Inconel 740H Research Articles

Modelling of cracking during beam oscillation laser welding of a creep-resistant nickel alloy

During high power laser welding of Inconel 740H, horizontal solidification cracks form at locations between approximately 70–80% of the weld depth. With the integration of circular beam oscillation, the laser energy density distribution and underlying thermo-mechanical conditions were altered. By coupling three-dimensional heat transfer, fluid flow, and stress modelling tools, the role that circular beam oscillation plays in the formation of the strain rates and stresses driving this cracking phenomenon was identified. While the addition of a circular oscillation pattern appeared to lower the stress levels along the solidification front, it did not eliminate the appearance of horizontal cracking. Only when the beam amplitudes reached 1.6 mm did solidification cracking disappear, but the weld depths were also significantly reduced.

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.

The Formation of γ′-Denuded Zone and the Effect on the Properties of Inconel 740H Welded Joint After Creep at 750°C

The Formation of γ′-Denuded Zone and the Effect on the Properties of Inconel 740H Welded Joint After Creep at 750°C

Inconel 740H Prepared by Additive Manufacturing: Microstructure and Mechanical Properties

Inconel 740H Prepared by Additive Manufacturing: Microstructure and Mechanical Properties

Crystal plasticity modeling and analysis for the transition from intergranular to transgranular failure in nickel-based alloy Inconel 740H at elevated temperature

The precipitation-strengthened Nickel-based alloy Inconel® 740H® (IN740H) exhibits increased ductility at higher applied strain rates during quasi-static tensile tests at an elevated temperature of 760 °C. The examination of fracture surfaces in this context reveals a noteworthy transition of underlying fracture mechanisms from transgranular to intergranular fracture as the applied strain rate decreases from 1×10−3/s to 0.83×10−4/s. To thoroughly understand the mechanical response of IN740H under these conditions, this study develops a crystal plasticity finite element (CPFE) model. This model incorporates various deformation mechanisms including dislocation slips, climb, and grain boundary sliding, which are relevant to the test conditions. The model is calibrated using data from both tensile tests at different strain rates and creep tests across a broad stress range at 760 °C, enabling the accurate determination of model parameters for each mechanism. Simulation results well captured the experimental observations of different failure modes. At higher strain rates, the model shows a dominance of dislocation slip leading to heterogeneous plastic deformation and formation of transgranular shear bands causing the failure, while at lower strain rates, an increased activity of grain boundary sliding causes grain boundaries crack leading to intergranular failure.

Creep Performance Study of Inconel 740H Weldment Based on Microstructural Deformation Mechanisms

Abstract The creep behavior of Inconel 740H weldment at the temperature of 760 °C is investigated experimentally and analytically using the deformation-mechanism-based true stress (DMTS) model. The Inconel 740H weldment specimens are prepared with the gas tungsten arc welding technique. Creep testing is performed on the Inconel 740H weldment specimens under a range of stress levels from 190 MPa to 447 MPa at the temperature of 760 °C. The DMTS model is employed to analyze the creep curves and creep rates. The model parameters for Inconel 740H weldment are determined from the analyses of the creep testing data in combination with that from the previous studies of similar materials based on the same creep mechanisms that involve grain boundary sliding and intragranular dislocation climb-plus-glide with dislocation multiplication. The creep life predictions of the DMTS model for Inconel 740H weldment agree very well with creep rupture test data within a temperature range of 700–800 °C. The fractured surfaces and longitudinal sections of creep-tested Inconel 740H weldment specimens are examined using scanning electron microscopy, which corroborates the DMTS model inference that the creep failure of Inconel 740H weldment is in a mode of predominantly intergranular fracture. The present study suggests that grain boundary sliding is the most significant controlling factor for the creep failure of Inconel 740H weldment.

Microstructure and Hardness Investigation of Tribaloy Alloy T-400C Hardfacing Deposited on Nickel-Based Alloy Inconel 740H via Plasma Transferred Arc Welding Subjected to Long-Time Aging

Microstructure and Hardness Investigation of Tribaloy Alloy T-400C Hardfacing Deposited on Nickel-Based Alloy Inconel 740H via Plasma Transferred Arc Welding Subjected to Long-Time Aging

Numerical Analysis and Experimental Validation of Temperature Induced Creep and Fatigue life of Inconel 740H and Haynes 282

The Nickel based super-alloys have gained lot of importance in the last decade or so owing to their applications in areas like power generation, military aircrafts, marine propulsion and nuclear reactors. Utilities worldwide are facing increased demand for additional electricity, reduced plant emissions and greater plant efficiency. To meet this challenge, it requires materials with very high temperature creep and fatigue strength and better coal ash corrosion resistance. For the realization of advanced ultra-supercritical (A-USC) thermal plant operating at service temperature and pressure about 700oC to 760oC and 24 MPa respectively, the use of Nickel based super alloys are indispensable. The two A-USC qualified alloys include Inconel 740H and Haynes 282. This study focus on improving the creep and fatigue life of the A-USC qualified alloys by predicting the optimum operating parameters through finite element modeling for temperature induced creep and fatigue analysis of the said A-USC alloys. The influence of various operating parameters like temperature, machining induced residual stress, surface finish, creep duration and fatigue loadings on output parameters like creep strain, elongation, creep and fatigue life were studied. Abaqus/Standard was used for the numerical simulation. Using ANOVA, the most influencing operating parameters were identified. It was observed that the machining induced residual stress and surface finish have greater influence on creep and fatigue life of alloys. Alloy with lower value of machining induced residual stress and better surface finish will have better creep and fatigue life. The proper validation of model was performed by comparing the results with relevant literature.

Novel Cr/Si-Slurry Diffusion Coatings for High Temperatures

Surface enrichment in Al, Si, and Cr can greatly improve high temperature oxidation resistance of many alloys. Al, Si, and Cr coatings are commonly applied via simple slurries or more complex pack cementation processes. Due to the high melting point of Cr, the deposition of Cr-based diffusion coatings by the slurry technique has proved challenging, and to date, Cr has mostly been applied by pack cementation. Here, a novel Cr-Si coating process via the slurry technique is described which has been developed and then demonstrated on two Ni-based superalloys, Rene 80 and Inconel 740H. The addition of Si to the slurry lowers the melting point via a Cr-Si eutectic and enables the formation of a liquid phase during heat treatment. Through this Cr-Si slurry coating process diffusion layers enriched by Cr and Si of about 150 µm were achieved. Oxidation behavior was studied through isothermal exposures at 900 °C for 1000 h in lab air. Uncoated Rene 80 and IN740H both showed formation of a Ti-containing Cr2O3 scale below a thin TiO2 top layer. Underneath the external scale a zone of internally oxidized Al grew over the exposure time and reduced the load-bearing cross-section progressively. In comparison, the Cr/Si-coated samples did not show internal Al oxidation, but a slow-growing Si-rich oxide film underneath the external Cr2O3 scale. This subscale represents an additional oxygen diffusion barrier. Thus, the weight gain during exposure for the coated samples was significantly lower than for the uncoated materials.

Prediction of Hot Deformation Behavior for Inconel 740H Alloy Based on Ensemble Learning

Prediction of Hot Deformation Behavior for Inconel 740H Alloy Based on Ensemble Learning

Keyhole mode wobble laser welding of a nickel base superalloy - Modeling, experiments, and process maps

Keyhole mode wobble laser welding is gaining increasing acceptance due to its ability to bridge gaps, refine microstructure, and enhance the mechanical properties of welds. However, the impact of amplitude, frequency, welding speed, laser beam power, and beam radius on the heat flux distribution, melting pattern, and three-dimensional temperature field is not well understood. To address this need, here we report a combined experimental and computational study to investigate the effects of the key wobble welding parameters on the energy distribution impinging on the welding track, keyhole formation, three-dimensional fluid flow and heat transfer during wobble laser welding of Inconel 740H. The modeling results were rigorously tested using experiments in which the welding speed, laser power, and wobble amplitude and frequency were varied. A bimodal power density distribution with higher power density near the edge than in the middle of the track occurred when the wobble amplitude significantly exceeded the laser beam diameter. A high wobble amplitude resulted in a wide and shallow pool while the wobble frequency used in this work did not significantly impact the fusion zone geometry. A set of process maps were constructed to understand the role of wobble laser parameters in achieving a desirable fusion zone geometry during keyhole mode wobble laser welding. Finally, wobble laser welding with a high amplitude was found to favor rapid solidification and the formation of finer solidification microstructure.

Coupled abrasion Erosion-Oxidation wear from particles in Concentrating solar thermal power facilities

Solid particles represent an attractive heat transfer and energy storage media for next generation solar thermal power facilities for their ability to operate at high temperatures without concerns for freezing or corrosion. A potential outstanding issue that still remains for particles as heat transfer media is the wear on components operating with particles flowing (sliding) in, along, or over them. Prior work has shown that even at the low velocities (∼1 cm/s to ∼ 1 m/s) expected in solar thermal facilities, material wear will still occur, and the lifetime and performance of components undergoing wear needs to be well understood. Abrasion erosion occurs when particles come into contact with containment materials at extremely shallow angles, and is likely to be seen in heat exchangers, storage bins, and flow control mechanisms. Additionally, because of the open nature of most of these systems to air, oxidation of metals is also of concern. Here, we show how critical the coupled erosion-oxidation mechanism is to understanding particle/material durability and therefore need for greater in-depth analysis. Abrasive wear experiments are conducted on metals such as SS316 (L and H grades), Inconel 740H, Haynes 230 with different particles (HSP 40/70, Wedload 430, and CarboMax HD) for different operating conditions. Results clearly indicate that oxide spallation and removal is critical to the overall wear seen at high temperatures.

Solar Disc Concentrator: Material Selection for the Receiver

Solar concentration is the ability to harness solar radiation in order to increase the temperature of a receiver. The receiver is a component into which a heat transfer fluid can flow in an ORC system, which produces electricity, or it can be used for high-temperature thermal storage or even to implement thermochemical cycles. The choice of material is critical to ensure optimal performance and long-lasting operation. It is also essential that such material can operate at high temperatures and high thermal gradients. In short, material identification involves high thermal stresses that result in structural deformation. Different metal alloys were used to verify that the yield strength limit was not exceeded due to thermal stress induced by concentrated solar radiation. Starting with the general heat equation, the problem was implemented in Matlab. The purpose was to test whether thermal stress exceeds the yield strength, which is the condition in which elastic bonds in the material are changed, causing deformation. This condition, if exceeded, is sufficient to discard the material; otherwise, it is a necessary but not sufficient condition to resist over time. The best material identified was Inconel 740H, which had a high yield strength value and the lowest temperature difference. Under extreme working conditions, it withstood induced thermal shocks.

Achieving High Strength and Creep Resistance in Inconel 740H Superalloy through Wire-Arc Additive Manufacturing and Thermodynamic-Guided Heat Treatment.

Inconel 740H superalloy is commonly used in advanced ultra-supercritical power plants since it possesses excellent strength and creep resistance. This study investigates the microstructure and mechanical properties of Inconel 740H superalloy fabricated using wire-arc additive manufacturing. The as-printed microstructure consisted of columnar γ grains with the Laves phase and (Nb, Ti)C carbides as secondary phases. The anisotropy in grain structure increased from the bottom to the top regions, while the hardness was highest in the middle portion of the build. To guide the post-heat treatment design, thermodynamic and kinetic simulations were employed to predict the temperature and time. Complete recrystallization with the Laves phase dissolution occurred throughout the build after homogenization at 1200 °C for 2 h. The peak hardness was achieved after aging at 760 °C for 12 h with the M23C6 carbides decorating the grain boundaries and γ' precipitates in the grain interior. The yield strength (655 MPa) and ductility (29.5%) in the post-heat treated condition exceeded the design targets (620 MPa, 20%). Stress rupture tests at 750 °C showed that the high-temperature performance was at par with the wrought counterparts. The fracture mode after rupture was identified to be intergranular with the presence of grain boundary cavities along with grain boundary sliding.

Using statistical analysis to understand creep modelling error and the ramifications for Solar Tower receivers

Concentrated Solar Power (CSP) receivers, especially those adopted in Solar Tower (ST) configurations, operate at high temperatures and low stresses making them susceptible to creep damage. Creep modelling used to predict components' life and therefore the accuracy of creep modelling can significantly impact life estimation, prediction of failures, and ultimately the design. The accuracy of creep modelling is highly variable and depends on the choice of model, the choice of fitting functions, and sometimes depends on ‘judgement’ decisions by the modeller. In this article the Larson-Miller and Wilshire creep models are fitted to three common power generation materials (Grade 22, SS316 and Inconel 740H) with differently sized datasets. Region splitting via activation energy is also examined. The fits are examined for accuracy and bias for stress, temperature and rupture time by a statistical process of bootstrapping to provide a better understanding of the impact of the creep model and dataset size on the design and lifing of CSP receivers.

Effect of microstructure on fatigue resistance of Inconel 740H and Haynes 282 nickel-based alloys at high temperature

Fatigue crack growth behavior of Inconel 740H and Haynes 282 nickel-based alloys at 20 °C, 700 °C and 750 °C was studied. Results showed increased fatigue crack growth rate for both the two alloys, while increased fatigue threshold in Inconel 740H at high temperatures. The size and distribution of MC carbides, serrated grain boundaries and twins deflected crack growth path. The strengthening γ' phase was interacted with dislocations by Orowan bypass and shear mechanisms at room temperature, while γ' was sheared in Haynes 282 and Orowan bypassed in Inconel 740H alloy at elevated temperatures. The cross slip, dislocation climbing and entanglement reduced the resistance of dislocation movement and accelerated the accumulation of damage. The higher content of Cr in Haynes 282 alloy promoted formation of M23C6 carbide while the lower content in Inconel 740H alloy promoted thicker oxide layer. The Cr content needed careful tuning as it was superior to microstructural factors for higher fatigue threshold at elevated temperatures.

Integrated modeling of cracking during deep penetration laser welding of nickel alloys

During deep penetration laser welding of nickel alloys, interactions between composition and processing conditions can lead to the formation of defects. Inconel 740H, for example, has demonstrated a susceptibility to horizontal fusion zone cracking at locations between 70% and 80% of the weld depth during laser welding at powers above 5 kW. Coupling three-dimensional heat transfer, fluid flow, and stress modeling tools allowed that both the strain rate and stress normal to the solidification direction to be calculated. In the Inconel 740H welds, cracks formed at locations where the strain rate and stress simultaneously reached critical levels. No cracking was observed in the Inconel 690 welds, since the strain rate and stress did not simultaneously reach these critical levels.

Application of neural network in micromechanical deformation behaviors of Inconel 740H alloy

Application of neural network in micromechanical deformation behaviors of Inconel 740H alloy

Corrosion behaviour of Ni-based alloy Inconel 740H in supercritical carbon dioxide at 650–700°C

ABSTRACT Corrosion tests of Ni-based alloy Inconel 740H were carried out in supercritical carbon dioxide (S-CO2) at 650–700°C under 25 MPa. The corrosion kinetics were measured by weight change as a function of time, and the surface oxide layers were characterised and identified by a series of characterisation methods. It is found that Inconel 740H experienced general oxidation, localised exfoliation and internal oxidation. A dense Cr2O3 oxide scale rapidly formed on the surface of Inconel 740H at 650–700°C, resulting in good general corrosion resistance. Nodular oxidation was triggered by Ti-rich and Nb-rich oxides. Internal oxidation selectively oxidised Al. The causes of oxide-induced exfoliation are discussed.

Dynamic thermal analysis and creep-fatigue lifetime assessment of solar tower external receivers

This paper proposes a methodology for the dynamic thermal analysis of solar tower external receivers and for the assessment of their lifetime. A dynamic thermal model is implemented in Modelica to assess the temperature distributions of receiver tubes and heat transfer fluid (HTF), considering real weather data with a 10-minute time resolution and PI controllers based mass flow rate control. Three representative days are simulated, and the resulting tubes temperature distributions are used to assess the elastic stresses distributions during the investigated days. Subsequently, the creep-fatigue lifetime of each receiver panel is evaluated accounting for material plasticity and creep-induced stress relaxation. The developed methodology is applied to compare three materials for solar receivers: Inconel 740H, Haynes 230, and Incoloy 800H.Results show that fatigue can be negligible with respect to creep for all investigated materials and the shortest lifetime is obtained for 800H, followed by H230, and 740H. The approximation of a receiver operation for 365 clear-sky days per year leads to errors around 30 % on the lifetime. For 740H and 800H, the damage accumulation during cloudy days with high DNI peaks is greater than during clear-sky days due to the remarkable creep damage originated during temperature spikes which follow clouds passages. H230 instead, accumulates more creep damage during clear-sky operation. This emphasizes the potential of the developed methodology to compare different HTF mass flow rate control strategies as well as receiver geometries and materials, HTFs, and heliostats aiming strategies, accounting for the trade-off between energy yield and receiver lifetime.