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9-12% Cr ferritic-martensitic stainless steels are widely used as high temperature construction materials in power plants due to their excellent creep resistance and good oxidation resistance. Creep resistance is considered as the primary parameter in material selection for base-load power plants, but the growing share of renewable energy sources in power generation forces many installations into more "flexible" operation with frequent load reductions and shutdowns. Under cyclic operation of power plants, temperature gradients occur especially in thick-walled components. Locally, these gradients lead to complex time- and temperature-dependent loading scenarios which may result in superimposed creep deformation/damage, creep-fatigue and thermo-mechanical fatigue. The combination of different damage processes may seriously reduce the lifetimes of respective components. A fundamental understanding of the damage evolution in ferritic-martensitic steels under combined static and cyclic loading is therefore required.
In the present contribution, the creep-fatigue behavior of two different 9% Cr steel grades (P91 and P92) was investigated. Standard creep-tests as well as LCF/TMF tests with hold time have been carried out to study the material behavior of the new loading scenarios. Microstructural investigations help to identify the observed deformation characteristics and the dominating damage mechanisms under different loads. The test programme is complemented by cyclic creep-tests (temperature change) and creep-tests under atmospheres. In a next step, the experimental results will be used for parameter identification of a deformation and lifetime model to predict the material behavior.
9-12% Cr ferritic-martensitic stainless steels are widely used as high temperature construction materials in power plants due to their excellent creep resistance and good oxidation resistance. Creep resistance is considered as the primary parameter in material selection for base-load power plants, but the growing share of renewable energy sources in power generation forces many installations into more "flexible" operation with frequent load reductions and shutdowns. Under cyclic operation of power plants, temperature gradients occur especially in thick-walled components. Locally, these gradients lead to complex time- and temperature-dependent loading scenarios which may result in superimposed creep deformation/damage, creep-fatigue and thermo-mechanical fatigue. The combination of different damage processes may seriously reduce the lifetimes of respective components. A fundamental understanding of the damage evolution in ferritic-martensitic steels under combined static and cyclic loading is therefore required.
In the present contribution, the creep-fatigue behavior of two different 9% Cr steel grades (P91 and P92) was investigated. Standard creep-tests as well as LCF/TMF tests with hold time have been carried out to study the material behavior of the new loading scenarios. Microstructural investigations help to identify the observed deformation characteristics and the dominating damage mechanisms under different loads. The test programme is complemented by cyclic creep-tests (temperature change) and creep-tests under atmospheres. In a next step, the experimental results will be used for parameter identification of a deformation and lifetime model to predict the material behavior.
Creep-fatigue of P92 in service-like tests with combined stress- and strain-controlled dwell times
(2023)
Complex service-like relaxation- and creep-fatigue tests with strain- and stress-controlled dwells and fatigue cycle durations of approx. 2200 s were performed exemplarily on a grade P92 steel at 620 ◦C in this study. The results indicate deviations in the prevailing creep mechanisms of long-term relaxation and creep dwells, affecting subsequent dwells, load shifts, and the macroscopic softening behavior quite differently. In addition, fracture surfaces and longitudinal metallographic sections reveal intergranular crack growth for complex loading with stress-controlled dwells, whereas complex strain-controlled tests enhance oxidation and transgranular crack propagation. These findings substantiate the limited transferability of relaxation-fatigue to creep-fatigue conditions.
The current competitive situation on electricity markets forces power plants into cyclic operation regimes with frequent load shifts and starts/shutdowns. In the present work, the cyclic mechanical behavior of ferritic-martensitic 9-12 % Cr steels under isothermal and thermomechanical loading was investigated for the example of grade P92 material. A continuous softening was observed under all loading conditions. The introduction of hold periods to the applied cycles reduced material lifetime, with most prominent effects at technologically relevant small strain levels. The microstructural characterization reveals a coarsening of the original “martensitic” lath-type microstructure to a structure with polygonal subgrains and reduced dislocation density. The microstructural data forms the input for a physically-based modelling approach.
The current competitive situation on electricity markets forces power plants into cyclic operation regimes with frequent load shifts and starts/shutdowns. In the present work, the cyclic mechanical behavior of ferritic-martensitic 9-12 % Cr steels under isothermal and thermomechanical loading was investigated for the example of grade P92 material. A continuous softening was observed under all loading conditions. The introduction of hold periods to the applied cycles reduced material lifetime, with most prominent effects at technologically relevant small strain levels. The microstructural characterization reveals a coarsening of the original “martensitic” lath-type microstructure to a structure with polygonal subgrains and reduced dislocation density. The microstructural data forms the input for a physically-based modelling approach, both of which are presented in “Part 2: Microstructural Evolution during Cyclic Loading and its Representation in a Physically-based Micromechanical Model“.
Hochwarmfeste ferritisch-martensitische Stähle mit 9-12 Gew.-% Chromgehalt werden wegen ihrer hohen Kriechfestigkeit und ihres gleichzeitig guten Oxidationswiderstands erfolgreich als Konstruktionswerkstoff für Hochtemperaturbauteile in Kraftwerken eingesetzt. Die zunehmend zyklische Fahrweise konventioneller Kraftwerke im lastflexiblen Betrieb führt zu häufigen Last- und Temperaturwechseln, die von den Bauteilen sicher ertragen werden müssen. Schnelle Lastwechsel verursachen vor allem in dickwandigen Bauteilen erhebliche thermische und mechanische Beanspruchungen. Während unter stationären Betriebs¬bedingungen der Lebensdauerverbrauch von der Werkstoffschädigung durch Kriechen dominiert wurde, verstärkt sich im zyklischen Betrieb die Schädigung durch Ermüdungsprozesse.
In der hier vorgestellten Arbeit wird am Beispiel des ferritisch-martensitischen Stahls P92 untersucht, welche Auswirkungen zyklische Fahrweisen auf die Schädigungsprozesse und Lebensdauern dieser Stähle haben. Das Versuchsprogramm kombiniert deshalb Standardtests mit betriebsnahen mechanischen Versuchen unter überlagerter Kriech-, Ermüdungs- und Temperaturwechselbeanspruchung. Diese werden im vorliegenden Beitrag anhand erster Versuchsergebnisse vorgestellt. Ziel der Arbeiten ist, die auftretenden mechanischen Effekte darzustellen und die zugrunde liegenden Schadensmechanismen durch umfangreiche mikroanalytische/fraktographische Nachuntersuchungen des Probenmaterials zu identifizieren.
Ermüdungsverhalten, Lebensdauer und Schädigungsprozesse von P92 unter zyklischen Betriebsbedingungen
(2016)
Schnelle Lastwechsel mit hohen Temperaturgradienten führen zu thermischen und mechanischen Beanspruchungen v.a. in dickwandigen Bauteilen. Daraus ergibt sich ein komplexes Lastkollektiv, bei dem der Werkstoff sowohl durch Kriechermüdung als auch durch thermomechanische Ermüdung (TMF) geschädigt wird. Welche Auswirkungen hat eine gleichzeitige Änderung von Temperatur, mechanischer Beanspruchung und Arbeitsmedium auf die Schädigungsprozesse?
This article refers to the research article entitled “Creep-Fatigue of P92 in Service-Like Tests with Combined Stress- and Strain-Controlled Dwell Times” [1]. It presents experimental mechanical data from complex service-like creep-fatigue experiments performed isothermally at 620 °C and a low strain amplitude of 0.2 % on tempered martensite-ferritic grade P92 steel. The data sets in text file format provide cyclic deformation (min. and max. stresses) and the total (hysteresis) data of all recorded fatigue cycles for three different creep-fatigue experiments: 1) a standard relaxation fatigue (RF) test with symmetrical dwell times of three minutes introduced at minimum and maximum strain, 2) a fully strain-controlled service-like relaxation (SLR) test combining these three-minute peak strain dwells with a 30-minute dwell in between at zero strain, and 3) a partly stress-controlled service-like creep (SLC) test combining the three-minute peak strain dwells with 30-minute dwells at constant stress. Such service-like (SL) tests with additional long-term stress- and strain-controlled dwell times are non-standard, rare, and expensive, making these data very valuable. They may be used to approximate cyclic softening in the technically relevant range, for the design of complex SL experiments, or for detailed analyses of stress-strain hystereses (e.g., for stress or strain partitioning methods, for the determination of hysteresis energies (work), inelastic strain components, etc.). In addition, the latter analyses may supply important input for advanced parametric lifetime modeling of components under creep-fatigue loading or model calibration parameters.
Schnelle Lastwechsel führen v.a. in dickwandigen Kraftwerksbauteilen zu starken thermischen und mechanischen Beanspruchungen, da sich hohe Temperaturgradienten über der Wand des Bauteils einstellen. Es ergeben sich komplexe Lastkollektive aus zeitlich veränderlichen Spannungen/Dehnungen und Temperaturen, die formal einer Kombination aus Kriechbeanspruchung, Kriechermüdung und thermomechanischer Ermüdung (TMF) entsprechen.