Study on creep-fatigue life prediction methods for low-carbon nitrogen-controlled 316 stainless steel (316FR)

Low-carbon, nitrogen-controlled 316 stainless steel called 316FR was developed and is regarded as a principal candidate for a main structural material of liquid metal-cooled fast breeder reactor plants in Japan. To develop a creep-fatigue evaluation method suitable for this steel, a number of uniaxial creep-fatigue tests have been conducted for three products of this steel. Long-term data up to about 35,000 h were obtained and applicability of failure life prediction methods was studied based upon their results. Cruciform shaped specimens were also tested under biaxial loading conditions to examine the effect of stress multiaxiality on failure life under creep-fatigue condition.     

Effect of ratcheting deformation on fatigue and creep-fatigue life of 316FR stainless steel

Components of fast breeder reactor (FBR) plants will be subjected to large thermal load, and progressive deformation with loading cycles (ratcheting) and creep-fatigue damage should be considered in their design. To clarify the effect of ratcheting on fatigue and creep-fatigue life, a series of fatigue and creep-fatigue tests coupled with strain progress were carried out for 316FR stainless steel. It was found that tensile ratcheting decreases the failure life to a large extent at small strain range, while compressive ratcheting does not decrease the failure life. Measurement of striation intervals on fracture surface showed small influence of strain increment on the crack propagation rate, suggesting that the main cause of the life reduction is the decrease in the crack initiation life. It was also found that failure life in various conditions is correlated well with a product of strain range and tensile peak stress.     

Development of flaw evaluation guideline for FBR components

Central Research Institute of Electric Power Industry (CRIEPI) has been conducting a research project on the verification of evaluation method for structural integrity of high-temperature components of Fast Breeder Reactor (FBR) plants, in which applicability of inelastic fracture mechanics to austenitic stainless steels used in these components has been studied. A flaw evaluation guideline was generated based on the research results. The guideline provides evaluation procedures for creep-fatigue crack propagation, ductile fracture, and sodium leak rate together with related material properties. This paper presents the evaluation procedures recommended in the guideline.     

Study on creep-fatigue failure prediction methods for type 304 stainless steel

Creep-fatigue failure is one of the principal failure modes to be avoided in elevated-temperature components of liquid metal fast breeder reactor (LMFBR) plants. To prevent this failure during the plant life with sufficient confidence, accurate and reliable methods should be employed for evaluating creep-fatigue endurance. A number of creep-fatigue tests have been conduced to establish a reliable creep-fatigue design methodology applicable to LMFBR plants in the last two decades but the conditions of these tests are generally far from those expected in actual plants. For the purpose of studying the characteristics of various creep-fatigue life prediction methods in conditions closer to actual plant conditions, the authors initiated creep and creep-fatigue tests for type 304 austenitic stainless steel with a special emphasis on tests with longer durations than past tests. Interim results are summarized in this paper. Two representative life prediction methods, linear damage fraction rule and ductility exhaustion method, were then applied to these test conditions. It was found that both methods can predict the failure lives with reasonable accuracy. Some comparisons were made regarding the characteristics of these two methods.     

Sodium effects on mechanical performance and consideration in high temperature structural design for advanced reactors

Sodium environmental effects are key limiting factors in the high temperature structural design of advanced sodium-cooled reactors. A guideline is needed to incorporate environmental effects in the ASME design rules to improve the performance reliability over long operating times. This paper summarizes the influence of sodium exposure on mechanical performance of selected austenitic stainless and ferritic/martensitic steels. Focus is on Type 316SS and mod.9Cr-1Mo. The sodium effects were evaluated by comparing the mechanical properties data in air and sodium. Carburization and decarburization were found to be the key factors that determine the tensile and creep properties of the steels. A beneficial effect of sodium exposure on fatigue life was observed under fully reversed cyclic loading in both austenitic stainless steels and ferritic/martensitic steels. However, when hold time was applied during cyclic loading, the fatigue life was significantly reduced. Based on the mechanical performance of the steels in sodium, consideration of sodium effects in high temperature structural design of advanced fast reactors is discussed.     

Influence of dynamic sodium environment on the creep-fatigue behaviour of Modified 9Cr-1Mo ferritic-martensitic steel

The use of liquid sodium as a heat transfer medium for sodium-cooled fast reactors (SFRs) necessitates a clear understanding of the effects of dynamic sodium on low cycle fatigue (LCF), creep and creep-fatigue interaction (CFI) behaviour of reactor structural materials. Mod. 9Cr-1Mo ferritic steel is the material of current interest for the steam generator components of sodium cooled fast reactors. The steam generator has a design life of 30-40 years. The effects of dynamic sodium on the LCF and CFI behaviour of Mod. 9Cr-1Mo steel have been investigated at 823 and 873 K. The CFI life of the steel showed marginal increase under flowing sodium environment when compared to air environment. Hence, the design rules for creep-fatigue interaction based on air tests can be safely applied for components operating in sodium environment. This paper attempts to explain the observed LCF and CFI results based on the detailed metallography and fractography conducted on the failed samples.     

A review of creep-fatigue life prediction methods: identification and extrapolation to long term and low strain cyclic loading

Eight creep-fatigue interaction models are identified on a set of LCF experimental data.The material is 316 L type stainless steel, the temperature is 600°C. The general agreement between tests and predictions is good in the experimental range.Tentative extrapolations are made toward low strain and long dwell.Opposite trends are then pointed out on stress dependent and strain range dependent models.The final results are still encouraging and general rules are given concerning the long term life prediction.     

High temperature design curves for high nitrogen grades of 316LN stainless steel

Nitrogen alloyed low carbon grade 316L(N) stainless steel (SS) is a major structural material for high temperature structural components of sodium cooled fast reactors. With a view to significantly enhance the high temperature mechanical properties of 316L(N) SS and thereby increase the design life of structural components from 40 years to 60 years, the influence of nitrogen content on the tensile and creep properties of this steel has been investigated. Four heats of 316LN SS with 0.07, 0.11, 0.14, and 0.22 wt.% nitrogen were used in this investigation. Tensile tests were carried out at various temperatures between room temperature and 850 °C. Creep tests were carried out at 650 °C at various stress levels in the range of 140-225 MPa. The maximum rupture life in these tests was 16,000 h. The tensile and creep data were analysed according to RCC-MR nuclear code procedures and the design curves have been generated. The tensile and creep strength of 316L(N) SS have been found to improve significantly by increasing the nitrogen content.     

Creep-fatigue interaction: data base analysis and applications

Creep-fatigue tests were conducted with a Type 304 stainless steel at 650°C using a wide variety of strain wave forms. Wave shape and hold-time effects were of special interest.Two distinct approaches were developed for analyzing the above test results in 10⁻⁹ mbar vacuum. Both approaches are based on a concept of “pure” creep-fatigue interaction.Data obtained in various environments such as air, 10⁻⁶ mbar vacuum and sodium are also listed. Creep-fatigue behavior in different environments are compared and the role of environmental effect is qualitatively discussed.     

A comparison between Japanese and French A16 defect assessment procedures for creep-fatigue crack growth

This paper presents the results of a benchmark on creep-fatigue crack growth evaluation for a plate subjected to cyclic bending loads with a 1 h dwell. The simplified creep-fatigue crack growth evaluation methods of JNC in Japan and A16 procedures proposed by CEA in France are presented. The methods, based on the reference stress approach, are compared each other. They are found to differ in the expression used for the reference stress solution used to estimate the creep strain. It is also pointed out that in contrast to the A16 procedures, the JNC method takes heterogeneous creep strain distribution into account for small scale yielding condition. The predictions obtained by the methods are also compared to the experimental data. It is found that the methods exhibit conservatisms which are significantly reduced when integrating the creep curve continuously without initialisation during the experiment [Proceeding of SMiRT 14(G13/2), Creep-Fatigue Crack Growth on CT25 Specimens in 316L(N) stainless steel at 650 °C].     

应变幅对国产锻造奥氏体不锈钢环境疲劳寿命影响的试验研究

为验证模拟压水堆核电站冷却剂服役环境对国产锻造主管道用奥氏体不锈钢疲劳寿命的影响,采用高温高压循环水疲劳测试系统对从产品锻件取样加工后的标准试样进行了低周疲劳试验,分析了试验数据与美国机械工程师学会(American Society of Mechanical Engineers,ASME)规范平均/设计疲劳曲线的关系,获得了应变幅对奥氏体不锈钢环境疲劳寿命的影响规律,并初步评价了ASME规范设计疲劳曲线和环境疲劳修正系数的适合性。     

An experimental validation of the guideline for inelastic design analysis through structural model tests

In this paper, the inelastic analysis procedures recommended to use in the advanced elevated temperature structural design guide under development in Japan for the improved design of future fast breeder reactors were validated through the structural model tests and the evaluation of the experimental results by the inelastic analyses. First, a thermal fatigue test of a 316FR hollow cylinder with two longitudinal weldments was conducted under the condition of combined constant axial load and cyclic movement of axial temperature distribution, which simulated the loading condition near the free surface of coolant sodium in the main vessel of fast breeder reactors (FBRs). In the experiments, longitudinal and radial ratcheting deformation were measured and crack initiation life was also examined. Second, the inelastic analyses were carried out in accordance with the recommended procedure by using the measured results of oscillating temperature distribution. Finally, the results of inelastic analyses were compared with the experimental results and it was validated that the recommended practice gave a conservative result for the deformation and a good estimation of strain range for the fatigue life evaluation.     

Balancing material selection and inspection requirements in structural design of fast breeder reactors based on “System Based Code” concept

The System Based Code concept proposed by Asada et al. [Asada, Y., Tashimo, M., Ueta, M., 2002a. System Based Code—Principal Concept. Proc. ICONE10, 22730; Asada, Y., Tashimo, M., Ueta, M., 2002b. System Based Code—Basic Structure. Proc. ICONE10, 22731] intends to realize margin exchange, in order to optimize design. This paper presents preliminary calculation of margin exchange between material strength and the accuracy and frequency of inservice inspection (ISI), taking a reactor vessel of a fast breeder reactor, of which dominant failure mode is creep-fatigue, as an example. The original design is a structure of forged rings of 316FR, material with superior creep strength. Alternative designs use either Type 304 stainless steel or welded structure of 316FR plates, leading to increased failure probability compared to the original design. The accuracy and frequency necessary to compensate this increase of failure probability was estimated. Results envisioned margin exchange between material strength and ISI under practical conditions. Sophistication of the procedure to calculate failure probability will ensure the application of the concept of margin exchange to practical design.     

Long-term creep rupture behavior of smoothed and notched bar specimens of low-carbon nitrogen-controlled 316 stainless steel (316FR) and their evaluation

Low-carbon, nitrogen-controlled 316 stainless steel is regarded as a principal candidate for a main structural material of future fast breeder reactor plants in Japan. To grasp creep deformation and rupture behavior of this steel whose modeling is indispensable in the design of high-temperature components, a number of uniaxial tensile creep tests have been conducted for four products of this steel at 550 °C and higher temperatures. Long-term creep rupture data up to about 94,000 h were obtained and used to examine the applicability of rupture and deformation estimation methods developed earlier. In addition, two tests were conducted using round-bar specimens with circumferential notches to make investigation of the effect of stress multiaxiality on creep damage.     

Effect of nonproportional loading on creep-fatigue properties of 304 stainless steel at low strain ranges near the elastic region

The effect of nonproportional strain path on fatigue/creep-fatigue properties was investigated with 304 stainless steel at 550°C under strain controlled biaxial conditions. The fatigue/creep-fatigue life reduction due to nonproportional strain path occurred even at the lowest strain range investigated, that is, 0.2% for fatigue loading and 0.3% for creep-fatigue loading. The Mises-type path-dependent equivalent strain range was employed in order to evaluate the fatigue/creep-fatigue strength under nonproportional loading conditions. Stress relaxation behavior under nonproportional loading was examined. It was shown that stress relaxes proportionally toward the origin of stress plane even under nonproportional loading. Fatigue damage and creep damage were calculated based on the linear damage summation rule. Life prediction was shown to be possible within an accuracy of a factor of about 2 for nonproportional loading along with other waveforms including pure axial loading, pure torsional loading and combined proportional loading.     

Thermal striping limits for components of sodium cooled fast spectrum reactors

With the objective of establishing thermal striping limits for future sodium cooled fast spectrum reactors (SFR), a fracture mechanics-based method employing ‘σ-d approach’ recommended in RCC-MR: Appendix A16 has been followed. Towards this, an idealized geometry, thermal fluctuations in the form of constant power spectral density and pessimistic material data were considered and temperature and thermal stresses are computed taking in to account frequency-dependent thermal attenuation on the structural wall. The effect of attenuation is found to be significant. The limits are derived at various potential locations in SFRs, which are also subjected to creep-fatigue damage due to major cycles caused by startup, shutdown, power failures and pump trips, etc. The maximum range of temperature fluctuations can be as high as 70 K where there is practically no accumulated creep-fatigue damage and 45 K is acceptable where the creep-fatigue is significant (0.9). These limits are found to be consistent with the broad limits extrapolated from the failure experiences of international SFRs and sodium facilities. Pool hydraulic computations carried out to identify and quantify the thermal striping zones confirmed that the proposed limits can be respected with good margins for SFRs.     

Main R&D issues for fast reactor structural design standard

For realization of economical and reliable fast reactor (FR) plants, the Japan Atomic Energy Agency (JAEA) and the Japan Atomic Power Company (JAPC) are cooperating on the “Feasibility Study on Commercialized FR Cycle Systems”. To certify the design concepts through evaluation of the structural integrity of FR plants, the research and development of the “Elevated Temperature Structural Design Guide for Commercialized Fast Reactor (FDS)” is recognized as an essential theme. The FDS focuses on particular failure modes of FRs such as ratchet deformation and creep-fatigue damage due to cyclic thermal loads. For precise evaluation of these modes, the research and development for three main issues is in progress. First, the “Refinement of Failure Criteria” needs to be addressed for particular failure modes of FRs. Secondly, the development of “Guidelines for Inelastic Design Analysis” is conducted to predict elastic plastic and creep deformation under elevated temperature conditions. Lastly, efforts are being made toward preparing “Guidelines for Thermal Load Modeling” for the design of FR components where thermal loads are dominant.     

Comparison of crack initiation life estimation procedures under creep-fatigue conditions

This paper describes the application of “high temperature structural integrity assessment procedures” developed in the UK and Japan to creep-fatigue crack initiation in welded Type 316 features tests. The components were subjected to both fatigue and creep-fatigue loading at 630 °C. The loadings are representative of those on the upper seal gimbal joint in an advanced gas cooled reactor (AGR), except that the tests were isothermal and the imposed dwell times were reduced. It is demonstrated that application of the procedures gives accurate predictions of the observed crack initiation in the weldment, based on two different advanced inelastic constitutive models (BE and CRIEPI models) and best estimate materials data. Application of simplified assessment methods based on elastic analysis is shown to be conservative. Where appropriate, contrasts between the UK and the Japanese assessment procedures and inelastic modelling techniques have been highlighted.     

Development of inelastic constitutive model for austenitic stainless steel for design use

To prevent creep-fatigue failure or excessive deformation in high-temperature components of fast reactor plants, accurate estimation of inelastic deformation is essential. In performing inelastic analysis, employment of constitutive models, which can precisely reproduce inelastic deformation of the material is of critical importance. The authors have been engaged in the development of inelastic constitutive model for the use in structural design assessment of liquid metal-cooled fast reactor plants. Various improvements were made on the nonlinear hardening model proposed by Ohno and Wang, placing an emphasis on capability to simulate inelastic deformation behavior of austenitic stainless steels, under regular or irregular cyclic loading possibly with temperature variation and hold time. It was demonstrated that the model can simulate the inelastic deformation behavior under various loading conditions with a sufficient accuracy.     

Creep-fatigue evaluation of normalized and tempered modified 9Cr---1Mo

Creep-fatigue is a fatal failure mode of the high temperature structural materials of liquid metal fast breeder reactors (LMFBRs). In this report, two important issues are discussed for creep-fatigue evaluation of normalized and tempered modified 9Cr---1Mo (modified 9Cr---1Mo(NT)) steel which is a promising structural material for the steam generator of large-scale LMFBRs in Japan. Several evaluation methods based on the ductility exhaustion concept are discussed for the prediction of tension strain hold creep-fatigue damage of this material. A time-fraction type of linear damage summation concept based on a new ductility exhaustion theory is proposed from the point of view of its appropriate conservatism for time extrapolation and its simplicity.Also, a life reduction mechanism of low cycle fatigue with strain hold at the compression side is discussed, based on the data observed by a scanning type electron microscope. Creep damage or the tension mean stress caused by compression strain hold hardly reduce the low cycle fatigue life of this material. A new concept based on the location of oxidation on the test specimen surface can explain the reduction in low cycle fatigue life of modified 9Cr-1Mo(NT) steel.