Pressure Vessel Steels Research Articles

Specimen reconstitution method for the assessment of fracture properties of reactor pressure vessel steels

Routine testing of the fracture properties of irradiated surveillance specimens is a critical method for evaluating irradiation embrittlement in reactor pressure vessel (RPV) steels. Given the limited space in irradiation surveillance tubes, specimen reconstitution technology is expected to provide a viable solution to the shortage of irradiated specimens. This study investigates the specimen reconstitution method for 16MND5 steel 0.5 T CT specimens used in the RPV. By studying the local mechanical properties of the residual specimen and performing finite element analysis of the crack tip plastic zone, the appropriate size for specimen reconstitution is determined. The electron beam welding method is used to join the residual specimen and the base material, and the J-integral formula for the reconstituted specimen is determined based on the finite element analysis, taking into account the influence of the weld seam and the degradation of the mechanical properties of the residual specimen. The feasibility of the specimen reconstitution method is validated through fracture tests on base material specimens and reconstituted specimens at different temperature.

Fracture behavior, mechanical properties, and microstructural analysis of vacuum automated GMAW welded dissimilar A353 and A516 steels for pressure vessels

In this study, the performance of the automatic gas metal arc welding (GMAW) process in vacuum for similar and dissimilar joints of A353 and A516 steel plates with different thicknesses was intensively evaluated. Fracture of all vacuum-welded samples occurred in the heat-affected zone (HAZ) of A516 steel, highlighting the significant influence of HAZ microstructure and width on the cryogenic impact energy and strength of these joints. According to microscopic observations and impact tests, the fractures were fully ductile for notches in the weld and A353 HAZ, where dimples were observed on the fracture surfaces and the impact energy exceeded 50 J. This ductile behavior is particularly significant for notches in the weld due to the presence of a vacuum during welding prevents the formation of gas voids and oxide and hydride compounds that are normally the origin of cracks. However, for notches in the A516 HAZ, where the cleavage faces were observed on the fracture surfaces and the impact energy was less than 30 J, the fractures were quite brittle. For dissimilar vacuum-welded samples, the impact energy and fracture type for notches in the weld and A353 HAZ were nearly the same as those in similar A353 joints. However, for notches in the A516 HAZ, the impact energy and fracture type were close to those observed in the A516 joints. Yield strength and ultimate tensile strength (UTS) of A353-A353 non-vacuum-welded samples compared to vacuum-welded samples decreased by more than 78% and 40%, respectively. As well as, yield strengths and UTSs of A516-A516 non-vacuum samples compared to vacuum samples decreased by more than 34% and 4%, respectively. On the other side, the impact samples with a notch position in the weld suffered brittle fracture instead of ductile fracture because their impact energy decreased by about 40%.

Fungal Methane Production Under High Hydrostatic Pressure in Deep Subseafloor Sediments

Fungi inhabiting deep subseafloor sediments have been shown to possess anaerobic methane (CH4) production capabilities under atmospheric conditions. However, their ability to produce CH4 under in situ conditions with high hydrostatic pressure (HHP) remains unclear. Here, Schizophyllum commune 20R-7-F01, isolated from ~2 km below the seafloor, was cultured in Seawater Medium (SM) in culture bottles fitted with sterile syringes for pressure equilibration. Subsequently, these culture bottles were transferred into 1 L stainless steel pressure vessels at 30 °C for 5 days to simulate in situ HHP and anaerobic environments. Our comprehensive analysis of bioactivity, biomass, and transcriptomics revealed that the S. commune not only survived but significantly enhanced CH4 production, reaching approximately 2.5 times higher levels under 35 MPa HHP compared to 0.1 MPa standard atmospheric pressure. Pathways associated with carbohydrate metabolism, methylation, hydrolase activity, cysteine and methionine metabolism, and oxidoreductase activity were notably activated under HHP. Specifically, key genes involved in fungal anaerobic CH4 synthesis, including methyltransferase mct1 and dehalogenase dh3, were upregulated 7.9- and 12.5-fold, respectively, under HHP. Enhanced CH4 production under HHP was primarily attributed to oxidative stress induced by pressure, supported by intracellular reactive oxygen species (ROS) levels and comparative treatments with cadmium chloride and hydrogen peroxide. These results may provide a strong theoretical basis and practical guidance for future studies on the contribution of fungi to global CH4 flux.

Development of a new irradiation-embrittlement prediction model for reactor pressure-vessel steels

Development of a new irradiation-embrittlement prediction model for reactor pressure-vessel steels

Fracture studies on cruciform bend specimens of pressure vessel steel subjected to thermo-mechanical loading

The safety of a nuclear power plant during incidents, such as a Loss of Coolant Accident (LOCA), heavily relies on conducting a comprehensive structural integrity assessment of both the Reactor Pressure Vessel (RPV) and its components, specifically to withstand Pressurized Thermal Shock (PTS). PTS is characterized by a combination of steep temperature gradient, resulting from the injected emergency coolant during a LOCA, and internal pressure within the RPV. Majority of the reported fracture assessment studies on RPV steel, whether experimental or numerical investigations, have predominantly focused on standard uniaxial specimens at iso-thermal loading conditions. To better simulate the thermal shock scenario in RPVs, the present work aims to assess the impact of a biaxial stress field on both fracture parameters (crack mouth opening displacement and J-integral) and plastic collapse load. This assessment is conducted through experimental and numerical investigations, both with and without prior transient thermal load. Fracture experiments are performed on cruciform bend specimens, featuring two different biaxiality ratios (1:1 and 2:1). Moreover, numerical studies on cruciform specimens are conducted using finite element analysis to validate and corroborate the observations derived from the fracture experiments.

Predicting creep life of CrMo pressure vessel steel using machine learning models with optimal feature subset selection

The data-driven approach for creep life prediction typically integrates numerous characteristics, including material compositions, manufacturing details, and service conditions, into machine learning models. In this study, a machine learning-based creep life prediction approach with optimal feature subset selection is established for 2.25Cr1Mo pressure vessel steel. Before model training and testing, six critical features that significantly impact the creep life of 2.25Cr1Mo steel are selected, specifically the applied stress, temperature, and chemical compositions consisting of Cr, Ni, Mn, and Mo. Various machine learning algorithms, along with the traditional L–M method, are utilized for model training and performance evaluation. Additionally, the developed models undergo validation using experimental data independent of the training and testing datasets to assess their generalization abilities. The results reveal that, among all tested models, the support vector regression (SVR) model, coupled with the optimal feature subset, demonstrates superior prediction accuracy and generalization capability. Finally, the creep life prediction model exhibiting optimal performance is deployed into a software application, leveraging the Python programming language. This predictor tool facilitates rapid and precise creep life predictions for 2.25Cr1Mo pressure vessel steel, relying solely on a limited amount of input information, and provides a clear and visual presentation of the prediction results.

Influence of welding angle in the process of submerged arc welding of pressure vessel steel

Abstract In the industrial production of pressure vessels (PV), a very important role is played by the welding of the elements that make up the vessel. The predominant welding technology in the case of manufacturing PV is the submerged arc welding (SAW) for which different welding regimes are defined depending on the characteristics of the base material. The welding regimes are made up of various parameters easy to manipulate by the operators of the welding machines, one of them is the welding angle. In this article, aspects are discussed regarding the way in which the welding angle of SAW influences the quality of welded joints. Tensile tests were carried out on specimens taken from plates joined by SAW using different values of the electrode tilt. Aspects regarding the geometry and dimensions of the welded joints obtained as a result of the variation of the welding angle are analysed and, in the end, an optimal angle is indicated for the welding process of PV. The basic material used in the experiments is a fine-grained material intended for the manufacture of vessels that work in high pressure and high temperature regimes, named in the technical literature P355 N.

How precisely are solute clusters in RPV steels characterized by atom probe experiments?

Atom probe tomography (APT) is a powerful microscopy technique to characterize nano-sized clusters of the alloying elements in the bulk of reactor pressure vessel (RPV) steels. These clusters are known to dominantly determine the evolution of mechanical properties under irradiation. The results are conventionally summarized as the overall number density N and the average diameter D of the solute clusters identified in the material. Here, we illustrate that these descriptors are intrinsically imprecise because they are steered by the parameters involved in the measurement and data processing, some of which are directly under the control of the operators, but some others not. Consequently, a direct comparison between data derived at different laboratories is compromised, and key trends such as the evolution with dose, are masked. This study relies on a state-of-the-art physical model for neutron irradiation in steels to make reliable estimates of the microstructure before the measurement is performed, which allows the prediction of the population of solute clusters that are not seen by APT. We mimic APT measurements from simulated microstructures, performing a detailed study of the effects of the parameters of the analysis. We show that the values of N and D reported in the scientific literature can be matched by the predictions of our theoretical model only if specific sets of parameters are used for each laboratory that issued the measurements. We also show that if, on the contrary, all studied cases are analyzed in a consistent way, the scatter of N and D values is reduced. Specifically, we find that the average diameter D is nearly a constant value with dose, independently of the material's chemical compositions, while N increases with dose, but is also influenced by other variables. The approach we developed and used proves to have added value as complement to APT experiments in reactor pressure vessel steels.

On the iron content of Mn-Ni-Si-rich clusters that form in reactor pressure vessel steels during exposure to neutron irradiation

Solute cluster formation during service is the primary cause of embrittlement in reactor pressure vessel (RPV) steels. Atom probe tomography (APT) has consistently shown that the solute clusters are enriched in Cu, P, Mn, Ni, and Si compared to the matrix. However, there is pronounced disagreement within the literature as to the Fe content of the solute clusters in low-Cu RPV steels; some authors report Fe contents in excess of 80 at.% whilst others attribute all measured Fe in the clusters to aberrations from APT and report Fe-free features. This discrepancy has profound implications for determining whether cluster formation is radiation-induced or radiation-enhanced.In this article, we perform a systematic analysis of the published literature to demonstrate the variance present in the measured Fe content of solute clusters characterised by APT. We investigate potential explanatory variables for this variation and discuss the difficulties in performing statistical analyses on these data. To determine the impact of APT aberrations on the measured Fe content of solute clusters, we combine results from: simulations that account for the limited spatial precision in APT; models that predict ion trajectories in the presence of non-uniform electrostatic fields; and experimental data.Our results show that APT aberrations can introduce large amounts of artificial Fe into solute clusters, especially at the small sizes (radius <1.5 nm) typically observed in RPV steels. We also show, however, that some of the variance in Fe content in the literature may be explained by real differences in the clusters’ Fe contents.

A Model to Account for the Effects of Load Ratio and Hydrogen Pressure on the Fatigue Crack Growth Behavior of Pressure Vessel Steels.

A phenomenological model for estimating the effects of load ratio R and hydrogen pressure PH2 on the hydrogen-assisted fatigue crack growth rate (HA-FCGR) behavior in the transient and steady-state regimes of pressure vessel steels is described. The "transient regime" is identified with crack growth within a severely embrittled zone of intense plasticity at the crack tip. The "steady-state" behavior is associated with the crack growing into a region of comparatively lower hydrogen concentration located further away from the crack tip. The model treats the effects of R and PH2 as being functionally separable. In the transient regime, the effects of the hydrogen pressure on the HA-FCGR behavior were negligible but were significant in the steady-state regime. The hydrogen concentration in the steady-state region is modeled as being dependent on the kinetics of lattice diffusion, which is sensitive to pressure. Experimental HA-FCGR data from the literature were used to validate the model. The new model was shown to be valid over a wide range of conditions that ranged between -1≤R≤0.8 and 0.02≤PH2≤103 MPa for pressure vessel steels.

Effect of prior microstructure on carbide precipitation in a Cr-Mo-V pressure vessel steel at 650 °C

Cr-Mo-V steels are key materials used for constructing thick reactor pressure vessels (RPV) owing to an impressive combination of their mechanical properties and weldability. Conventionally, these steels are subjected to a quality heat treatment that comprises austenitization, quenching and tempering. Owing to its large thickness, an RPV experiences widely different cooling rates across its thickness during quenching, leading to considerable variation in the microstructure from the surface to the centre of the vessel. In this study, a Cr-Mo-V steel was austenitized at 950 °C for 1 h and cooled at two rates (water quenching and 10 °C/min), representative of the cooling rates at the surface and centre of a typical RPV, to study the effect of prior microstructure on the carbide precipitation during tempering of the steel at 650 °C. Electron microscopy of the as-cooled samples revealed the presence of martensitic microstructure in water quenched sample and predominantly granular bainitic microstructure in slow cooled sample. Synchrotron studies revealed the presence of retained austenite containing ∼0.8% carbon in the slow-cooled sample. Tempering of the steel at 650 °C for 200 h precipitated M7C3 and MC (VC) carbides in the water-quenched sample, while the slow cooled samples precipitated M23C6 as an additional constituent. This difference in the carbide precipitation in the two samples has been attributed to the excess carbon in the martensite/austenite (M/A) regions in slow cooled samples and explained on the basis of carbide precipitation sequence predicted using Thermo-kinetic simulations. This analysis has shown that M23C6 and M7C3 carbides in the slow cooled sample precipitate simultaneously as critical radii of their nucleation as well as their incubation time become comparable when the matrix contains more than 0.25% C. The present study has demonstrated that the microstructure prior to tempering may significantly affect the precipitation sequence of carbides during tempering.

On the grain level deformation of BCC metals with crystal plasticity modeling: Application to an RPV steel and the effect of irradiation

Capturing realistic deformation behavior in BCC metals at the polycrystal scale is an important aspect of predicting the material’s strength and failure. Furthermore, local deformation/strength heterogeneity also influences the lifetime and its assessments in reactor pressure vessel (RPV) steels, especially with accumulating irradiation doses during long-term operational conditions. This work utilizes a micromorphic crystal plasticity (CP) model for BCC materials with the capability to address temperature-dependent stress–strain response and irradiation effects relevant to RPV materials. The microstructure of the investigated material was characterized prior to and during testing using electron microscopy experiments, which are used for finite element model generation and simulation result validation. To analyze the validity of the model to predict strain localization under monotonic tensile loading, micro digital image correlation (DIC) was employed jointly with the CP simulations. Different modeling choices, such as the use Schmid/non-Schmid laws and gradient based CP modeling, greatly affected the capability of the model to represent similar magnitudes in strain localization and grain reorientation. The requirement for experimental measurements, including image based analyses, on a microstructural level as a validation tool for CP modeling is clearly demonstrated.

Investigation of Irradiation Hardening and Effectiveness of Post-Irradiation Annealing on the Recovery of Tensile Properties of VVER-1000 Realistic Welds Irradiated in the LYRA-10 Experiment

Assessing the embrittlement and hardening of reactor pressure vessel steels is critical for the extension of the service lifetime of nuclear power plants. This paper summarises the tensile test results on the irradiation behaviour of realistic VVER-1000 welds from the STRUMAT-LTO project. The welds were irradiated at the HFR (Petten, the Netherlands) to a fluence of up to 1.087 × 1020 n·cm−2, and their irradiation hardening was studied by means of tensile testing. The four grades, with different Mn and Ni contents, show different hardening behaviours. The highest degree of irradiation hardening is observed for the weld that has the highest combined Ni + Mn content. The results show that there is a synergetic effect of Mn and Ni on the irradiation hardening behaviour of the VVER-1000 welds. Besides irradiation hardening, the effectiveness of post-irradiation annealing treatments on the recovery of the tensile properties is studied in the present work. Post-irradiation annealing treatments conducted at 418 °C and at 475 °C proved to be effective for three of the four investigated welds. For the realistic weld with the highest combined Ni + Mn, only the annealing at 475 °C led to the complete recovery of the tensile properties.

Exploring variations in the weight, size and shape of liquid hydrogen tanks for zero-emission fuel-cell vessels

We report an exploration of liquid hydrogen (LH2) tank technology, determining if improving LH2 tank weight, multiplicity or shape enables more hydrogen to be stored on hydrogen vessels. The improvements investigated are well beyond the current LH2 technology state-of-the-art. The platform for this study is a monohull H2 Baseline research vessel powered 100% by hydrogen.Regarding weight reductions, we found that the research vessel does not benefit significantly from large weight reductions of the LH2 tanks. A 50% reduction in mass of the inner pressure vessel led to a 3.1% reduction in the total research vessel weight. Reducing the LH2 tank weight to the asymptotic limit of zero results in a 7.1% reduction in the overall research vessel weight. This maritime application, while benefitting from a reduction in LH2 tank weight, is not a strong driver for LH2 tank weight improvements.The two large LH2 tanks of the H2 Baseline Vessel can be replaced with a multitude of smaller LH2 tanks. In two Multiplicity design variants, the total amount of stored LH2 was ∼5–9% less than that of the H2 Baseline Vessel, which does not motivate conducting the needed R&D that would drive the technology to smaller high-performing LH2 tanks.We did find a significant benefit to improving the shape of LH2 tanks, towards prismatic tanks that would better match the vessel hullform. Considering a “Shape Variant” that included space-consuming features such as tank connection spaces, manifolding and ventilation, we found a 26% improvement in stored LH2 compared to the H2 Baseline Vessel. The large improvement in storage capacity could warrant further LH2 tank R&D that can enable high performing prismatic LH2 tanks, such as pressure vessel steel developments allowing for higher strength/ductility at 20 K, improved insulation systems, methods for efficiently building prismatic tanks with insulation systems fit for 20 K service and flare-less techniques for managing heat leak (venting).The results are reviewed considering the current regulatory restrictions as well as prevailing limitations in LH2 tank manufacturing.

Cluster dynamics study on nano damage of RPV steels under proton irradiation at 290°C

Irradiation-induced defects such as dislocation loops, cavities or solute clusters and chemical composition segregation of reactor pressure vessel (RPV) steel are the root causes of irradiation embrittlement. Combining two nucleation mechanisms, namely, the uniform nucleation and non-uniform nucleation of solute clusters (such as Cu-rich phase), a cluster kinetic simulation was established based on the reaction rate theory, and the co-evolution of matrix damage and Cu-rich phase in low-copper RPV steel was simulated under irradiation. And the average size and number density of defective clusters and solute clusters were established with irradiation dose. Compared with the average size and number density of dislocation loops observed by transmission electron microscopy (TEM) of proton irradiated RPV steel at 290°C, the verification results show that the cluster dynamics model considering both the nucleation mechanism of interstitial dislocation loops and vacancy clusters can well simulate the irradiation damage behavior of materials.

Research progress on thermal aging of reactor pressure vessel steel

Nuclear energy is highly valued in many countries for its reliability, cleanliness and cost-effectiveness. Ensuring the safe development and utilization of nuclear energy has become crucial for addressing the global energy shortage and mitigating climate change. The reactor pressure vessel (RPV) is exposed to a high-temperature, high-corrosion and high-radiation environment, the RPV materials have a significant impact on the stability and safety of a nuclear power station. In this paper, the effects of long-term high-temperature hot aging on microstructure and mechanical properties of RPV steel, as well as the research progress in embrittlement mechanism and service life prediction, are reviewed. At the same time, the existing problems and further research directions of RPV steel are pointed out.

Simulation Study on Defect Damage Behavior of Fe under Irradiation Environment

Abstract As a commonly used structural material in nuclear power plants, Reactor pressure vessel (RPV) steel is subjected to high-energy neutron irradiation from the reactor core for a long time, and the service environment is harsh. The accumulation of point defects (interstitial atoms and vacancies) generated by irradiation over a long period can seriously affect the microstructure of the material. The macroscopic properties of the material changed until the material failed, which threatened the safety and operation stability of nuclear power plants. This paper used the method of molecular dynamics to simulate the cascade collision process of Fe in the irradiation environment. The relationship between different factors and radiation damage defects was studied. Firstly, the quantity of the Frenkel pairs increases rapidly in the irradiation environment, and then recombination occurs after reaching the peak, which makes the quantity of the Frenkel pairs decrease rapidly. Finally, the quantity of Frenkel pairs is in a stable trend. When PKA energy and temperature increase, the higher the quantity of Frenkel pairs at the peak is, the higher the recombination rate of defects is. Meanwhile, the larger the cluster size of interstitial atoms and vacancies is, the greater the corresponding quantity of clusters is. As PKA energy increases, the quantity of residual Frenkel pairs at stability increases, while the number of residual Frenkel pairs at stability decreases with temperature. This is attributed to the intense thermal motion of molecules at high temperatures, resulting in the quantity of Frenkel pairs decreasing at the stable stage. Therefore, by simulating the irradiation damage process of Fe, the prediction of material irradiation damage under a neutron irradiation environment is provided, and the service life of materials can be provided with theoretical guidance.

Analysis of Shift in Nil-Ductility Transition Reference Temperature for RPV Steels Due to Irradiation Embrittlement Using Probability Distributions and Gamma Process

Reactor pressure vessel (RPV) steels are highly susceptible to irradiation embrittlement due to prolonged exposure to high temperature, high pressure, and intense neutron irradiation. This leads to the shift in nil-ductility transition reference temperature—∆RTNDT. The change in ∆RTNDT follows a certain distribution pattern and is impacted by factors including chemical composition, neutron fluence, and irradiation temperature. Existing empirical procedures can estimate ∆RTNDT based on fitting extensive irradiation embrittlement data, but their reliability has not been thoroughly investigated. Probability statistical distributions and the Gamma stochastic process were performed to model material property degradation in RPV steels from a pressurized water reactor due to irradiation embrittlement, with the probability models considered being normal, Weibull, and lognormal distributions. Comparisons with existing empirical procedures showed that the Weibull distribution model and the Gamma stochastic model demonstrate good reliability in predicting ∆RTNDT for RPV steels. This provides a valuable reference for studying irradiation embrittlement in RPV materials.

Experimental and modeling study on irradiation effect of A508-Ⅲ steel

Irradiation can induce microscopic defects in reactor pressure vessel (RPV) steel, resulting in macroscopic hardening and embrittlement. This paper proposes a micro‑meso-macroscale calculation framework for the mechanical properties of irradiated RPV steel based on experimental and numerical investigations. The mean size and number density of Fe-ion-irradiation-induced dislocation loops were measured using transmission electron microscopy (TEM). These parameters were described by a power-function relationship with the irradiation dose at various temperatures and were used as input parameters for the crystal plasticity finite element model (CPFEM). Nano-indentation tests of A508-Ⅲ steel under different irradiation conditions were successfully simulated. In addition, microstructural characterization and molecular dynamics (MD) simulations revealed the phenomenon of dislocation pinning and the sweeping of irradiation defects during dislocation migration, implying that the dislocation-loop interactions could be responsible for the formation of dislocation channels and curved dislocation lines. Furthermore, increase in yield stress and the ductile-brittle transition temperature (DBTT) at various temperatures were investigated. Results indicated that yield stress, DBTT, and the degree of irradiation hardening and embrittlement increased with the irradiation dose and decreased with irradiation temperature. Finally, the adjusted reference temperature (ART), a significant design parameter for nuclear reactors, was calculated and evaluated using the multiscale framework. The framework can serve as a reference text for extending the life of nuclear reactors.

A Study on the Microstructure and Mechanical Properties of Electron Beam Welds of SA508 Gr.3 Cl.1 steel with Different Heat Treatment conditions for Small Modular Reactor

Electron beam welding was conducted on SA508 Gr.3 Cl.1 steel, which is being considered as a material used in the pressure vessel steel of small modular reactors. The characteristics of the welds were analyzed under various heat treatment conditions. The heat treatment conditions were categorized as as-welded, post weld heat treatment(PWHT), quality heat treatment(QHT), and their features were examined and compared through cross-sectional structure and composition analyses, as well as mechanical property tests. The electron beam welded joints displayed no defects, including pores or cracks. weld metal of the as-welded specimen revealed a needle-type martensite with high hardness, whereas the base metal was characterized by tempered bainite. The weld cross-section bead of the QHT specimen exhibited no significant difference in microstructure compared to the base metal. Tensile testing revealed that both the as-welded and PWHT specimens fractured at the base metal, whereas the QHT specimen fractured at the weld metal. The PWHT specimens showed enhanced impact values in the welds compared to the as-welded specimens. In the QHT specimens, both the base metal and the weld metal demonstrated similarly favorable impact values, approximately 200 Joules. It is evident that post-welding heat treatment improves the toughness value, and quality heat treatment can result in the weld metal being similar to the base metal.