Life expectations and inspection strategies for

parent materials and welds of 9-12% Cr-steels

Part
Part
Creep damage development and evaluation in parent material Creep damage development and evaluation in parent material
Karl Maile Karl Maile
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2
Content
Content
Introduction
Experimental work
Creep damage development
Metallographic findings
Influence of stress state (multiaxiality)
Influence of temperature and steel grade
Life time assessment
Creep damage assessment
Summary and conclusion
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3
Introduction
Introduction
Aim
Enlargment of knowledge basis
about the evolution of creep
damage in components made of
new martensitic steels
Prevention of premature failure of
component
Optimization of inspection intervalls
AVIF Projects Damage Evolution I III (2000 2009)
Supported by FDBR and VGB
MPA Universitt Stuttgart and SPG Dresden
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Experimental
Experimental
work
work
Creep tests P91, E911
575, 600C 50000 h
Quotient of multiaxiality h=
H
/
V
0.33 (uniaxial) 0.5 (internal pressure, circumf. notch, tension
force)
Measuring of creep strains
Replica
Metallographic investigations
Optical microscopy, SEM, TEM
Numerical simulation
strains, stresses
Evolution of microstructure (precipitates)
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Creep damage development
Creep damage development
Creep cavities metallographic appearance
Polished by vibration technology etched
Labor microsection
Replica
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6
Parameters on formation of creep cavities number, size
Multiaxiality of stress state
Notch tip
Inner surface of hollow cylinder
p
Creep damage development
Creep damage development
E911, notched, 600C,
32000 h, integral strain
over notch =1,6 %
Gradient due to the influence of loading
situation/multiaxiality
Verification by Computertomography
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7
Parameters on formation of creep cavities number, size
Multiaxiality of stress state
Creep damage development
Creep damage development
smooth cylinder
internal pressure
Notched cylinder
internal pressure/tension
Trend to an increase of number of cavities with increasing multiaxiality
0,2 0,4 0,6
0
200
400
600
t/t
B
>0,9 E911
t/t
B
<0,75 E911
t/t
B
>0,9 P91
t/t
B
<0,75 P91
n
u
m
b
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f

c
a
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1
/
m
m
2
Quotient of multiaxiality h
8
8
0,5 1,0 1,5 2,0
0
200
400
600
800
t/t
B
> 0,9 E911, 600C
t/t
B
< 0,75 E911, 600C
t/t
B
> 0,9 P91, 600C
t/t
B
< 0,75 P91, 575C
n
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m
b
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f

c
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1
/
m
m
2
creep strain %
Creep damage development
Creep damage development
smooth cylinder
internal pressure/tension
smooth cylinder
internal pressure
Trend to a decrease of number of cavities with increasing creep strain
Parameters on formation of creep cavities number, size
Multiaxiality of stress state
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Creep damage development
Creep damage development
Larger number of cavities at 575 in comparison to that at 600C
Parameters on formation of creep cavities number, size
Temperature
Specimens with test durations > 10000 h
No failure
Life time expenditure max. 80%
Different melts
0,2 0,4 0,6
0
500
1000
P91 - 575C
E911- 575C
P91 - 600C
E911- 600C
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1
/
m
m
2
quotient of multiaxiality h
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Life time assessment
Life time assessment should be based on findings/data of
Replica (optical microscopy)
assessment of the microstructure
number of cavities (qualitatively, quantitatively) and/or porosity
orientation of cavities, microcracks to maximum principal stress
Strain measurement
evolution of time-dependent local creep strain
Extraction replica
assessment of precipitations
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0,2 0,4 0,6 0,8 1,0
0
500
1000
1500
2000
P91
E911
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1
/
m
m
2
life time expenditure t/t
B
Analysis:
P91, E911 575 C, test duration min 10200 h, max. 23000 h
Life time assessment
Clear indication of cavities
Increase number of cavities
Validation by ongoing tests with duration > 30000h
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0,4 0,6 0,8 1,0
0
200
400
1500
2000
E911
P91
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/
m
m
2
life time expenditure t/t
B
Analysis:
P91, E911 600 C, test duration min 10200 h, max. 48000 h
Life time assessment
Uncertainty (artefactes)
Clear indication of cavities limited number of cavities < 500
notched, lowrupture strain
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Richtreihe zur Bewertung der Gefgeausbildung und schdigung zeitstandbeanspruchter
Werkstoffe von Hochdruckrohrleitungen und Kesselbauteilen. VGB-TW 507 2. Ausgabe
2005; VGB PowerTech Service GmbH, Essen
Rating class Structural or damage condition Limit criteria
1 Subject to creep loading without creep
cavities

2a Individual creep cavities Up to 150 voids per mm
2b Numerous creep cavities, randomly
oriented
More than 150 voids per mm
3a Numerous creep cavities, specific
orientation
See remarks
3b Chains of creep cavities; individual grain
boundary separations
At least 2 successive grain
boundaries with at least 3 voids
4 Microcracks More than one grain boundary
length
5 Macrocracks

Smaller amount of creep cavities in comparison with low alloy ferritic steels
At more than 50 hollow cylinders investigated with test durations up to
50000 h no orientation, no chains of creep cavities (1 exception) were found
Microstructure Rating charts for Evaluating the Microstructure and Creep Damage of High-Temperature Steels for High-
Pressure piping and Boiler Components VGB TW 507e 2nd edition
Damage assessment
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Comparison E911 with 14MoV6-3
14MoV6-3; Replica pipe bend,
Rating chart 2b
Specimen EH8, E911, 600C, t/t
B
=0,7
t=37700 h, 268 C/mm
2
14MoV6-3; Replica pipe bend,
Rating chart 3b
Specimen EH17, E911, 600C, t/t
B
=0,94
t=24410 h, 140 C/mm
2
Damage assessment
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Comparison E911 with 14MoV6-3
14MoV6-3; Replica pipe bend,
Rating chart 4
Specimen EH22, E911, 600C, t/t
B
= 1
t
B
=32000 h, 167 C/mm
2
,
Available results showdifferent course of creep damage development in
E911 in comparison to that for lowalloy ferritic steels reported in TW 507
Damage assessment
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High degree of multiaxiality notched specimen, 48.000 h internal
pressure and additional axial tension load, 600 C, steel E911
Shortly bevor rupture: indications of chains of cavities with orientation to
max principal stress
Comparable with rating chart 3b/4 TW 507
Damage assessment
However exceptions have been observed
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Cavity size and porosity
specimen Cavity size
Min Max
m
average
number of
cavities
Porosity Temperature
C
Ex-
haustion
t/t
B
(%)
Creep
strain
%
Test du-
ration
h
P5
smooth;
P91
0,56 3,45 638 1,0094 575 >70 0,45 10196
EH24
notched;
E911
0,77 3,29 156 1,0079 600 100 3,9 7250
EH7
smooth,
E911
1,09 7,69 278 1,0482 600 90 0,9 38000
Cavities of P91 at 575C seems to be smaller than that observed in E911
specimens at 600C
If the damaged area as parameter Porosity is used, it is obvious that specimen
P5 shows a lower damage degree although the number of cavities in this
specimen is larger in comparison to specimen EH7
The comparison of specimen EH24 with EH7 concludes that cavity growth is
influenced by the creep strain
Damage assessment
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Summary and conclusions
Summary and conclusions
The available data with longtermcreep tests under multiaxial load show:
Creep cavity formation is a clear indication for creep damage also in
9%Cr-steels
Replica technique therefore has to be considered as an essential
basis for life time assessment of critical components
The number of creep cavities is lower than in low alloy ferritic steels
however the influence of temperature and casts has to be analyzed in
detail
At vast majority of the specimens no orientation of the cavities could be
found. Also the formation of chains of cavities were rarely observed even
at the end of life time (90%).
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Criteria used for low alloy ferritic steels in the rating charts of VGB
TW 507 have to be adjusted to the specific situation with 9%Cr-
steels (no reduced creep rupture ductility):
Rating class Structural or damage condition
Limit criteria (approximately - only for
600 C)
1
Subject to creep loading without creep
cavities,
Up to 50 cavities per mm
2

2 Individual creep cavities Up to 100 cavities per mm
2

3
Increased number of cavities without
orientation
More than 100 cavities up to 200
cavities per mm
2

4
numerous number of cavities without
orientation
More than 200 cavities cavities per mm
2

5
numerous number of cavities without
orientation, single chains of cavities,
individual grain boundary separations


Rating class for 9-11%Cr steels at 600C:
No class 2b und 3b
Summary and conclusions
Summary and conclusions
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Based on the findings and knowledge from the AVIF-project
Damage Evolution the following criteria for life time assessment
of components made of 9%Cr-steels could be suggested:
Condition:
homogenous stress state
no fatigue interaction
Global total strain 1%
Local creep strain 2%
Increase of creep velocity of 10%
Life time exhaustion on basis of Robinson-Rule of max 60%
Summary and conclusions
Summary and conclusions
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Attaining these values special examimations have to be
taken:
Surface replica identification of cavities
Extraction replica evaluation of state of
precipitation
Inelastic stress analysis taking into account the
real loading conditions and melt specific material
(creep) characteristics
Summary and conclusions
Summary and conclusions
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22
Thanks for your attention
Diese Arbeit wurde gefrdert von der Stiftung
Stahlanwendungsforschung im Stifterverband fr die Deutsche
Wissenschaft e.V. unter Nummer A 229 gefrdert, wofr an dieser Stelle
gedankt sei.
Ferner wird dem VGB fr die finanzielle Untersttzung sowie dem
Lenkungskreis unter dem Vorsitz von Herrn Hahn (V&M) fr die
fachliche Untersttzung gedankt.