Effect of thermal aging on fracture toughness of RPV steel

The effect of thermal aging on mechanical properties and fracture toughness was investigated on pressure vessel steel of light water reactors. Submerged are welded plates of ASME SA508 C1.3 steel were isothermally aged at 350°C, 400°C and 450°C for up to 10,000 hrs. Tensile, Charpy impact and fracture toughness testings were conducted on the base metal and the weld heat affected zone (HAZ) material to evaluate whether thermal aging induced by the plant operation is critical for the integrity of the pressure vessel or not. Tensile properties of the base metal was not changed by thermal aging as far as the thermal aging conditions were concerned. Relatively distinct degradation was observed in fracture toughness J_IC and J-resistance properties of both the base metal and the weld HAZ material, while only slight changes were observed in Charpy impact properties for both of them. However, it was concluded that the effect of thermal aging estimated by 40–80 years of plant operation on fracture toughness of both materials is small.     

Investigation of the ductile fracture properties of type 304 stainless steel plate, welds, and 4-inch pipe

J-integral fracture toughness tests were performed on welded 304 stainless steel 2-inch plate and 4-inch diameter pipe. The 2-inch plate was welded using a hot-wire automatic gas tungsten arc process. This weldment was machined into 1T and 2T compact specimens for single specimen unloading compliance J-integral tests. The specimens were cut to measure the fracure toughness of the base metal, weld metal and the heat affected zone (HAZ). The tests were performed at 550°F, 300°F and room temperature. The results of the J-integral tests indicate that the J_Ic of the base plate ranged from 4400 to 6100 in lbs/in² at 550°F. The J_Ic values for the tests performed at 300°F and room temperature were beyond the measurement capacity of the specimens and appear to indicate that J_Ic was greater than 8000 in lb/in². The J-integral tests performed on the weld metal specimens indicate that the J_Ic values ranged from 930 to 2150 in lbs/in² at 550°F. The J_Ic values of the weld metal specimens tested at 300°F and room temperature were 2300 and 3000 in lbs/in² respectively. One HAZ specimen was tested at 550°F and found to have a J_Ic value of 2980 in lbs/in² which indicates that the HAZ is an average of the base metal and weld metal thoughness. These test results indicate that there is a significant reduction in the initiation fracture toughness as a result of welding.The second phase of this task dealt with the fracture toughness testing of 4-inch diameter 304 stainless steel pipes containing a gas tungsten arc weld. The pipes were tested at 550°F in four point bending. Three tests were performed, two with a through wall flaw growing circumferentially and the third pipe had a part through radial flaw in combination with the circumferential flaw. These tests were performed using unloading compliance and d.c. potential drop crack length estimate methods. The results of these test indicate that the presence of a complex crack (radial and circumferential) reduces in the initiation toughness and the tearing modulus of the pipe material compared to a pipe with only a circumferentially growing crack.     

Observations on the effect of post-weld heat treatment on J-resistance curves of sa-106b seamless piping welds

Ontario Hydro has developed a leak-before-break (LBB) methodology for application to large diameter piping (21, 22 and 24 inch) Schedule 100 SA106B heat transport (HT) piping as a design alternative to pipe whip restraints and in recognition of the questionable benefits of providing such devices. Ontario Hydro's LBB approach uses elastic-plastic fracture mechanics (EPFM).In order to assess the stability of HT piping in the presence of hypothetical flaws, the value of the material J-integral associated with crack extension (J— R curve) must be known. In a material test program J-resistance curves were determined from various pipe heats and four different welding procedures that were developed by Ontario Hydro for nuclear Class 1 piping. The test program was designed to investigate and quantify the effect of various factors such as test temperature, crack plane orientation and welding effects which have an influence on fracture properties. An acceptable lower bound J-resistance curve for the piping steels and welds were obtained by machining maximum thickness specimens from the pipes and weldments and by testing side-grooved compact tension specimens. This paper addresses the effect of test temperature and post-weld heat treatment on the J-resistance curves from the welds.The fracture toughness of all the welds at 250°C was lower than that at 20°C. Welds that were post-weld heat treated showed high crack initiation toughness, J_lc, rising J-resistance curves and stable and ductible crack extension. Non post-weld heat treated welds, while remaining tough and ductile, showed comparatively lower J_Ic, and J-resistance curves at 250°C. This drop in toughness is possibly due to a dynamic strain aging mechanism evidenced by serrated load-displacement curves. The fracture toughness of non post-weld heat treated welds increased significantly after a comparable post-weld heat treatment.The test procedure was validated by comparing three test results against independent tests conducted by Materials Engineering Associates (MEA) of Lanham, Maryland. The J_Ic and J-resistance curves obtained by Ontario Hydro and MEA were comparable.     

Compatibility of CLAM steel weldments with static LiPb alloy at 550 °C

CLAM steel is considered as a structural material to be used in the Test Blanket Module as a barrier or blanket adjacent to liquid LiPb in fusion reactors. In this paper, CLAM steel is welded by tungsten inert gas (TIG) welding, and the compatibility of the weldment with liquid LiPb is tested. Specimens were corroded in static liquid LiPb, with corrosion times of 500 h and 1000 h, at 550 °C, and the corresponding weight losses are 0.272 mg/cm² and 0.403 mg/cm² respectively. Also the corrosion rate decreases with increased corrosion time. In the as-welded condition, corrosion resistance of the weld zone is higher than that of the HAZ (Heat Affected Zone). Likely, thick martensite lath and large residual stresses at the welding zone result in higher corrosion rates. The compatibility of CLAM steel weld joints with high temperature liquid LiPb can be improved to some extent through a post-weld tempering process. The surface of the as-welded CLAM steel is uniformly corroded and the concentration of Cr on the surface decreases by about 50% after corrosion. Penetration of LiPb into the matrix is observed for neither the as-welded nor the as-tempered conditions. Influenced by thick martensite lath and large residual stresses, the welded area, especially the weld zone, is easily corroded, therefore it is of primary importance to protect the welded area in the solid blanket of the fusion reactor.     

An overview of the welding technologies of CLAM steels for fusion application

China Low Activation Martensitic steel (CLAMs), a kind of RAFM steel with Chinese intellectual property rights, is considered as the primary structural material for the China-designed ITER test blanket module (TBM). As one of the key issues in the fabrication of the fusion reactor, the welding technologies of CLAMs are reviewed. Emphasis is placed on the weldability of CLAMs by different welding methods, and on the properties of as-welded and post-weld heat-treated joints. Recent highlights in research and development for the welding of CLAMs show that proper welding procedure could provide welds with adequate tensile strength but the welds exhibit lower impact toughness compared with the base metal. Post-weld heat treatment (PWHT) and the application of ultrasonic energy during TIG welding could dramatically improve impact toughness. Research also shows that welds in CLAMs have sufficient resistance to swelling under irradiation as well as suitable compatibility with liquid LiPb. The microstructure, mechanical and other physical properties of welds are significantly different from those of the base metal due to the complicated welding thermal cycle. The weld joint is the area most likely to fail one or more of the design requirements within the fusion reactor. Therefore significant additional research is necessary to ensure safe application of welded CLAM steel for fusion reactor construction.     

Creep rupture strength of heat affected zone for 9Cr ferritic heat resisting steels

This paper describes creep rupture characteristics of weld heat affected zone, HAZ for 9Cr ferritic steels that are promising materials for nuclear energy uses. In general, creep rupture strength in the heat affected zone of peak temperature between 900 and 1000°C is lower than that in the base metal for ferritic steels. Grain refinement and coagulation of carbides for 9Cr–1Mo steels cause decrease in creep rupture strength of the HAZ. The hardness in the simulated HAZ heated to around 1000°C decreases during creep. This seems to be related to weakening of the HAZ at 1000°C. However, substitution of W for Mo is very effective in enhancement of creep rupture strength of the HAZ due to higher stability of carbides and increase in quantity of precipitated carbides during creep rupture test.     

Toughness investigation on simulated weld HAZs of SQV-2A pressure vessel steel

In order to get detailed information about weld HAZs toughness of SQV-2A steel and determine the optimum welding and heat treatment parameters, the toughness of simulated CGHAZs (coarse grained heat affected zone) and CGHAZs (intercritically reheated CGHAZ) were systematically investigated. The influence of tempering thermal cycles on weld ICCGHAZs toughness was clarified. The effect of post weld heat treatments (PWHT) on weld CGHAZs toughness was also determined. The results showed that high toughness (absorbed energy >200 J) of weld HAZs could be achieved by selecting the optimum welding and PWHT parameters (cooling time Δt_8/5: 6–40 s, PWHT: 893 K, 3.6–7.2 ks). Tempering thermal cycles with peak temperature of above 573 K could remarkably improve the toughness of deteriorated ICCGHAZs and reduce the hardness, when cooling time Δt_8/5(2) of the reheating thermal cycle was 6 s, which implies that welding of SQV-2A without PWHT is possible, provided that low heat input welding is adopted and welding procedure is correctly arranged. Metallography and fractography revealed that M–A constituents in weld HAZs played an important role in controlling weld HAZ toughness.     

Properties of heavy components of steel grade 91 and their welds

The use of the modified 9% Cr1% Mo steel grade (grade 91) for the manufacturing of heavy products (forgings, plates) for pressure vessels is evaluated on the following aspects: (i) possibility to produce heavy components (base material) with the required properties, (ii) conditions for welding without cracking, and (iii) availability of welding products and determination of their mechanical properties. Heavy plates with thickness ranging from 20 to 300 mm have been manufactured and tested. All mechanical properties (tensile, Charpy V notch impact, creep…) have been obtained in conformity with the requirements of ASTM specifications and literature data on thinner materials. Some laboratory tests have been carried out to determine the sensitivity of this material to cracking phenomena during welding (cold cracking) or during the postweld heat treatment (reheat cracking). They show that this material does not present major welding difficulties in comparison with more conventional materials used for the manufacture of pressure vessels. To obtain high toughness properties of the weld metal and low residual stresses, the postweld heat treatment temperature was found to be high (750 to 770°C). A significant modification of the weld metal deposit chemistry was found to be necessary to achieve the convenient level of impact properties, but correlatively, a decrease of its creep resistance may be expected for this very low Nb weld material.     

Effect of aging at 700 °C on precipitation and toughness of AISI 321 and AISI 347 austenitic stainless steel welds

A detailed knowledge of changes in microstructures and mechanical behaviour that occur in austenitic stainless steels with or without Nb/Ti-stabilized weld during heat treatment is of great interest, since the ductility and toughness of the material may change drastically after long aging times. Two kinds of materials, i.e. AISI 321 base and without Ti-stabilized weld steel and AISI 347 base with Nb-stabilized weld steel, were compared during aging at 700 °C up to 6000 h. Both materials present increased amount of precipitate and decreased impact energy as the aging time increases. The decreased extent of impact energy with aging is almost the same for both base materials. However, it presents differences for 347 and 321 weld samples. The latter shows a more drastic decrease of impact energy than the former due to the different amount of precipitates. 321 weld sample precipitates more numerously than 347 weld sample due to the absence of stabilized Ti/Nb on the former. Large amount of carbides is formed on 321 weld sample immediately after welding. The carbides are transformed to sigma phase, which is mainly responsible for the much more sigma phase precipitation compared with other samples, after high-temperature aging. The fractographs showed, in general, brittle fracture mode in 321 weld impact-fractured specimens after aging at 700 °C for 6000 h. However, other samples show ductile fracture mode in general. Several approaches should be employed to control sigma phase precipitation in weld material. These approaches include: decreasing content of ferrite and M₂₃C₆ carbide in weld and selecting Nb added weld wire during welding.     

Definition of a ‘materials’ database for heavy structures by experimental characterization of toughness-impact strength

With the prospect of a rapid and well-adapted application of the existing methods of predicting the fracture behaviour of welded assemblies in the presence of a defect, this study aims at gathering experimental data on the toughness of butt welded assemblies used in heavy sructures. This analysis of the toughness properties shows that the weld, and hence the various zones which compose it, have mechanical properties which are at least equal to those of the base metal. Although the E355 base metal contained niobium, the weld itself did not constitute a brittle zone in the welded assembly. Furthermore, the thickness of the welded plates seemed to have an effect on the mechanical behaviour of the HAZ only. For a thickness of 30 mm, this zone exhibits by far the highest toughness in the case of butt welded assemblies. Lastly, it is difficult to assess the beneficial or detrimental effect of the heat treatment applied for relieving the internal stresses because the metallurgical evolution in the weld, which takes place during the thermal cycle, sometimes embrittles or improves the toughness of the welded assembly. The application of the six models for predicting toughness as a function of temperature from the impact values of the base metal has shown that these correlations have a conservative range of validity. Outside the temperature-related range of validity, it was observed that Model (Rolf–Novak–Barsom), defined for the ‘end of ductile transition’ upper part was the most representative for predicting the toughness of the base metal as a function of temperature.     

European experiences of the proposed ASTM test method for crack arrest toughness of ferritic materials

The proposed ASTM test method for measuring the crack arrest toughness of ferritic materials using wedge-loaded, side-grooved, compact specimens was applied to three steels: A514 bridge steel tested at −30°C (CV30–50°C), A588 bridge steel tested at −30°C (CV30–65°C), and A533B pressure vessel steel tested at +10°C (CV30-12°C) and +24°C (CV30+2°C). Five sets of results from different laboratories are discussed here; in four cases FOX DUR 500 electrodes were used for notch preparation, in the remaining case HARDEX-N electrodes were used. In all cases, notches were prepared by spark erosion, although root radii varied from 0.1–1.5 mm. Although fast fractures were successfully initiated, arrest did not occur in a significant number of cases.The results showed no obvious dependence of crack arrest toughness, K_a, (determined by a static analysis) on crack initiation toughness, K₀. It was found that K_a decreases markedly with increasing crack jump distance, Δα/W. A limited amount of further work on smaller specimens of the A533B steel showed that lower K_a values tended to be recorded.It is concluded that a number of points relating to the proposed test method and notch preparation are worthy of further consideration. It is pointed out that the proposed validity criteria may screen out lower bound data. Nevertheless, for present practical purposes, K_a values may be regarded as useful in providing an estimate of arrest toughness — although not necessarily a conservative estimate.     

Analysis of the deformation and damage development of a dissimilar weld operating in the creep regime

The analysis of the deformation and damage behaviour of stress rupture tests with specimens out of the dissimilar metal weld seam 12% Cr-steel welded with a nickel base electrode for alloy 800 exhibits two competing processes:

• - Crack initiation occurs along the melting line due to high thermal stresses;

• - Creep deformation and damage concentrates in a heat affected zone of the ferritic 12% Cr steel due to long term stresses. The velocity of stress relaxation determines the resulting damage mechanism. At high temperatures with predominant creep deformation the cracks initiated in the melting line arrest and the creep deformation is concentrated in the heat affected zone (HAZ). At lower temperature the fracture area along the melting line increases. Long term tests at 535°C lead to lower stress rupture values compared to the scatterband of X 20 CrMoV 12 1 due to the reduced cross section after crack initiation in the melting line.

The analysis of stress rupture tests leads to the conclusion that grinding of melting line cracks is a reasonable measure because of sufficient stress relaxation.     

The Laser Welding with Hot Wire of 316LN Thick Plate Applied on ITER Correction Coil Case

ITER correction coil (CC) cases have characteristics of small cross section, large dimensions, and complex structure. The cases are made of heavy thick (20 mm), high strength and high toughness austenitic stainless steel 316LN. The multi-pass laser welding with hot wire technology is used for the case closure welding, due to its low heat input and deformation. In order to evaluate the reliability of this welding technology, 20 mm welding samples with the same groove structure and welding depth as the cases were welded. High purity argon was used as the shielding gas to prevent oxidation because of the narrowness and depth of the weld. In this paper investigation of, microstructure characteristics and mechanical properties of welded joints using optimized welding parameters are presented. The results show that the base metal, fusion metal, and heat affected zone (HAZ) are all have fully austenitic microstructure, and that the grain size of fusion metal was finer than that of the base metal. The welding resulted in an increase of hardness in the fusion metal and HAZ. It was confirmed that the tensile strength of fusion metal was higher than that of base metal and the impact toughness value is higher than industry standard requirement. Thus, this welding process was determined to be reliable for manufacture of the ITER CC cases manufacture.     

Studies on A-TIG welding of Low Activation Ferritic/Martensitic (LAFM) steel

Low Activation Ferritic–Martensitic steels (LAFM) are chosen as the candidate material for structural components in fusion reactors. The structural components are generally fabricated by welding processes. Activated Tungsten Inert Gas (A-TIG) welding is an emerging process for welding of thicker components. In the present work, attempt was made to develop A-TIG welding technology for LAFM steel plates of 10 mm thick. Activated flux was developed for LAFM steel by carrying out various bead-on-plate TIG welds without flux and with flux. The optimum flux was identified as one which gave maximum depth of penetration at minimum heat input values. With the optimized flux composition, LAFM steel plate of 10 mm thickness was welded in square butt weld joint configuration using double side welding technique. Optical and Scanning Electron Microscopy was used for characterizing the microstructures. Microhardness measurements were made across the weld cross section for as welded and post weld heat treated samples. Tensile and impact toughness properties were determined. The mechanical properties values obtained in A-TIG weld joint were comparable to that obtained in weld joints of LAFM steel made by Electron beam welding process.     

Microstructure of the NPP Kozloduy Unit 1 Weld 4 Metal

The microstructure of the base metal (BM), heat affected zone (HAZ) and the weld metal (WM) of NPP Kozloduy Unit1 Weld 4 after re-irradiation was investigated by scanning and transmission electron microscopy. Structure of tempered upper bainite (enlarged in the HAZ zone) was found in the BM and HAZ. The WM showed a typical fan-like radial structure with a central zone containing fine equiaxial ferrite grains divided by ferrite bands. The structure changed to fully equiaxial at the periphery towards HAZ. Fine elongated particles (up to 50 nm) were distributed irregularly along the grain boundaries in the WM. Regularly distributed structural inhomogeneities (dots) were observed in the grain volume both in WM (with diameter up to 15 nm) and in BM (with diameter up to 50 nm). An annealing experiment was undertaken in order to prove the character of the dots. The 2 h annealing of the thin foils at 560°C showed that the dots of larger size were precipitations, but the character of the smallest ones could not be determined unambiguously. The impact fracture in vacuum of a 1 mm² specimen at −120°C developed mainly by transcrystal cleavage and quasi-cleavage.     

The behaviour of WB 35 piping material under dynamic loading in the high speed tensile test

For the determination of the strength-, deformation- and fracture behaviour of the material 17 MnMoV 6 4 (WB 35) which is used for piping components, tensile tests were carried out at different loading rates (monotonic and impact-type) on smooth and notched pipe strip specimens over a temperature range extending from − 30°C to 250°C.For the conduct of the tests a hydraulic high speed tensile machine having a free motion device was used; the velocity of impact was preset at ca. 7 m/s.With impact-type (dynamically) loaded specimens in general higher strength and deformation values were obtained than with monotonic (statically) loaded ones. In all of the specimens having low deformation values which were investigated microfractographically, ductile portions were found adjacent to the notch on the fracture surface.     

Welding consumables for nuclear power plants

In nuclear power plants, submerged arc welding and covered arc welding have long been employed especially for main weld seams, including the core region of RPV.This paper investigates the mechanical properties of several welding consumables we have developed for industrial plants — that is, welding consumables which lower the phosphorus and copper content of the welded metal, those for plates possessing particularly high tensile strength and those for the narrow gap welding method.Recent data derived from irradiation embrittlement tests show that these welded metals using a non-copper coating are highly effective in minimizing shifts in the transition curve.Welding consumables for A533B C1.2, A543 C1.1 or A508 C1.4 steels have a higher tensile strength than those for A533B C1.1 or A508 C1.3.We have developed submerged arc and covered arc welding consumables to be used with these kinds of steels, and it was confirmed that these consumables possess excellent tensile strength and notch toughness.Our tests also confirmed that the narrow gap SAW and MIG welds are more efficient than the conventional ones. Moreover, the mechanical properties of the welded metals are also excellent.     

焊后热处理对SA517 Gr.F焊接接头力学性能与组织的影响

为更好地掌握焊后热处理（PWHT）对SA517 Gr.F调质钢焊接接头性能的影响,对SA517 Gr.F调质钢手工电弧焊（SMAW）焊接接头进行了焊态（AW）与PWHT试样力学性能和组织分布特征的对比分析研究。分析结果表明:PWHT与AW相比,焊接接头室温拉伸和360℃高温拉伸的抗拉强度均有所下降;焊缝和热影响区（HAZ）峰值硬度降低。PWHT降低了焊接接头的残余应力,但未能改善焊缝和HAZ的冲击性能。建议对于SA517 Gr.F调质钢若满足ASME规范案例N-71-18条件,可免除焊后热处理。      

Microstructure alterations in the base material, heat affected zone and weld metal of a 440-VVER-reactor pressure vessel caused by high fluence irradiation during long term operation; material: 15 Ch2MFA ≈0.15 C–2.5 Cr–0.7 Mo–0.3 V

Within the scope of the EC research project Tacis ’91 (‘RPV-Embrittlement’), trepans were taken from the highly irradiated circumferential RPV-weld of the Novovoronesh power plant unit-2 of the type VVER-440/230. The cumulated fast fluence level in this position reaches up to 6.5×10¹⁹/cm² (E>0.5 MeV). In a joint research work, the mechanical properties, the chemical composition, and the microstructure of the base material, the heat affected zone (HAZ), and the weld metal have been investigated in order to study the influence of irradiation, and of post irradiation heat treatment (475°C, 560°C) on the properties. The examination of the microstructure performed by analytical transmission electron microscopy (200 kV) shows the existence of dislocation loops (‘black dots’), irradiation induced precipitates, and segregation of copper in the carbides. These changes in microstructure, which are due to service affection (neutron irradiation, temperature) have occurred more pronounced in the weld metal and the HAZ than in the base material.     

焊后热处理对SA517 Gr.F焊接接头力学性能与组织的影响

In order to better understand the effect of PWHT (post weld heat treatment) on SA517 Gr.F quenched and tempered steel welded joint, the mechanical properties and microstructure distribution characteristics of SA517 Gr.F welded joint by SMAW (shielding metal arc welding) before and after PWHT were compared and analyzed. The analysis results show that, compared with that of as-weld welded joint, both the room temperature and 360℃ high temperature tensile properties of the welded joint decrease, and the peak micro-hardness of weld metal and HAZ also decrease after PWHT. The residual stress of the welded joint is decreased by PWHT, however, the impact properties of the weld and HAZ are not improved. It is suggested that PWHT can be exempted for SA517 Gr.F quenched and tempered steel if the requirements of ASME Code Case N-71-18 can be satisfied.