipitate sizes after PWHT are small compared with those developed during the subsequent aging. For longer heat treatments, up to 100 h at 700°C, the I interfacial precipitates develop to significant sizes, but growth then ceases because of the limited carbon migration from the 2·25Cr–1Mo steel. Aging at 630°C then causes carbon redistribution in the heat-affected zone, resulting in an incubation period before further interfacial precipitate growth can occur. The net result is that after aging for ≥500 h at 630°C, PWHTs of 2–100 h at 700°C have negligible effects on the interfacial-precipitate sizes and distributions, compared with those found in similarly aged as-welded specimens.

MST/119     

Comparison of creep behaviour of 2.25Cr–1Mo/9Cr–1Mo dissimilar weld joint with its base and weld metals

Abstract

Evaluation of the creep behaviour of 2.25Cr–1Mo and 9Cr–1Mo ferritic steel base metals, 9Cr–1Mo steel weld metal, and 2.25Cr–1Mo/9Cr–1Mo ferritic–ferritic dissimilar weld joints has been carried out at 823 K in the stress range 100–260 MPa. The weld joint was fabricated by shielded metal arc welding using basic coated 9Cr–1Mo electrodes. Investigations of the microstructure and hardness variations across the joint in the as welded, post-weld heat treated (973 K/1 h), and creep tested conditions were performed. The heat affected zone (HAZ) in both the steels consisted of a coarse prior austenitic grain region, a fine prior austenitic grain region, and an intercritical structure. In the post-weld heat treated condition, a white etched soft decarburised zone in 2.25Cr–1Mo steel base metal and a black etched hard carburised zone in 9Cr–1Mo steel weld metal around the weld fusion line developed. Hardness troughs also developed in the intercritical HAZ regions of both the steels. The width of the carburised and decarburised zones and hardness differences of these zones were found to increase with creep exposure. The 9Cr–1Mo steel weld metal showed higher creep strength compared to both the base metals. The 9Cr–1Mo steel base metal exhibited better creep resistance than the 2.25Cr–1Mo steel base metal at lower applied stresses. The dissimilar joint revealed lower creep rupture strength than both the base metals and weld metal. The creep strain was found to concentrate in the decarburised zone of 2.25Cr–1Mo steel and in the intercritical HAZ regions of both the steels. Creep failure in the stress range examined occurred in the intercritical HAZ of 2.25Cr–1Mo steel even though this region showed higher hardness than the decarburised zone. Extensive creep cavitation and cracks were observed in the decarburised zone.     

Experimental Study of the Creep Lifetime of the 1.25Cr 0.5Mo Steel Pipes

Abstract: In this paper, physical parameters for the creep constitutive equations of the low alloy ferritic steel 1.25Cr0.5Mo have been determined using experimental data. This alloy is used mostly in power generation and petrochemical industries because of its high temperature creep resistance. Test samples have been obtained from a new super‐heater pipe wall of a steam‐generating boiler in Tabriz Petrochemical Plant according to the ASTM standards. By conducting creep rupture tests for 1.25Cr0.5Mo steel, creep behaviour and creep‐rupture properties were examined for this material. Creep rupture tests have been carried out at four temperatures of 700, 725, 750 and 800 °C, under applied uni‐axial stresses of 30, 35, 40 and 50 MPa. The experimental data have been used to obtain the constitutive parameters using numerical optimisation techniques. Also the temperature and stress dependency of the creep lifetime for this alloy has been investigated using Larson–Miller and Monkman–Grant parameters. The results show good agreement with other test data such as ASTM and API. Finally, these constitutive equations have been used to study the creep behaviour of the super‐heater pipe. The results show that the super‐heater tube has been over designed in terms of the creep lifetime and this is in accordance with the in‐plant observations.     

Through-thickness creep damage in a service-exposed header of 2.25Cr1 Mo steel

A creep damage investigation was made on a service-exposed header of 2.25Cr 1Mo steel with a service time of 200 000 h. Weldments and the flanged parts at both outer and inner surfaces were studied as well as the damage in the through-thickness direction. Extensive cavitation was observed not only at the outer surface, but also well inside the component in the weldments. A model for the prediction of rupture position is introduced to explain the appearance of the observed creep damage.     

Precipitation in 9Cr–1Mo steel after creep deformation

The carbides present after creep testing a 9Cr–1Mo steel at 566 °C over a range of stress levels giving rupture times of up to 7300 h have been characterized and identified using a transmission electron microscopy, energy-dispersive X-ray spectroscopy and electron diffraction. The initial carbide precipitates present were M₇C_3, (NbV)C and VC and it was determined that M₆C carbide precipitates were present in all specimens after elevated temperature exposure for greater than approximately 1700 h. No precipitation of M₂₃C₆ was detected. The evolutionary sequence from the initially present carbides during high temperature exposure involved the formation of the stable M₆C carbide directly, without the intermediate formation of M₂₃C₆, as is reported to occur in other Cr–Mo steels.     

Weld repair of Grade 91 piping and components in power generation applications,creep performance of repair welds

Creep strength-enhanced ferritic steels, such as Grade 91, are the preferred material for much of the high-energy boiler tubing and piping components used in modern power generating plants. Weld repair techniques that achieve the necessary performance without the need for high-temperature post weld heat treatment (PWHT) offer particular benefits for Grade 91 steel. These benefits arise since there are many examples of poor heat treatment control which have resulted in component microstructures with below the minimum properties expected by design codes. Furthermore, even a controlled PWHT at temperatures at around 760 °C will further temper the base material. This is significant because excessive base metal tempering is one suggested criterion requiring component replacement. Successful demonstration of controlled welding techniques linked to minimal or no PWHT would alleviate these problems. This article presents results from a major project which is aimed at considering options for designing a ‘well-engineered’ repair. In this project, the creep performance of candidate repair methods was evaluated using large, feature test-type specimens containing the entire weldment including both fusion lines and heat-affected zones. The results show that the cross-weld life in Grade 91 steels does not appear to be a function of whether or not the welding procedures include PWHT. The results offer the potential to qualify ‘cold’ weld repairs in these steels.     

Creep rupture properties of nickel-base transition joints after long-term service

Abstract

Three superheater transition joints, between 2·25Cr–1 Mo and 316 stainless steel, welded with nickel–base weld metal, removed from service after 72337 h, have been examined using optical and scanning electron microscopy. In addition, microhardness measurements have been made and local chemical compositions have been analysed using the energy dispersive X-ray attachment on a scanning electron microscope. Temperature accelerated creep rupture tests have been carried out between 590 and 625°C at stresses of 31–62 MN m^?2 on cross–weld tensile specimens machined longitudinally from the walls of the joints. Detailed metallographic examinations showed the same failure mode as that found in long–term service failures. Therefore, the use of post-exposure temperature accelerated testing of uniaxial cross-weld specimens appears to be a viable method of assessing the remanent life of nickel-base transition joints operating at elevated temperatures. The applicability of various multiaxial stress rupture equations to transition joint failures is considered. The present rupture data are compared with previous data generated from initially as-welded specimens to provide upper and lower estimates of the long-term failure lives.

MST/403     

Cr-Mo耐热钢焊接接头蠕变过程中Mo_2C变化规律的研究

研究了 2 .2 5Cr- 1 Mo钢焊接接头蠕变时母材和焊缝中的 Mo2 C的变化规律。试验结果表明 ,在焊接接头中 Mo2 C呈针状、片状和碎屑状三种形貌 ,但主要以针状形态析出 ,当以片状或碎屑状析出时 ,会使材料的蠕变抗力降低。针状 Mo2 C在铁素体中比在贝氏体中尺寸粗大     

High temperature stability of 2.25Cr-1Mo steel during creep

The creep rapture behaviour of 2.25Cr—1Mo steel in air and in a salt mixture was studied. The salt coating, which can form a liquid phase at the test temperatures, increased the creep rate and reduced the rupture life of the material. The coating reduced the available cross-section of the material by removing the surface layers, thereby resulting in a reduction of the rupture life. Cross-sections of coated samples showed an outer oxide layer comprising oxide of the metal and precipitates of sulphide at the metal/oxide interface. This subsurface penetration of the corrodants was responsible for the early failure of the coated samples. This is typical of hot corrosion mechanisms. The formation of various carbides like M₂₃C₆ and M₆C, as observed by transmission electron microscopy, during creep reduced the creep strength of the material both in air and in the coated state. Increasing temperature enhanced the formation of these carbides with a consequent decrease in creep strength. Applied stress did not seem to play much of a role in the degree of carbide precipitation.     

Thermal aging of 16Cr – 5Ni – 1Mo stainless steel Part 2 – Mechanical property characterisation

Abstract

Mechanical property characterisation has been carried out on specimens of 16Cr - 5Ni - 1Mo stainless steel, subjected to various aging cycles. The heat treatment cycles involved solution treatment at 1050 ° C for 1 h followed by heating in the temperature range 400 - 750 ° C for different holding times (1 - 16 h). After heat treatment, tensile, hardness, impact, and creep tests were conducted. Specimens aged at 475 ° C exhibited maximum values of tensile strength and hardness with minimum values of ductility and impact toughness, while specimens aged at 625 ° C had maximum values of impact toughness and ductility. The results were correlated with the microstructural data presented in Part 1 of this study. Softening of the martensitic matrix at 625 ° C occurs as a result of the elimination of internal stresses, the decrease in the dislocation density, and the high volume fraction of austenite which lead to the drop in values of tensile strength and hardness. The results of the study reveal that aging at 550 ° C for 4 h gives the optimum combination of strength, hardness, ductility and toughness for this steel.     

Effect of post weld heat treatment on the microstructure and mechanical properties of ITER-grade 316LN austenitic stainless steel weldments

The effect of postweld heat treatment (PWHT) on the microstructure and mechanical properties of ITER-grade 316LN austenitic stainless steel joints with ER316LMn filler material was investigated. PWHT aging was performed for 1 h at four different temperatures of 600 °C, 760 °C, 870 °C and 920 °C, respectively. The microstructure revealed the sigma phase precipitation occurred in the weld metals heat-treated at the temperature of 870 °C and 920 °C. The PWHT temperatures have the less effect on the tensile strength, and the maximum tensile strength of the joints is about 630 MPa, reaching the 95% of the base metal, whereas the elongation is enhanced with the rise of PWHT temperatures. Meanwhile, the sigma phase precipitation in the weld metals reduces the impact toughness.     

Creep behaviour of parent,weld and HAZ materials of new,service-aged and repaired 1/2Cr1/2Mo1/4V: 2 1/4Cr1Mo pipe welds at 640°C

Abstract

The results of a series of creep tests on the materials of CrMoV weldments, in main steam pipes, are presented in this paper. The tests were performed at 640°C, using uniaxial, notched, impression and cross-weld creep test specimens. The materials involved include service-aged and ‘as-new’ 1/2Cr1/2Mo1/4V parent materials, service-aged and new 2 1/4Cr1Mo weld metals and the HAZ materials in the new, service-aged and fully repaired welds. Based on the test data obtained, material constants in creep continuum damage constitutive equations for the parent, weld and HAZ materials were determined. Direct comparison of the test data allows the creep deformation and rupture behaviour of the parent, weld and HAZ materials to be identified. The material properties of these CrMoV weldment materials can be used in numerical FE modelling to contribute to the understanding of the performance of the new, service-aged and repaired welds in similar materials.     

Determination of material constants in creep continuum damage constitutive equations

Experimental creep and creep rupture data are presented for copper at 150, 200 and 250°C and for 0.5Cr0.5Mo0.25V steel at 640°C. Creep continuum damage constitutive equations have been shown to be capable of accurately representing the creep behaviour of both materials. A six variable optimisation program, which was developed to efficiently obtain the material constants, is described.     

Remnant life assessment of service-exposed pendent superheater tubes

Remnant life assessment and life extension has become an integral part of plant maintenance activities, Cr–Mo steels are widely used in thermal power plants at a temperature of about 550°C. This paper deals with the high temperature tensile and creep rupture properties of 1Cr–0.5Mo steels for pendent superheater tubes in a boiler of a thermal power plant after five years service exposure for 43,000 h. Based on stress vs Larson Miller Parameter plot and at the operating hoop stress level, the pendent superheater tubes in general are found to be in a good state of health and can continue to remain in service for a length of 10 years, provided the temperature of the tube is brought down below 500°C. This observation may not be true for those selected tubes where already expansion in the diameter has taken place. Such tubes should be identified and replaced. In the case that it is not possible to bring down the temperature below 500°C, it may be desirable to use a superior grade of material like 2.25Cr–1Mo or 9Cr–1Mo steel. A thicker tube of the same grade may also be considered provided the overall load of the panel does not exceed the limit. It is, however, recommended that a similar health check be carried out after five years.     

Stress relief cracking in high strength structural steel BS 4360 grade 55F

Abstract

The stress relief cracking susceptibility of a commercial cast of BS 4360 55F, a high strength structural steel, has been investigated by short term creep rupture testing of crossweld specimens. The weld was made with a heat input of 1·75 kJ mm^?1, which is typical of that encountered during fabrication. The creep specimens fractured in the coarse grained heat affected zone with low deformation over a wide range of test conditions. In all instances failure was by intergranular cracking at prior austenite grain boundaries, generally by the formation of creep cavities. This indicates that the steel is susceptible to stress relief cracking for the high welding heat inputs used. Special precautions may be necessary when welding high strength steels of this type when postweld heat treatment is specified.

MST/745     

Mechanistic approach for prediction of creep deformation,damage and rupture life of different Cr–Mo ferritic steels

Abstract

A mechanistic approach based on finite element analysis of continuum damage as proposed by Kachanov has been used to assess and compare creep deformation, damage and rupture behaviour of 2·25Cr–1Mo, 9Cr–1Mo and modified 9Cr–1Mo ferritic steels. Creep tests were carried out on the steels at 873 K over a stress range of 90–230 MPa. Modified 9Cr–1Mo steel was found to have highest creep deformation and rupture strength whereas 2·25Cr–1Mo steel showed the lowest among the three ferritic steels. Creep damage in the steels has been manifested as the microstructural degradation. 2·25Cr–1Mo steel was more prone to creep damage than 9Cr–steels. Finite element estimation of creep deformation and rupture lives were found to be in good agreement with the experimental results.