Creep Resistance Research Articles

Research of creep parameters of VVER reactor steel 15Kh2NMFA-A AT temperatures of 500 – 1200°C

The paper is devoted to the study of the creep characteristics of 15Kh2NMFA-A vessel steel in the temperature range of 500 – 1200 °C, which can be achieved during emergency operating conditions of VVER-type nuclear reactors. An analysis of the creep curves of the 15Kh2NMFA-A steel in the studied temperature range obtained during specimens tensile tests was carried out with the construction of the parametric Larson – Miller relationship. It is shown that in the temperature range of 600 – 850 °C the generalized Larson – Miller temperature dependence has a changed slope, resulting in a high error in estimating the time to fracture of 15Kh2NMFA-A steel under creep conditions in this temperature range. To reveal the reasons for the change in creep resistance in the specified temperature range, the studies of the metal microstructure using optical and scanning electron microscopy on specimens in the initial state and after creep testing were carried out. Studies of the microstructure of steel have shown that in the temperature range of 600 – 700 °C, coagulation of V(CN) type carbonitrides occurs, leading to a change in the slope of the Larson – Miller parametric relationship. It is shown that in the temperature range of Ac1 – Ac3 there is an abrupt change in creep characteristics associated with phase transformations. The feasibility of dividing the Larson – Miller parametric relationship into several sections depending on temperature, taking into account structural changes in the steel, is substantiated, which makes it possible to increase the accuracy of estimating the destruction time of 15Kh2NMFA-A steel by at least an order of magnitude. Based on the results of the study, a calculated dependence of the long-term strength of steel on temperature was obtained on a basis of 6,24 and 120 hours.

Mechanical behavior of powdered iron aluminide Fe – 28Al manufactured by direct powder forging

This study examines the impact of direct powder forging of powders on the composition, structure, and mechanical properties of iron aluminide Fe–28 at. % Al. During the synthesis and forging of Fe3Al powders, a homogeneous A2 phase is formed at a temperature of 1100 °C. Porosity after forging is 2–2.5 %. Residual pores are predominantly planar in shape and are located at the boundaries of the powder particles. Annealing at 1300 °C improves the quality of interparticle boundaries and all samples exhibit transcrystalline fracture mechanism. Samples forged at 1100 °C and annealed at 1300 °C show maximum strength σbend = 1050 MPa and fracture toughness K1c = 32.3 MPa·m1/2. The yield strength demonstrates anomalous temperature sensitivity with a maximum of 400 °C and at 500 °C. Samples tested at 600 °C show a decrease in yield strength, but a high enough yield point σy ∼400 MPa and a high strengthening rate are very important for high-temperature creep resistance. In creep experiments at a load of 120 MPa at 600 °C, the strain rate varies in the range of 10−7–10−6 s−1, the value of the rate sensitivity n ≈ 4. The main mechanism of creep is dislocation glide.

Study on the investigation of creep behaviour in squeeze cast Ca-modified AZ91 magnesium alloy

ABSTRACT The AZ91 (Mg-Al) alloy is the most commonly used Mg-cast alloy with high specific strength and excellent die-castability; however, its poor creep performance limits its applications at elevated temperatures. In the present investigation, the effect of Ca addition on the microstructure development and creep performance of squeeze-cast AZ91 alloy recognised as AZX911 alloy has been investigated at 150°C–250°C temperature under 65 and 80 MPa stress. The addition of Ca in the AZ91 alloy results in the precipitation of the thermally stable Al2Ca intermetallic phase, which partially suppresses the precipitation of the thermally unstable β-Mg17Al12 phase and significantly improves the creep resistance of the AZ91 Mg alloy. The governing creep mechanism of AZX911 alloy is found to follow power law creep with n = 3.49 at 150°C that mainly results from dislocation climb. In contrast, a transition to power-law breakdown is observed at 175°C. The resistance to creep deformation of AZX911 further improves with heat treatment at 450°C as compared to the as-cast specimen of the same alloy due to the complete dissolution of the β-Mg17Al12 phase. The activation energy of phase dissolution, estimated using the Kissinger method, is found to be higher (923 kJ/mol) for the Al2Ca intermetallic phase as compared to that for β-Mg17Al12 phase (664 kJ/mol) in AZX911 alloy.

Study on Mechanical and Microstructural Evolution of P92 Pipes During Long-Time Operation

To investigate the mechanical properties and microstructure evolution of P92 steel during long-term service, the operated P92 main steam pipes from the first ultra-supercritical units in China were sectioned into samples representing various service durations and stresses (0# (as-received state, 1# (82,000 h, 67.3 MPa), 2# (85,000 h, 78.0 MPa), and 3# (100,000 h, 80.3 MPa)). Thereafter, a comprehensive assessment of their mechanical properties, including tensile strength, impact, hardness, and creep resistance, as well as a detailed microstructure analysis, was carried out. The effect of stress on the aging of material properties during operation is discussed. The results show that the circumferential stress caused by the increase in the internal steam pressure can significantly promote the creep life consumption of P92 steel, resulting in the degradation of mechanical properties and the expedited aging of the microstructure. The Rp0.2 and Rm of the P92 main steam pipe at room temperature and 605 °C decreased with the service time increase, reflecting the influence of stress in operation, which is expected to be used for the residual life evaluation of P92 steel. The relationship between the impact absorption energy (FATT50), Brinell hardness, and the operating time of P92 operating pipes is non-monotonic, indicating that these parameters are not sensitive indicators of material aging due to stress. The evaluation of performance degradation in P92 operating pipes due to stress-induced aging is not reliably discernible through optical metallography alone. To achieve a thorough assessment, the use of transmission electron microscopy (TEM) is essential.

Effect of molybdenum addition on precipitate coarsening kinetics in Inconel 740H: A phase-field study

Inconel 740H (IN740H) has emerged as an important candidate for the advanced ultra-supercritical (AUSC) steam turbines due to its superior microstructural stability and creep resistance under service conditions. In the present work, we have reparameterized a multicomponent Ni-based superalloy (IN740H) into an equivalent ternary Ni-Al-Mo superalloy, based on the partitioning coefficients of the elements, using the thermodynamic database (CALPHAD). We use this thermodynamic description to employ a quantitative phase-field model to assess the long-term stability of γ′ precipitates in IN740H utilizing GPU-based supercomputing architecture. The assessment helps us to enhance our understanding of the effect of the atomic diffusivity of Mo on coarsening kinetics of the γ′-precipitates in equivalent ternary Ni-Al-Mo superalloy. Investigation reveals that our phase-field model can accurately predict the experimentally observed coarsening kinetics in IN740H.

Effect of carbon content on the microstructure and stress rupture properties of a 4th-generation nickel-based single crystal superalloy

The balance between the stress rupture properties and castability of a 4th-generation Ni-based single crystal superalloy can be achieved by addition of appropriate carbon content. In this work, the effects of carbon content on the microstructure and stress rupture properties of a 4th-generation Ni-based single crystal superalloy were investigated in detail. The results showed that minor carbon addition could aggravate the dendrite segregation, while the addition of carbon had no obvious effect on the rafting and distortion of γ′ phase during stress rupture deformation. At 760 °C/810 MPa and 1100 °C/210 MPa, the stress rupture lives of the three experimental alloys initially increased and subsequently decreased with the increasing carbon content. However, under condition of 1140 °C/137 MPa, the increased carbon content resulted in the reduction of the stress rupture lives of alloy. It was discovered that minor carbon elements addition (0.045 wt%) can promote formation of interfacial dislocation networks and improve creep resistance at high temperatures. At intermediate temperature, the introduction of carbon could reduce the stacking fault (SF) energy of γ matrix, thus facilitating the formation of SFs in γ matrix. The M6Cgranular carbides precipitated at high temperature, which was considered to be beneficial to stress rupture properties.

High-Temperature Creep Resistance of FeAlOY ODS Ferritic Alloy.

A significant effort in optimizing the chemical composition and powder metallurgical processing led to preparing new-generation ferritic coarse-grained ODS alloys with a high nano-oxide content. The optimization was aimed at high-temperature creep and oxidation resistance at temperatures in the range of 1100-1300 °C. An FeAlOY alloy, with the chemical composition Fe-10Al-4Cr-4Y2O3 (wt. %), seems as the most promising one. The consolidation of the alloy is preferably conducted by hot rolling in several steps, followed by static recrystallization for 1 h at 1200 °C, which provides a stable coarse-grain microstructure with homogeneous dispersion of nano-oxides. This represents the most cost-effective way of production. Another method of consolidation tested was hot rotary swaging, which also gave promising results. The compression creep testing of the alloy at 1100, 1200, and 1300 °C shows excellent creep performance, which is confirmed by the tensile creep tests at 1100 °C as well. The potential in such a temperature range is the target for possible applications of the FeAlOY for the pull rods of high-temperature testing machines, gas turbine blades, or furnace fan vanes. The key effort now focuses on expanding the production from laboratory samples to larger industrial pieces.

Analysis of the effect of temperature on creep resistance in nickel-based alloys used in gas turbines

Analysis of the effect of temperature on creep resistance in nickel-based alloys used in gas turbines

Surface engineering of silica to control creep failure resistance of natural rubber-based composites for potential application in the suspension of rolling stock

Immobilization of polymer chains by silica on one side could increase the viscoelastic energy loss and on the other could postpone chain relaxations and temporarily conceal creep deformation. It is not yet clear how the formation of an interphase layer contributes to the change of creep resistance. Bifunctional silane, “Bis(triethoxysilylpropyl) disulfide” is employed to induce various degrees of covalent bonds at the rubber-silica interface, and also brings multiple degrees of immobilization. Interestingly, it was found that by controlling interfacial phenomena, the creep rate can be altered in a wide range of 4.35–1.65 (%/decade). It was mechanistically explained how the maximum creep resistance is observed for the sample having a medium level of surface treatment. The formation of a filler network indicated an essential role in increasing the high-temperature creep failure of systems having no favorable polymer-filler interaction.

Strengthening effects from Mg and Ni in Al-mischmetal eutectic alloys: Insights from microstructures and Bayesian analysis

This study investigates, both experimentally and via machine-learning modeling, the strengthening mechanisms and effects of Mg and Ni additions to Al-MM (mischmetal, a sustainable Ce+La+Nd mixture to replace Ce) alloys, aiming to develop creep- and coarsening-resistant Al-MM-Mg-Ni alloys with a focus on twin eutectic co-solidification microstructures. Based on near-eutectic Al-9MM (wt%) alloy, the Mg and Ni additions introduce solid-solution and eutectic strengthening, respectively. Ternary hypo-eutectic Al-9MM-0.25/0.5/0.75Mg variants improve hardness up to 592 MPa. Ternary Al-9MM-2/4Ni display hypo-eutectic microstructures. Al-9MM-2Ni shows separated growth of Al11MM3 and Al3Ni eutectic phases, while Al-9MM-4Ni features finely intertwined Al11MM3-Al3Ni fibers from co-solidification. The hyper-eutectic Al-9MM-5Ni contains primary Al3Ni particles alongside the intertwined fibers, raising the hardness to 739 MPa. Finally, quaternary Al-9MM-0.5/0.75Mg-4/4.5Ni alloys maintain hypo-eutectic microstructures with a significant increase of hardness to 929 MPa. The series Al-9MM, Al-9MM-0.75Mg, Al-9MM-4Ni, and Al-9MM-4.5Ni-0.75Mg exhibits increasing tensile yield strengths of 70, 83, 88, and 105 MPa, with decreasing ductility of 12.0, 5.8, 2.0, and 0.8 %. All Al-9MM-Mg-Ni alloys exhibit excellent hardness retention and coarsening resistance after thermal exposure at 300 or 350°C for up to 11 weeks. A machine-learning model accurately predicts the alloy's hardness evolution under thermal exposure. Feature analysis quantitively shows the strengthening impact of MM, Ni, and Mg addition and demonstrate enhanced strengthening retention, under thermal exposure, of Al11MM3 over Al3Ni, alongside the beneficial effects of Mg homogenization. At 300 °C, Al-9MM-Mg-Ni alloys demonstrate higher creep resistance than most precipitation-strengthened Al-Sc-Zr-based alloys and solid-solution-strengthened Al-Mg alloys, with Al-9MM-4Ni as the best performer.

Impact of oxide layer on performance and creep life of a superheater tube in a coal-fired power plant

The failure of a superheater tube in a coal-fired power plant, designed to resist creep damage at high temperatures and pressures, was investigated after it ruptured following 115,360 h of operation, which was significantly shorter than its expected 200,000-hour life. An oxide layer measuring 106 µm was discovered on the inner side of the tube, which acted as a thermal insulator, raising the tube’s temperature and reducing its thickness. This led to increased stress, decreased creep resistance, and a shortened tube life. The oxide layer’s growth, tube temperature, and stress were estimated. After 115,360 h, at a flue gas velocity of 22 m/s, the oxide layer reached an estimated thickness of 120 µm. The outer and inner tube surface temperatures were 522 °C and 510 °C, respectively, and the stress was estimated at 79.9 MPa. To extend tube life to the designed 200,000 h, it was determined that reducing the flue gas velocity to 15.8 m/s or lower would be required. At this velocity, the tube’s creep life was estimated at 200,070 h when accounting for tube thinning. Without accounting for the reduction in thickness, the estimated life was 210,650 h, which was approximately 1.2 years longer.

Nanoindentation creep response of Ti–6Al–4V ELI alloy manufactured via laser powder bed fusion

The anisotropic creep response in both the XY and XZ planes of Ti–6Al–4V ELI manufactured by powder bed fusion (PBF) was examined under nanoindentation creep loading at room temperature, ranging from nm to μm scales. The stress exponent values of 4.06–4.30, rationalised through threshold stress, indicate that the creep behaviour is primarily dominated by dislocation gliding. Creep displacement results show that the anisotropic creep behaviour in the XY and XZ planes of the as-built, and heat treatment enhances the creep resistance of the XZ plane, while there is no significant difference in creep displacement between the as-built and heat-treated XY planes. Due to the higher dislocation density and compressive residual stress in the XY plane compared to the XZ plane, the creep resistance is higher in the XY plane for the as-built. It is highlighted that compressive residual stress is more relieved in the XY plane than in the XZ plane through heat treatment. The heat treatment results in improved creep resistance due to the formation of the Widmanstätten structure and β precipitates, which can impede dislocation movement under creep loading. The combination of residual stress and microstructural effects leads to anisotropic creep behaviour, suggesting that the anisotropy is inherited from the additive manufacturing process at micron scales.

Fuel performance modelling of Cr-coated Zircaloy cladding under DBA/LOCA conditions

Chromium coatings are being developed for advanced technology fuel (ATF) claddings, offering negligible corrosion during normal operation, improved resistance to high-temperature steam oxidation, and superior high-temperature strength, the latter two being of utmost relevance during design basis accidents (DBAs). Demonstrating the improved response of Cr-coated Zircaloy requires the development or extension of fuel performance codes to coating simulations.In this work, material models and correlations for Cr-coated Zircaloy cladding have been derived or obtained from the literature and implemented into TRANSURANUS and the FRAPTRAN-TUmech suite. These extended tools have been used to simulate two complementary LOCA tests: QUENCH-L1 rod 4 (out-of-pile bundle test on fresh Zircaloy cladding) and IFA-650.10 (in-pile single rod test on high-burnup Zircaloy-UO2 fuel), enabling a gradual cross-verification of results between codes and a comparative performance analysis between coated and uncoated cladding.The results indicate negligible impact of coating properties other than creep on the burst time. While the superior high-temperature creep resistance of coated cladding slightly delays the burst time, additional burst data would be necessary to draw sound conclusions on the balloon size. Regarding the modelling approach, treating the coated cladding as a composite material through the definition of effective properties might result in worse performance relative to uncoated cladding, contradicting experimental observations. Therefore, the separate modelling of the coating and the cladding is recommended.

Controlled creep resistance and melt-flow properties of vitrimers in a facile dual-catalytic system

Interest in vitrimers has increased due to the growing importance of recyclable thermosets. Controlling the flow properties of vitrimers to enhance creep resistance and processability presents challenges, particularly in extending the operating temperature range. Herein, a facile approach using a dual-catalytic system with varied activation energies (Ea) was applied to control the creep and flow properties of vitrimers. We employed an asymmetric dual-catalytic system, where a catalyst with a lower Ea facilitated the formation of a highly cross-linked structure, ensuring high creep resistance at low temperatures, while a catalyst with a higher Ea increased the deformation rate at elevated temperatures. The temperature range with distinct stress-relaxation behaviors were observed when the proper asymmetric dual-catalytic system was applied, where creep was effectively suppressed at lower temperatures, and a dormant catalyst with a higher Ea significantly accelerated the exchange reaction upon activation at higher temperatures. These findings and characterization offer valuable insights into the potential for vitrimer properties control, and vitrimer recycling using diverse catalytic systems.

Exploring the brittle-to-ductile transition and microstructural responses of [formula omitted]−TiAl alloy with a crystal plasticity model incorporating dislocation and twinning

γ−TiAl alloy, with its high specific strength and creep resistance, is ideal for aerospace engines and gas turbines, but its brittleness poses significant manufacturing and processing challenges. To address these issues, this study employs a crystal plasticity finite element method incorporating dislocation and twinning to analyze the brittle-to-ductile transition behavior of γ−TiAl alloy at different temperatures. Additionally, the Bayesian optimization methods are employed to efficiently and accurately obtain parameters related to numerical calculations of crystal plasticity. The results indicate that at room temperature, the high activation resistance of the slip systems in the α2 phase leads to limited slip activity, resulting in poor plasticity. However, at 750 °C and 850 °C, the strength of the slip systems decreases significantly, allowing more α2 phase lamellae in the γ-TiAl alloy to undergo greater plastic deformation. This enhancement in the plastic deformation capacity of the α2phase lamellae reduce the overall deformation incompatibility in the TiAl alloy, thereby improving the overall ductile of the γ-TiAl alloy.

Development of Mg-3Al-0.5Zn-0.4Mn-1Gd Alloys as a Clavicle Bone Implant Material: A Literature Review

Abstract Magnesium alloys are widely used as implant materials such as Magnesium-Aluminium, Magnesium-Mangan, Magnesium-Zirconium, and others. These alloys still need further research regarding the mechanical properties of the alloy materials, resistance to corrosion rate, and anti-toxic properties to the human body. This article reviews the Magnesium alloy AZ31 (Magnesium-3Al-1Zn-0.4Mn) with the addition of the Gadolinium element as a candidate for the implant of the clavicle bone. The novelty of the proposed research is the change in composition in the form of a reduction of 0.5% Zn and the addition of 1% Gd. Furthermore, anodizing and coating treatment is implemented to improve the mechanical stability of the alloy. This alloy is supposed to improve the physical, mechanical, and chemical properties of magnesium. The addition of gadolinium can increase the mechanical strength, creep resistance, and rate of corrosion resistance.

High creep resistance in amorphous/crystalline dual-phase nanostructured CoCrFeNiMn high entropy alloys

Amorphous/crystalline dual-phase metallic materials received great attention owing to their synergistic combination of strength and ductility. However, the mechanisms governing creep deformation in these dual-phase materials are largely elusive. In the present letter, the creep deformation of amorphous/nanocrystalline CoCrFeNiMn high-entropy alloy (HEA) films is investigated through nanoindentation creep testing. It is suggested that dual-phase HEAs exhibit reduced creep strain compared to their monophase counterparts, and even surpass the performance of coarse-grained variants. This behavior arises from diffusion processes within the amorphous phase and the capacity for nucleation/annihilate of dislocations at amorphous/nanocrystalline interfaces. Furthermore, it is proposed that the presence of glass shell significantly influences the creep behavior of dual-phase HEAs.

Elevated-temperature performances of Al-Si-Cu casting alloys for cylinder head applications

In this study, high-temperature properties of two newly developed Al-Si-Cu alloys (2Cu and 3.5Cu alloys) were investigated and compared to the commercial-grade A356 + 0.5Cu alloy (R alloy). 3.5Cu alloy exhibited the highest strength, outperforming R alloy by over 50 MPa at room temperature and by more than 20 MPa at elevated temperatures in ultimate tensile strength. However, R alloy demonstrated three to four times higher elongation than 3.5Cu alloy at room temperature, though this difference diminished at high temperatures. The minimum creep rate of 3.5Cu alloy was 2.4 times lower than that of 2Cu alloy and 14.5 times lower than that of R alloy, showing the superior creep resistance. Under low cycle fatigue loadings, the fatigue lifetimes of R and 2Cu alloys were similar, and slightly longer than that of 3.5Cu alloy. Conversely, in the high cycle fatigue regime, 3.5Cu alloy exhibited the highest fatigue resistance, followed by 2Cu and R alloys. The superior high-temperature performances of 3.5Cu alloy were attributed to the enhanced thermal stability of θ' precipitates compared to β' precipitates in R alloy, as confirmed during long-term thermal exposures at 250 and 300 °C. These findings suggest that 3.5Cu alloy is a promising candidate to replace the traditional A356 + 0.5Cu alloy for cylinder head applications.

Material volume reduction for creep testing using composite cantilevers and its application for residual life assessment

Digital image correlation (DIC) and finite element analysis (FEA) demonstrate that creep deformation in bending occurs primarily in ≈30 % of the cantilever volume near the fixed end, especially when the creep stress exponent ranges from 5 to 7. As an alternative approach to minimize the material volume required for testing, the concept of fabricating composite cantilevers is proposed and validated in this study. A composite cantilever sample consists of an “active” creeping portion (e.g., T22 boiler steel) and an additively extended “passive” non-creeping portion (e.g., IN718). The volume reduction process involved varying the length of the “active” section, a, while keeping the total length of the cantilever, L, constant. The DIC measurements conducted at 600 °C to assess the creep behavior of T22 steel revealed that analytical expressions for monolithic cantilevers could aptly predict the constitutive steady-state creep laws from the composite cantilevers if measurements are made in a region at a critical distance away from the interface. FEA indicates that accurate stress estimation enables predicting monolithic creep behavior using composite samples with “a/L” ratios of as small as 5 %. Using the developed approach, the loss of creep resistance of T11 boiler steel that was in service for ∼ 240,000 h was ascertained in high throughput fashion using a composite cantilever having only 30 vol % of the “active” material. Guidelines to minimize the volume fraction of the “active” portion in the composite cantilever and the implications of the observations for estimating the residual life of in-service high-temperature components are discussed.

Creep-to-rupture of T91 steel in static liquid lead-bismuth eutectic: Effects of cyclic temperature and oxygen environment

The creep-to-rupture behavior of T91 steel in static liquid lead–bismuth eutectic (LBE) is investigated, focusing on the impacts of cyclic temperature and oxygen condition. The results indicate that thermal cycling, oxygen deficiency, and high applied stress levels significantly accelerate creep deformation and reduce the creep-to-rupture lifetime of T91 steel in LBE. Surface oxide scales on T91 steel and their self-healing mechanisms play a crucial role in enhancing the creep resistance by isolating the LBE contact and delaying crack initiation and propagation. However, the integrity of this oxide scale is compromised under cyclic thermal conditions and low oxygen levels, leading to premature failure. Microstructural examinations reveal the evolution of oxide scale damage and self-healing mechanisms. The findings suggest that oxide scale failure mechanisms should be considered when designing the long-term operational performance of advanced LBE-based reactors.